Instrumented fracturing slurry flow system and method
Embodiments include a method for monitoring a fracturing operation that includes positioning a pump at a well site where fracturing operations are being conducted. The method also includes arranging one or more sensors at at least one of a pump inlet or a pump outlet, the one or more sensors monitoring a flow rate of a slurry. The method includes receiving flow data from the one or more sensors. The method also includes determining a pump efficiency, based at least in part on the flow data, is below a threshold. The method further includes adjusting one or more operating parameters of the pump.
1. A method for monitoring a fracturing operation, comprising:
positioning a pump at a well site where fracturing operations are being conducted;
arranging one or more flow sensors at at least one of a pump inlet or a pump outlet, the one or more flow sensors monitoring a flow rate of a slurry;
arranging one or more pump sensors on the pump or a component associated with a pumping system;
receiving flow data from the one or more flow sensors;
receiving pump operating data from the one or more pump sensors, the pump operating data being different from the flow data;
determining a pump efficiency, based at least in part on the flow data and the pump operating data, is below a threshold;
determining one or more operating parameters of the pump for adjustment;
determining an adjustment for the one or more operating parameters of the pump;
determining the one or more operating parameters, after the adjustment is applied, are within a range; and
adjusting the one or more operating parameters of the pump.
2. The method of claim 1 , further comprising:
determining the one or more operating parameters, after the adjustment is applied, exceed the range; and
providing an alert.
3. The method of claim 1 , further comprising:
receiving second flow data from the one or more flow sensors, after the one or more operating parameters are adjusted; and
determining a second pump efficiency.
4. The method of claim 3 , further comprising:
determining the second pump efficiency is above the threshold; and
storing the one or more adjusted operating parameters of the pump.
5. The method of claim 1 , wherein the one or more flow sensors are non-contact sensors arranged exterior of a tubular transporting the slurry.
6. The method of claim 5 , wherein the non-contact sensors are Doppler effect flow meters, electromagnetic flow meters, radar flow meters, mass flow meters, laser flow meters, or a combination thereof.
7. The method of claim 1 , wherein the one or more operating parameters of the pump include a speed, a suction pressure, a discharge pressure, a vibration level, or a combination thereof.
8. A method for adjusting a pump during a fracturing operation, comprising:
receiving first data from a first sensor arranged at a suction side of the pump;
receiving second data from a second sensor arranged at a discharge side of the pump;
determining a pump efficiency, based at least in part on the first data and the second data;
comparing the pump efficiency to a threshold, the threshold being a pre-determined value indicative of an operational condition of the pump;
determining the pump efficiency is below the threshold;
adjusting one or more operating parameters of the pump;
receiving third data from a third sensor arranged on the pump; and
determining a damage threshold, for the pump, is below a pre-determined limit, based at least in part on the third data.
9. The method of claim 8 , wherein adjusting one or more operating parameters of the pump comprises:
adjusting a speed of the pump;
adjusting a discharge pressure of the pump;
adjusting a suction pressure of the pump; or
adjusting a pump motor operating parameter.
10. The method of claim 8 , further comprising:
receiving fourth data from the third sensor arranged on the pump;
determining the damage threshold exceeds the pre-determined limit; and
taking the pump offline.
11. The method of claim 8 , further comprising:
recording the adjusted one or more operating parameters of the pump; and
using the recorded adjusted one or more operating parameters of the pump on a second pump.
12. The method of claim 8 , further comprising:
associating the first data with a first damage threshold;
associating the second data with a second damage threshold; and
determining at least one of the first data or the second data exceeds the respective first or second damage thresholds; and
adjusting one or more operating parameters of the pump.
13. The method of claim 8 , wherein the first sensor and the second sensor are arranged proximate the pump such that no intermediate equipment is positioned between the first sensor and a pump inlet and no intermediate equipment is positioned between the second sensor and a pump outlet.