Pump Health Assessment via Predictive Parameter Modeling
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Solution Overview
Problem
High-volume, high-pressure pumps used in wellsite operations face mechanical fatigue and failure due to high fluid pressures, flow rates, and vibrations, leading to operational inefficiencies and increased non-productive time, necessitating a large number of pumps on site to ensure availability.
Innovation Solution
A processing system utilizing a processor and memory with computer program code generates predicted data on pump operational parameters by relating them to real-time data, allowing for health assessment and optimization of pump performance, thereby reducing mechanical stress and failure rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple pumps are brought to the job site to ensure availability, then reliability is improved, but device complexity and loss of time increase
Solution Approach 1:
The system performs preliminary health assessments and predicts potential failures before they occur by continuously monitoring operational parameters and comparing them against degradation thresholds. This allows maintenance to be scheduled proactively, ensuring pump availability without needing to bring multiple units to the job site.
Solution Approach 2:
The system continuously monitors real-time operational data from pumps, compares it against predicted values and degradation thresholds, and provides feedback that triggers maintenance alerts. This closed-loop approach enables proactive maintenance scheduling, reducing non-productive time while maintaining reliability.
2Reliability
If multiple pumps are brought to the job site to ensure availability, then reliability is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary health assessments and predicts potential failures before they occur by continuously monitoring operational parameters and comparing them against degradation thresholds. This allows maintenance to be scheduled proactively, ensuring pump availability without needing to bring multiple units to the job site.
Solution Approach 2:
The system enables self-monitoring and self-diagnosis of pump health through continuous operational parameter collection, prediction modeling, and automated alerting. This reduces the need for manual inspection and maintenance coordination, simplifying the overall system while maintaining reliability.
3Productivity
If high fluid pressures and flow rates are used, then productivity is improved, but mechanical stress and failure rates increase
Solution Approach 1:
The system performs preliminary health assessments and predicts potential failures before they occur by continuously monitoring operational parameters and comparing them against degradation thresholds. This allows maintenance to be scheduled proactively, ensuring pump availability without needing to bring multiple units to the job site.
Solution Approach 2:
The system continuously monitors real-time operational data from pumps, compares it against predicted values and degradation thresholds, and provides feedback that triggers maintenance alerts. This closed-loop approach enables proactive maintenance scheduling, reducing non-productive time while maintaining reliability.
Data Source
AI summary
Method and apparatus for assessing health of fracturing fluid pump assemblies and other wellsite equipment. For example, predicted data indicative of a first operational parameter of a pump assembly is generated utilizing: a model relating the first operational parameter to each of a plurality of second operational parameters of the pump assembly; and real-time data indicative of each of the second operational parameters. Health of the pump assembly is then assessed based on: the predicted data indicative of the first operational parameter; and real-time data indicative of the first operational parameter.