Pressure Control Valve for Pump Overpressure Mitigation
Solution Overview
Problem
Current pumping systems, especially those driven by electric motors, face challenges in rapidly stopping operations to prevent damage during overpressure conditions, leading to increased costs and downtime due to the inability to instantaneously control the kinetic energy and the need for costly emergency relief valve replacements.
Innovation Solution
A controllable pumping system with an information handling system that uses pressure control valve assemblies and valve trains to selectively and automatically control the pump rate, allowing for instantaneous stoppage of fluid discharge and gradual power down of electric motors, thereby preventing damage and reducing downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the electric motor or powertrain is shutdown quickly to stop pump operation during overpressure conditions, then the pump stops rapidly and fluid flow is controlled, but damage occurs to the electric motor, powertrain, or surrounding equipment due to high kinetic energy
Solution Approach 1:
The system performs preliminary action by gradually reducing motor power before complete shutdown. The control system ramps down the electric motor power in a controlled manner before stopping the pump, preventing damage from sudden kinetic energy release while still achieving rapid fluid flow control when needed.
2Object-affected harmful factors
If the entire pumping system is shut down to prevent overpressure damage, then equipment safety is improved, but operational costs increase and downtime extends due to valve replacement or system reset
Solution Approach 1:
The system segments the shutdown function by applying it only to the affected pump or motor rather than the entire pumping system. When overpressure or malfunction is detected, only the problematic component is shut down while other pumps can continue operating, minimizing downtime and maintaining partial system productivity.
Solution Approach 2:
The control system provides self-service by automatically detecting malfunctions and initiating selective shutdown procedures without requiring manual intervention. The system monitors pump performance, identifies overpressure conditions or valve failures, and autonomously shuts down only the affected components, reducing operational costs and minimizing downtime.
3Speed
If the clutch is disengaged to stop the diesel engine pump instantly, then the pump stops substantially instantaneously and fluid flow is controlled, but the transmission and clutch mechanism experience mechanical stress
Solution Approach 1:
The system performs preliminary action by gradually reducing power transmission before complete shutdown. The control system reduces motor power in steps before stopping the pump, preventing sudden mechanical stress on the transmission and clutch mechanism while still achieving rapid fluid flow control when needed.
Data Source
AI summary
Certain conditions or triggering events require preventing or throttling the discharge of a servicing fluid from a pump to a wellhead or a borehole. Powering down may not be desirable or may require a duration that allows the condition or triggering event to persist. Selectively and automatically activating one or more pressure control valves may throttle or prevent the servicing fluid from being pumped from the pump during the power down sequence or without requiring a power down sequence. Selective activation of a pressure control valve may introduce pressurized fluid into a cylinder of the pump extending a rod to force or maintain a suction valve in an open position. While the suction valve is in the open position, the stroke of the plunger may not create enough pressure to pump the servicing fluid causing the servicing fluid to flow between a fluid header and a chamber of the pump.