Automated Pumping Equipment Valve Configuration
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Solution Overview
Problem
The existing methods for configuring and diagnosing the valve positions in oil well pumping equipment are often inconclusive and time-consuming, leading to potential operational issues and maintenance challenges due to the lack of precise data on the current configuration and operational condition of the equipment.
Innovation Solution
An automated valve configuration process using a unit controller that performs diagnostic tests by setting valve positions, operating pumps at predetermined flowrates, and recording data from sensors, allowing for real-time logging and adjustment of valve positions, and optionally transmitting results wirelessly for remote analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If personnel perform manual diagnostic tests of pumping equipment components before a job, then some data about component operation is obtained, but the data is not conclusive regarding current configuration and operational condition
Solution Approach 1:
The patent replaces manual mechanical diagnostic testing with an automated electronic system that uses sensors, processors, and communication interfaces to automatically detect, record, and analyze equipment configuration and operational data, eliminating the inconclusiveness of manual tests while maintaining system simplicity through standardized automated procedures
Solution Approach 2:
The pumping equipment performs self-diagnosis by automatically monitoring its own components through integrated sensors and controllers that detect configuration states and operational conditions without requiring external manual testing, providing conclusive data about the equipment's current state
2Loss of information
If manual diagnostic testing is performed on pumping equipment, then some operational data is collected, but the process is time-consuming and may miss critical configuration details
Solution Approach 1:
The automated system continuously monitors equipment configuration and operational parameters throughout the testing process, ensuring that no critical data is missed while completing the diagnostic evaluation quickly without the time-consuming nature of manual step-by-step testing
Solution Approach 2:
The system automatically receives feedback from sensors monitoring equipment components, processes this data through a processor, and generates conclusive configuration information that is communicated to users, ensuring complete configuration data is captured efficiently
3Reliability
If diagnostic data is collected manually during equipment testing, then basic operational information is obtained, but reliable configuration data for job readiness is not ensured
Solution Approach 1:
The patent replaces unreliable manual data collection with automated electronic sensing and processing systems that objectively detect and record equipment configuration and operational data, ensuring reliable and consistent results that confirm job readiness without requiring high levels of complex automation
Data Source
AI summary
A method of configuring a flow control valve of a mixing system may comprise establishing a flow loop via a pump, a flow control valve, and a flow rate sensor. The method may also include performing a valve configuration process that includes positioning the flow control valve in a first position, operating the pump to communicate a fluid via the flow loop at a first speed, measuring a first periodic dataset while the fluid is communicated via the flow loop, and recording the first periodic dataset. The method may also include comparing a result of the valve configuration process to a valve position dataset and an operational indicator set and determining an pass/fail status based upon the comparison, and outputting, by the unit controller, indicia of the pass/fail status of the mixing system via the input output device.