Pumping Systems with Continuous Proppant Concentration Control
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Solution Overview
Problem
Conventional pumping systems for hydraulic fracturing lack the ability to control proppant concentration and flow rate across a continuous spectrum, leading to discrete or step-wise adjustments, which limits the precision and efficiency in delivering proppant downhole.
Innovation Solution
A system comprising multiple pumps connected to clean and dirty fluid sources, regulated by valves and a controller, allowing for continuous variation of proppant concentration and flow rate, with sensors providing feedback for closed-loop control, and electric motors enabling adjustable pump speeds to maintain desired downhole conditions even if pumps fail.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple pumps are used for volume and redundancy in proppant delivery, then reliability and productivity are improved, but device complexity increases and manual adjustment is required when pumps fail
Solution Approach 1:
The patent implements a control system with sensors that continuously monitor proppant concentration and flow rate, providing feedback to automatically adjust pump operations. This eliminates the need for manual adjustment when pumps fail, while maintaining reliability through automated compensation for pump failures.
Solution Approach 2:
The system performs self-adjustment when pumps fail by automatically redistributing flow and concentration control among remaining operational pumps. The control system detects pump failures and compensates without human intervention, making the system self-servicing and reducing operational complexity.
2Manufacturing precision
If conventional pumping systems deliver proppant, then basic hydraulic fracturing function is achieved, but precision in controlling proppant concentration and flow rate is limited to discrete adjustments
Solution Approach 1:
The patent employs dynamic control of pump speeds and valve positions to achieve continuous adjustment of proppant concentration and flow rate. Instead of discrete steps, the system can vary parameters continuously to match precise downhole requirements, improving manufacturing precision while maintaining ease of operation through automated control.
Solution Approach 2:
The system changes operational parameters (pump speed, valve position, injection rate) dynamically to achieve desired proppant concentration and flow rate. By adjusting multiple parameters in coordination, the system achieves precise control while the automated nature maintains ease of operation.
3Reliability
If operators manually adjust pumps to compensate for failures, then desired concentration and flow rate can be maintained, but loss of time and productivity occur due to human intervention
Solution Approach 1:
The control system continuously monitors proppant concentration and flow rate with sensors and automatically adjusts pump operations in real-time. When a pump fails, the system immediately detects the change and compensates by adjusting remaining pumps, eliminating the time loss associated with manual detection and adjustment while maintaining desired concentration and flow rate.
Solution Approach 2:
The system automatically compensates for pump failures without human intervention by redistributing flow and adjusting concentrations among operational pumps. This self-service capability eliminates the time operators would spend on manual adjustments while maintaining the reliability of concentration and flow rate control.
Data Source
AI summary
A system includes a first plurality of pumps connected to draw from a clean fluid supply junction. A second plurality of pumps is operatively connected to a dirty fluid supply. A first valve is connected between the clean fluid supply junction and the dirty fluid supply for supplying clean fluid to the dirty fluid supply. A second valve is connected to feed a dirty fluid to the dirty fluid supply. A controller is operatively connected to the first and second valves and to the first and second pluralities of pumps for controlling downhole concentration and flow rate of proppant from the dirty fluid supply, wherein downhole concentration and flow rate are varied across a continuous spectrum.