System of controlling a hydraulic fracturing pump or blender using cavitation or pulsation detection
Systems and methods for monitoring, detecting, and/or intervening with respect to cavitation and pulsation events during hydraulic fracturing operations may include a supervisory controller. The supervisory controller may be configured to receive pump signals indicative of one or more of pump discharge pressure, pump suction pressure, pump speed, or pump vibration associated with operation of the hydraulic fracturing pump. The supervisory controller also may be configured to receive blender signals indicative of one or more of blender flow rate or blender discharge pressure. Based on one or more of these signals, the supervisory controller may be configured to detect a cavitation event and/or a pulsation event. The supervisory controller may be configured to generate a cavitation notification signal indicative of detection of cavitation associated with operation of the hydraulic fracturing pump, and/or a pulsation notification signal indicative of detection of pulsation associated with operation of the hydraulic fracturing pump.
1. A hydraulic fracturing control assembly to detect one or more of (a) cavitation or (b) pulsation, associated with operating a plurality of hydraulic fracturing units, each of the plurality of hydraulic fracturing units including one or more hydraulic fracturing pumps to pump fracturing fluid into a wellhead, the hydraulic fracturing control assembly comprising:
a plurality of pump sensors to generate one or more pump signals indicative of one or more of pump discharge pressure, pump suction pressure, pump speed, or pump vibration associated with operation of the plurality of hydraulic fracturing units;
one or more blender sensors to generate one or more blender signals indicative of one or more of a blender flow rate or a blender discharge pressure;
a supervisory controller in communication with one or more of:
the plurality of hydraulic fracturing units,
the plurality of pump sensors, or
the one or more blender sensors,
the supervisory controller to:
(1) receive one or more of:
pump signals indicative of one or more of pump discharge pressure, pump suction pressure, pump speed, or pump vibration associated with operation of the one or more of the hydraulic fracturing pumps; or
blender signals indicative of one or more of the blender flow rate or a blender discharge pressure; and
(2) one or more of:
(a) associate, via the supervisory controller, one or more cavitation values with one or more of the one or more pump signals or the one or more blender signals, combine the one or more cavitation values to determine a combined cavitation value, compare the combined cavitation value to a threshold cavitation value, and when the combined cavitation value equals or exceeds the threshold cavitation value, generate one or more cavitation notification signals indicative of detection of cavitation associated with operation of the one or more hydraulic fracturing pumps, thereby to cause a reduction of one or more of a pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of a blender; or
(b) determine, based at least in part on the one or more pump signals at a first time, a first average pump suction pressure and a first average pump discharge pressure, determine, based at least in part on the one or more pump signals at a second time after the first time, a second average pump suction pressure and a second average pump discharge pressure, determine a suction pressure difference between the first average pump suction pressure and the second average pump suction pressure, and a discharge pressure difference between the first average pump discharge pressure and the second average pump discharge pressure, compare the suction pressure difference to a suction pressure threshold, compare the discharge pressure difference to a discharge pressure threshold, and when the suction pressure difference is equal to or exceeds the suction pressure threshold and the discharge pressure difference is equal to or exceeds the discharge pressure threshold, generate one or more pulsation notification signals indicative of detection of pulsation associated with operation of the one or more hydraulic fracturing pumps, thereby to cause reduction of one or more of the pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of the blender.
2. The hydraulic fracturing control assembly of claim 1 , wherein the associate one or more cavitation values comprises associate an integer value with one or more of the one or more pump signals or the one or more blender signals.
3. The hydraulic fracturing control assembly of claim 2 , wherein the combine the one or more cavitation values to determine a combined cavitation value comprises add the integer values.
4. The hydraulic fracturing control assembly of claim 1 , wherein the associate one or more cavitation values with one or more of the one or more pump signals or the one or more blender signals comprises associate integer values with each of the one or more pump signals indicative of pump suction pressure, pump speed, and pump vibration, and the one or more blender signals indicative of the blender discharge pressure.
5. The hydraulic fracturing control assembly of claim 1 , wherein the one or more cavitation values are integer values, and wherein at least two of the integer values associated with the one or more pump signals and the one or more of the blender signals are weighted differently from one another.
6. The hydraulic fracturing control assembly of claim 1 , wherein the compare the combined cavitation value to a threshold cavitation value comprises count cavitation occurrences each time the combined cavitation value equals or exceeds the threshold cavitation value, and generate the one or more cavitation notification signals indicative of detection of cavitation associated with operation of the one or more hydraulic fracturing pumps.
