Hydraulic Fracturing Pump Leakage Detection via Multi-Zone Pressure Sensing
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Solution Overview
Problem
Pumps used in hydraulic fracturing operations face challenges in detecting leakage due to high working pressures, which can lead to component failure and affect overall pump performance, necessitating a system for early and accurate detection of leaks.
Innovation Solution
A system comprising first, second, and third pressure sensors located in the suction manifold, discharge manifold, and cylinders of the pump, respectively, communicating with a controller to determine the amplitude and location of leaks based on pressure values, along with a method and non-transitory computer-readable medium for executing these functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple pressure sensors are installed in the pump system to detect leaks, then leak detection precision is improved, but device complexity increases
Solution Approach 1:
The pump system is segmented into multiple monitoring zones (suction manifold, discharge manifold, and individual cylinders) with pressure sensors installed in each zone. This segmentation enables localized leak detection and identification, allowing the system to pinpoint leak locations precisely while maintaining manageable system complexity through modular sensor placement.
2Loss of information
If pressure sensors are installed in all cylinders and manifolds to locate leaks accurately, then leak location identification is improved, but cost increases
Solution Approach 1:
The controller receives pressure data from multiple sensors and continuously monitors for anomalies. When a leak is detected, the system provides feedback by comparing pressure readings across different zones to identify the affected area. This feedback mechanism enables accurate leak location identification without requiring sensors in every possible location, optimizing the sensor network for cost-effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables timely detection and localization of leaks, facilitating maintenance and reducing downtime and costs by providing operators with visual representations of leak amplitude and location, thus improving pump reliability and operational efficiency.
Implementation Method 1
a first pressure sensor located in a suction manifold of the pump and configured to output a pressure value associated with the suction manifold; a second pressure sensor located in a discharge manifold of the pump and configured to output a pressure value associated with the discharge manifold
Data Source
AI summary
A system for detecting leakage in a pump includes a first pressure sensor, a second pressure sensor, multiple third pressure sensors, and a controller. The first pressure sensor is configured to output a pressure value associated with a suction manifold of the pump. The second pressure sensor is configured to output a pressure value associated with a discharge manifold of the pump. The third pressure sensors are configured to output a pressure value associated with the cylinders of the pump. The controller is disposed in communication with the first pressure sensor, the second pressure sensor, and the third pressure sensors. The controller is configured to determine amplitude of a leak, and a location of the leak in the pump on the basis of pressure values received from the first pressure sensor, the second pressure sensor, and the third pressure sensors.