Pumping System Phase Control for Pressure Spike Reduction
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Solution Overview
Problem
Reciprocating pumps in oilfield operations experience amplified high-pressure spikes due to resonance phenomena when multiple pumps are connected in parallel, leading to piping and equipment failures, which are mitigated by over-designing systems with large safety factors and dampening systems, increasing size, weight, and cost.
Innovation Solution
A control system that includes position sensors to monitor the phase and speed of each pump, pressure sensors to detect fluid pressure spikes, and a controller to synchronize the speed and adjust the phase of pumps, ensuring that each fluid pressure spike is out of phase with respect to another, thereby reducing resonance-induced high-pressure spikes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple reciprocating pumps are connected in parallel to increase pumping capacity, then productivity is improved, but amplified high-pressure spikes occur due to resonance phenomena causing piping and equipment failures
Solution Approach 1:
The system dynamically adjusts the phase relationship between multiple pumps using variable frequency drives and control systems. The phase angle between pumps is continuously monitored and adjusted to optimize pressure spike cancellation, transforming a static parallel pumping configuration into a dynamically controlled system that adapts to operating conditions.
Solution Approach 2:
The invention utilizes periodic reciprocating pump cycles with controlled phase differences. By synchronizing the periodic discharge cycles of multiple pumps at specific phase angles (such as 180 degrees), the system creates alternating pressure waves that cancel each other out, reducing amplified pressure spikes while maintaining continuous pumping capacity.
2Reliability
If dampening systems are introduced to reduce high-pressure spikes, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The control system incorporates pressure sensors that continuously monitor fluid pressure in the common discharge line. This feedback is fed to the controller which adjusts the phase relationship between pumps in real-time, creating a closed-loop control system that actively compensates for pressure spikes without requiring passive dampening hardware.
Solution Approach 2:
The invention replaces mechanical dampening systems (such as accumulators, surge tanks, or shock absorbers) with an electronic control system using variable frequency drives and phase control algorithms. This substitution reduces mechanical complexity while achieving the same reliability goal through intelligent control of pump synchronization.
3Reliability
If pumps are over-designed with large safety factors to prevent pressure failures, then reliability is improved, but weight and cost increase
Solution Approach 1:
The invention changes the operational parameters of the pumping system by controlling the phase relationship between pumps. By adjusting the phase angle and synchronization timing, the system modifies the pressure wave characteristics to minimize peak pressures, allowing the use of lighter-duty piping and equipment that would otherwise require large safety factors.
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
The solution effectively minimizes amplified high-pressure spikes, reducing the need for oversized systems and associated costs while maintaining operational efficiency and safety.
Implementation Method 1
amplified high-pressure spikes may be transmitted through a piping system and/or other portions of the pumping system connected downstream from the reciprocating pumps due to resonance phenomena
Data Source
AI summary
A pumping system including a plurality of pumps each having a pump fluid outlet, a drive shaft, a prime mover, and fluid displacing members operatively coupled with the drive shaft. A common fluid conduit may be fluidly coupled with each pump fluid outlet. A control system of the pumping system includes position sensors operable to generate information relating to phase and/or speed of each pump, pressure sensors operable to generate information relating to fluid pressure spikes, and a controller in communication with the position and pressure sensors. The controller is operable to cause the prime movers to adjust the phasing of the pumps with respect to each other, based on the information relating to fluid pressure spikes, and synchronize the speed of the pumps.