Wellsite Pumping System Control for Adverse Condition Mitigation
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Solution Overview
Problem
Current pumping systems in well servicing operations lack clear indications and automated solutions for addressing adverse conditions, such as filter plugging or component failures, which necessitate manual intervention and can disrupt system operation.
Innovation Solution
A pumping system equipped with sensors and a control system that monitors the motor, transmission, and pump, allowing for automatic adjustments or recommended actions to mitigate adverse conditions, enabling continued operation at reduced rates if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual intervention is used to address adverse conditions, then the operator can address the condition, but the system operation is disrupted and the operator lacks clear indication of actions to take
Solution Approach 1:
The control system continuously monitors pumping system parameters and provides real-time feedback to the operator through the display interface. When adverse conditions are detected, the system automatically generates and displays specific recommended actions, enabling the operator to quickly understand and respond to system status without manual diagnostics or system shutdown
Solution Approach 2:
The system performs self-diagnosis by automatically detecting adverse conditions through sensors and control logic. The control system independently identifies problems, determines appropriate corrective actions, and presents these recommendations to the operator, reducing the need for manual intervention and minimizing operational disruption
2Reliability
If automated control system is implemented, then quick identification and mitigation of adverse conditions is enabled, but the device complexity increases
Solution Approach 1:
The control system serves multiple functions: it monitors pumping system parameters, detects adverse conditions, determines recommended actions, displays information to the operator, and controls pumping system adjustments. By consolidating these diverse functions into a single multi-functional control unit, the patent minimizes the addition of separate components while achieving automated reliability improvement
3Reliability
If pumping system operates at reduced rate to mitigate adverse conditions, then continued operation is enabled, but the productivity decreases
Solution Approach 1:
The control system dynamically adjusts pumping system parameters based on real-time condition monitoring. When adverse conditions are detected, the system automatically modifies operational parameters such as pumping rate to maintain reliable operation. This dynamic adaptation allows the system to continue operating at optimized rates rather than shutting down completely, balancing reliability with productivity
Data Source
AI summary
A pumping system for performing a borehole operation including pumping a fluid into a borehole. The system may include a motor, a transmission, a pump, and a control system. The motor, transmission, and pump may each include sensors. The transmission may be operatively coupled to the motor. The pump may be operatively coupled to the transmission and configured to pump fluid into the borehole. The control system may be in communication with the motor sensors, the transmission sensors, and the pump sensors. The control system may be configured to monitor the operation of the motor, the transmission, and the pump, determine if at least one of the motor, the transmission, or the pump is operating outside of predetermined parameters, and determine at least one component of the motor, the transmission, or the pump that is most likely to cause the operation to be outside of the predetermined parameters.