Automated High-Pressure Pump Testing with Worm Gear Choke Control
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Solution Overview
Problem
Current high-pressure fracking operations face challenges with manual choke valve adjustments, leading to slower pressure control and increased risk of user error, especially at higher pressures, where precise control is difficult due to the sensitive flow coefficient curve of the choke valve, resulting in frequent overshoots and undershoots of desired pressure values.
Innovation Solution
A fracking system with a choke valve system that includes a motor and worm gear with a high gear ratio, allowing for precise control of the choke valve's position and torque, and a controller that adjusts torque and speed based on intermediate positions and a control error function to maintain desired pressures, along with an automated testing system for high-pressure pumps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual adjustment of the choke valve is used, then the system is simpler and easier to manufacture, but the pressure control speed is slower and user error risk increases
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated motor-driven choke valve system. The motor and gear mechanism automatically adjust the choke valve position based on pressure feedback, eliminating manual intervention and significantly increasing pressure control speed while reducing user error risk.
Solution Approach 2:
The patent implements a feedback control system where pressure sensors continuously monitor the actual pressure and compare it with the desired pressure setpoint. The controller automatically adjusts the motor-driven choke valve based on this feedback, enabling rapid and accurate pressure control while eliminating the need for manual adjustment.
2Manufacturing precision
If manual adjustment of the choke valve is used, then the device complexity is lower, but the manufacturing precision and pressure control accuracy deteriorate at high pressures
Solution Approach 1:
The feedback control system continuously monitors pressure and automatically adjusts the choke valve position to maintain the desired pressure setpoint. This closed-loop control eliminates the imprecision of manual adjustment, especially in the sensitive low-flow-coefficient region at high pressures, by providing real-time corrections.
Solution Approach 2:
The automated motor-driven system replaces manual mechanical adjustment, providing precise and repeatable choke valve positioning. The motor control system can achieve fine positional adjustments that are difficult to accomplish manually, thereby improving pressure control accuracy at high pressures.
3Manufacturing precision
If a high gear ratio motor and worm gear are used, then the torque control precision is improved, but the device complexity increases
Solution Approach 1:
The worm gear acts as an intermediary mechanism between the motor and the choke valve. It provides mechanical advantage and precise torque multiplication, enabling fine control of the choke valve position. The high gear ratio allows small motor movements to translate into precise choke valve adjustments, improving torque control precision.
Solution Approach 2:
The control system is segmented into distinct functional components: the motor provides rotational motion, the worm gear provides torque multiplication and mechanical advantage, and the choke valve provides flow control. This segmentation allows each component to be optimized for its specific function while working together to achieve precise torque and pressure control.
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 system enables accurate and automated control of high-pressure outputs, reducing user error and maintaining precise pressure control, even at pressures over 10,000 psi, by using a high gear ratio and advanced control algorithms to manage torque and speed, thereby preventing damage and ensuring safety.
Implementation Method 1
a motor connected to the choke valve with a worm gear and configured to selectively position the choke valve, the motor and the worm gear having a total gear ratio greater than or equal to 100
Data Source
AI summary
A system for automated testing of a high-pressure pump comprises a choke valve, actuator and actuator drive for operating the choke in response to receiving control signals. A system control unit includes a processor unit, system memory, I/O interface, human-machine interface, and display device. A pressure sensor is connected to the pump outlet line for sensing and reporting outlet pressure to the control unit. The control unit can execute a test phase by causing the pump to run at a test speed and causing the actuator to change the restriction value of the choke until a predetermined pressure is sensed in the outlet line and reported to the control unit. The control unit can cause the actuator to maintain the predetermined pressure for a predetermined period of time. The control unit can cause the display device to show a result or print a report of one or more test phases.