7. The hydraulic fracturing control assembly of claim 1 , wherein the supervisory controller further is configured to, based at least in part on the one or more cavitation notification signals, provide an alarm indicative of the detection of cavitation, the alarm comprising one or more of a visual alarm, an audible alarm, or a tactile alarm.
8. The hydraulic fracturing control assembly of claim 1 , wherein the supervisory controller further is configured to, based at least in part on the one or more cavitation notification signals, cause storage of cavitation data indicative of the detection of cavitation in a hydraulic fracturing unit profiler.
9. The hydraulic fracturing control assembly of claim 1 , wherein the supervisory controller further is configured to:
count detected cavitation occurrences to determine a cavitation occurrence count; and
thereafter, when the cavitation occurrence count is equal to or exceeds a threshold cavitation occurrence count, cause reduction of one or more of the pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of the blender.
10. The hydraulic fracturing control assembly of claim 9 , wherein the supervisory controller further is configured to, following reduction of the one or more of the pump flow rate or the blender flow rate, reset the cavitation occurrence count.
11. The hydraulic fracturing control assembly of claim 1 , following the generate the one or more pulsation notification signals indicative of detection of pulsation associated with operation of the one or more hydraulic fracturing pumps, the supervisory controller further is configured to:
determine, based at least in part on the one or more pump signals at a third time, a third average pump suction pressure and a third average pump discharge pressure;
determine, based at least in part on the one or more pump signals at a fourth time after the third time, a fourth average pump suction pressure and a fourth average pump discharge pressure;
determine, a second suction pressure difference between the third average pump suction pressure and the fourth average pump suction pressure, and a second discharge pressure difference between the third average pump discharge pressure and the fourth average pump discharge pressure;
compare the second suction pressure difference to the suction pressure threshold;
compare the second discharge pressure difference to the discharge pressure threshold; and
when the second suction pressure difference is equal to or exceeds the suction pressure threshold and the second discharge pressure difference is equal to or exceeds the discharge pressure threshold a second pulsation signal is generated, wherein the generation of the one or more pulsation notification signals includes the second pulsation notification signal indicative of a second detection of pulsation associated with operation of the one or more hydraulic fracturing pumps.
12. The hydraulic fracturing control assembly of claim 11 , wherein the supervisory controller further is configured to, based at least in part on the second pulsation notification signal, cause storage of pulsation data indicative of the detection of pulsation in a hydraulic fracturing unit profiler.
13. The hydraulic fracturing control assembly of claim 11 , wherein the supervisory controller further is configured to, based at least in part on the second pulsation notification signal, cause reduction of one or more of the pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of the blender.
14. A hydraulic fracturing system comprising:
a plurality of hydraulic fracturing units, each of the plurality of hydraulic fracturing units including one or more hydraulic fracturing pumps to pump fracturing fluid into a wellhead and one or more engines to drive the one or more hydraulic fracturing pumps;
a plurality of pump sensors configured to generate one or more pump signals indicative of one or more of pump discharge pressure, pump suction pressure, pump speed, or pump vibration associated with operation of the plurality of hydraulic fracturing units;
one or more blender sensors configured to generate one or more blender signals indicative of one or more of a blender flow rate or a blender discharge pressure;
a supervisory controller in communication with one or more of:
the plurality of hydraulic fracturing units,
the plurality of pump sensors, or
the one or more blender sensors,
the supervisory controller being configured to:
receive one or more of:
pump signals indicative of one or more of pump discharge pressure, pump suction pressure, pump speed, or pump vibration associated with operation of one or more of the hydraulic fracturing pumps; or
blender signals indicative of one or more of the blender flow rate or the blender discharge pressure; and
one or more of:
(1) associate, via the supervisory controller, one or more cavitation values with one or more of the one or more pump signals or the one or more blender signals,
combine the one or more cavitation values to determine a combined cavitation value,
compare the combined cavitation value to a threshold cavitation value, and
when the combined cavitation value equals or exceeds the threshold cavitation value, generate a cavitation notification signal indicative of detection of cavitation associated with operation of the one or more hydraulic fracturing pumps, thereby to cause a reduction of one or more of a pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of a blender; or
(2) determine, based at least in part on the one or more pump signals at a first time, a first average pump suction pressure and a first average pump discharge pressure,
determine, based at least in part on the one or more pump signals at a second time after the first time, a second average pump suction pressure and a second average pump discharge pressure,
determine a suction pressure difference between the first average pump suction pressure and the second average pump suction pressure, and a discharge pressure difference between the first average pump discharge pressure and the second average pump discharge pressure, compare the suction pressure difference to a suction pressure threshold,
compare the discharge pressure difference to a discharge pressure threshold, and
when the suction pressure difference is equal to or exceeds the suction pressure threshold and the discharge pressure difference is equal to or exceeds the discharge pressure threshold, generate a pulsation notification signal indicative of detection of pulsation associated with operation of the one or more hydraulic fracturing pumps, thereby to cause reduction of one or more of the pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of the blender.
