Wellsite Equipment Maintenance Data Tracking System
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Solution Overview
Problem
Current methods for recording and managing wellsite maintenance data for multiplex pumps in oilfield operations are manual, prone to errors, and lack automation, leading to inefficiencies and increased costs due to incomplete or inaccurate data, making it difficult to determine maintenance needs and equipment conditions.
Innovation Solution
A maintenance system comprising a communication interface device for monitoring equipment health, a database for prior health status, and a central data server for analyzing data to prescribe maintenance, allowing for timely, accurate, and effective maintenance planning and execution, with features like handheld input devices and remote control capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual recording methods are used for maintenance data, then device complexity is reduced, but measurement precision and data reliability deteriorate
Solution Approach 1:
The patent replaces manual mechanical recording processes with automated electronic monitoring systems. Sensors and communication interface devices automatically capture maintenance data from equipment, eliminating human error in data collection and entry, thereby improving measurement precision without significantly increasing overall system complexity.
Solution Approach 2:
The maintenance system enables equipment to self-monitor and self-report its own maintenance needs through integrated sensors and automated data transmission. This self-service capability ensures accurate, real-time maintenance data collection without requiring manual intervention, improving data reliability while keeping the system relatively simple.
2Device complexity
If manual data entry methods are used, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The patent replaces manual data entry with automated electronic data capture and transmission systems. Communication interface devices automatically transmit maintenance data to the central server, eliminating time-consuming manual entry processes and significantly improving maintenance management productivity.
Solution Approach 2:
The system enables continuous automated data collection and transmission, ensuring maintenance information is constantly updated and available without interruption. This continuous operation eliminates the gaps and delays inherent in manual data entry,大幅提升 maintenance management efficiency.
3Device complexity
If manual monitoring methods are used, then device complexity is reduced, but loss of information increases
Solution Approach 1:
The patent replaces manual monitoring with automated sensor-based monitoring systems that continuously track equipment parameters. This automation ensures comprehensive data collection without human error or omission, preventing information loss while maintaining reasonable system complexity.
Solution Approach 2:
The system implements automated feedback loops where maintenance data is continuously collected, transmitted to the central server, and used to generate maintenance prescriptions. This closed-loop feedback ensures complete information flow from equipment to decision-making, eliminating information loss inherent in manual processes.
4Measurement precision
If automated monitoring systems are implemented, then measurement precision and productivity improve, but device complexity increases
Solution Approach 1:
The patent divides the automated monitoring system into modular components: communication interface devices at individual equipment locations, a central server for data processing, and maintenance planning modules. This segmentation allows the system to achieve high measurement precision through automation while managing complexity through modular architecture.
Solution Approach 2:
The central server performs multiple functions including data reception, storage, analysis, and maintenance prescription generation. This multi-functionality consolidates what would otherwise require separate systems, achieving high measurement precision and productivity while minimizing the increase in overall device complexity.
5Reliability
If frequent maintenance is performed based on manual data, then reliability may improve, but loss of time and resources increase due to unnecessary maintenance
Solution Approach 1:
The system uses real-time feedback from automated sensors to accurately assess actual equipment condition. This enables maintenance to be performed only when truly needed based on objective data, improving reliability by ensuring maintenance is timed correctly while reducing unnecessary maintenance time and resource waste.
Solution Approach 2:
The system performs preliminary analysis of maintenance data using algorithms that predict when maintenance will actually be needed. This preliminary assessment prevents premature or unnecessary maintenance actions, optimizing the balance between reliability improvement and time/resource conservation.
Data Source
AI summary
A maintenance system includes a plurality of wellsite equipment located at or nearby a wellsite, and a communication interface device for monitoring data that is representative of a health status of the equipment. The system further includes a database containing prior health status of the equipment, and a central data server in communication with the database which is capable of communicating with the communication interface device for generating analysis of the equipment. The analysis includes comparing the monitored data with the prior health status to prescribe if maintenance is required.