Virtual Rate Control for Well Treatment Fluid Coordination
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Solution Overview
Problem
Current well treatment systems operate independently, leading to inconsistencies in well treatment fluid composition and flow rate, which can result in fluid that does not meet the needs of the well formation, as there is no direct consideration of physical dynamics between subsystems.
Innovation Solution
A method that includes determining output rates from sand, water, and pumping systems, and using a virtual rate control system to produce a drive signal for the pumping system, ensuring coordinated operation and real-time monitoring and adjustment of well treatment fluid production to maintain consistent performance and account for system dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If subsystems operate independently with passed setpoint data, then each subsystem can be controlled individually, but the well treatment fluid composition and flow rate become inconsistent and may not meet well formation needs
Solution Approach 1:
The patent merges independent subsystem controls into a unified coordinated control system where the sand system, water system, resin system, gel system, and pumping system operate together under a common control framework. This integration ensures that fluid composition and flow rate remain consistent while maintaining the operational independence of each subsystem through virtual rate control and interconnectivity.
2Device complexity
If subsystems operate without interconnectivity, then system complexity is reduced, but systems may run ahead or behind of other systems leading to non-compliant well treatment fluid
Solution Approach 1:
The patent introduces virtual rate control systems and interconnectivity mechanisms as intermediaries between subsystems. These intermediaries enable coordination and synchronization of sand, water, resin, gel, and pumping systems without requiring direct physical interconnection, thus maintaining reliability while managing system complexity.
3Manufacturing precision
If real-time monitoring and coordination of all subsystems is implemented, then fluid production consistency is improved, but system complexity and control requirements increase
Solution Approach 1:
The patent implements a universal control framework where the coordinated control system manages multiple subsystems (sand, water, resin, gel, pumping) through common principles and mechanisms. This multi-functional approach improves fluid production consistency while avoiding the need for separate complex control systems for each subsystem.
Data Source
AI summary
A method and apparatus for controlling the production of well treatment fluid is disclosed. The apparatus includes: a sand system, a water system, a pumping system, a blender tub, and a virtual rate control system. The method includes determining an output rate from a sand system; sensing an output rate from a water system; sensing an output rate from a pumping system; sensing the height within a blender tub of a mixture of sand from the sand system and water from the water system; providing a virtual rate control system; and producing a drive signal to the pumping system using the virtual rate control system using a desired rate of well treatment fluid to be delivered to a well, the output rate of the sand system, the output rate of the water system, and the output rate of the pumping system.