15. The hydraulic fracturing system of claim 14 , wherein the associate one or more cavitation values comprises associate an integer value with one or more of the one or more pump signals or the one or more blender signals.
16. The hydraulic fracturing system of claim 15 , wherein the combine the one or more cavitation values to determine a combined cavitation value comprises add the integer values.
17. The hydraulic fracturing system of claim 14 , wherein the associate one or more cavitation values with one or more of the one or more pump signals or the one or more blender signals comprises associate integer values with each of the one or more pump signals indicative of pump suction pressure, pump speed, and pump vibration, and the one or more blender signals indicative of the blender discharge pressure.
18. The hydraulic fracturing system of claim 14 , wherein the one or more cavitation values are integer values, and wherein at least two of the integer values associated with the one or more pump signals and the one or more of the blender signals are weighted differently from one another.
19. The hydraulic fracturing system of claim 14 , wherein the compare the combined cavitation value to a threshold cavitation value comprises count cavitation occurrences each time the combined cavitation value equals or exceeds the threshold cavitation value, and generate the one or more cavitation notification signals indicative of detection of cavitation associated with operation of the one or more hydraulic fracturing pumps.
20. The hydraulic fracturing system of claim 14 , wherein the supervisory controller further is configured to, based at least in part on the one or more cavitation notification signals, provide an alarm indicative of the detection of cavitation, the alarm comprising one or more of a visual alarm, an audible alarm, or a tactile alarm.
21. The hydraulic fracturing system of claim 14 , wherein the supervisory controller further is configured to, based at least in part on the one or more cavitation notification signals, cause storage of cavitation data indicative of the detection of cavitation in a hydraulic fracturing unit profiler.
22. The hydraulic fracturing system of claim 14 , wherein the supervisory controller further is configured to:
count detected cavitation occurrences to determine a cavitation occurrence count; and
thereafter, when the cavitation occurrence count is equal to or exceeds a threshold cavitation occurrence count, cause reduction of one or more of the pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of the blender.
23. The hydraulic fracturing system of claim 22 , wherein the supervisory controller further is configured to, following reducing one or more of the pump flow rate or the blender flow rate, reset the cavitation occurrence count.
24. The hydraulic fracturing system of claim 14 , following the generate the one or more pulsation notification signals indicative of detection of pulsation associated with operation of the one or more hydraulic fracturing pumps, the supervisory controller further is configured to:
determine, based at least in part on the one or more pump signals at a third time, a third average pump suction pressure and a third average pump discharge pressure;
determine, based at least in part on the one or more pump signals at a fourth time after the third time, a fourth average pump suction pressure and a fourth average pump discharge pressure;
determine, a second suction pressure difference between the third average pump suction pressure and the fourth average pump suction pressure, and a second discharge pressure difference between the third average pump discharge pressure and the fourth average pump discharge pressure;
compare the second suction pressure difference to the suction pressure threshold;
compare the second discharge pressure difference to the discharge pressure threshold; and
when the second suction pressure difference is equal to or exceeds the suction pressure threshold and the second discharge pressure difference is equal to or exceeds the discharge pressure threshold a second pulsation signal is generated, wherein the generation of the one or more pulsation notification signals includes the second pulsation notification signal indicative of a second detection of pulsation associated with operation of the one or more hydraulic fracturing pumps.
25. The hydraulic fracturing system of claim 24 , wherein the supervisory controller further is configured to, based at least in part on the second pulsation notification signal, cause storage of pulsation data indicative of the detection of pulsation in a hydraulic fracturing unit profiler.
26. The hydraulic fracturing system of claim 24 , wherein the supervisory controller further is configured to, based at least in part on the second pulsation notification signal, cause reduction of one or more of the pump flow rate of the one or more hydraulic fracturing pumps or the blender flow rate of the blender.