High rate safety shutdown system with hydraulic driven fluid ends

1. A high rate safety shutdown system, comprising:

an engine;

a gearbox,

a hydraulic pump having a swashplate and a hydraulically driven reciprocating cylinder operable to drive a reciprocating piston in a fluid end of the pump;

a pressure sensor;

a pressure relief valve; and

a control system operable to control the swashplate of the hydraulic pump and the engine, the control system comprising a processor in data communication with at least one input/output device, and computer memory, the computer memory comprising a program having machine readable instructions that, when effected by the processor, perform the following steps:

(a) receive set threshold values from the input/output device for maximum treating pressure, maximum allowable equipment pressure, maximum rate of change of pressure, pressure relief valve setting, and flow rate;

(b) determine a first position of the swashplate as a function of the flow rate;

(c) activate the engine to provide power to the hydraulic pump;

(d) determine a first discharge pressure of the system via the pressure sensor;

(e) determine a rate of change of pressure via the pressure sensor;

determine if:

(f1) the first discharge pressure is greater than the pressure relief valve setting;

(f2) the first discharge pressure is greater than the maximum allowable equipment pressure; and

(f3) the rate of change of pressure is greater than the maximum rate of change of pressure;

(g) determine if:

(g1) the first discharge pressure is less than the maximum allowable equipment pressure but greater than the maximum treating pressure; and

(g2) the rate of change of pressure is less than the maximum rate of change of pressure;

(h) trigger the pressure relief valve and determine a second position of the swashplate upon the occurrence of (f1), (f2), or (f3); and

(i) determine a third position of the swashplate upon the occurrence of (g1) and (g2).

2. The safety shutdown system of claim 1 , wherein, upon the occurrence of (f1), (f2), or (f3), the instructions further perform the following step:

(j) de-power the engine.

3. The safety shutdown system of claim 2 , wherein the second position of the swashplate is neutral.

4. The safety shutdown system of claim 3 , wherein the instructions further perform the following steps:

(k) determine a second discharge pressure via the pressure sensor;

(l) determine if the second discharge pressure is below the maximum treating pressure;

(m) if the second discharge pressure is below the maximum treating pressure, set the swashplate to the first position; and

(n) repeat steps (b)-(i).

5. The safety shutdown system of claim 1 , wherein the triggering of the pressure relief valve at step (h) causes an unanticipated change in the first discharge pressure, and wherein the instructions further perform the following step:

(j) de-power the engine to eliminate power in response to the unanticipated change in the first discharge pressure.

6. The safety shutdown system of claim 5 , wherein the second position of the swashplate is neutral.

7. The safety shutdown system of claim 6 , wherein the instructions further perform the following step:

(k) verify, via an input, a safe operational condition of the system prior to repowering the system.

8. The safety shutdown system of claim 1 , wherein the instructions further perform the following step:

(j) upon the non-occurrence of steps (f1), (f2), (f3), (g1), and (g2), repeating steps (b)-(j).

9. The safety shutdown system of claim 1 , wherein the pressure sensor comprises a plurality of pressure sensors.

10. The safety shutdown system of claim 1 , wherein the control system further comprises a networking device, and wherein the input/output device is a mobile device in operable communication with the control system over a network.

11. The safety shutdown system of claim 1 , wherein the hydraulic pump is hydraulically driven via hydraulic fluids.

12. A high rate safety shutdown system, comprising:

an engine;

a gearbox;

a hydraulic pump having a swashplate and a hydraulically driven reciprocating cylinder operable to drive a reciprocating piston in a fluid end of the pump;

a pressure sensor; and

a control system operable to control the swashplate of the hydraulic pump and the engine, the control system comprising a processor in data communication with at least one input/output device, and computer memory, the computer memory comprising a program having machine readable instructions that, when effected by the processor, iteratively perform the following steps:

(a) receiving set threshold values from the input/output device for maximum treating pressure, maximum allowable equipment pressure, maximum rate of change of pressure, pressure relief valve setting, and flow rate;

(b) determining a first position of the swashplate as a function of the flow rate;

(c) activating the engine to provide power to the hydraulic pump;

(d) determining a first discharge pressure of the system via the pressure sensor;

(e) determining if:

(e1) the first discharge pressure is greater than the pressure relief valve setting;

(e2) the first discharge pressure is greater than the maximum allowable equipment pressure; and

(e3) the rate of change of pressure is greater than the maximum rate of change of pressure; and

(f) upon the occurrence of (e1), (e2) or (e3), setting the swashplate to a neutral position, activating the pressure relief valve, and reducing the power to the engine.

13. The safety shutdown system of claim 12 , wherein reducing the power to the engine at step (f) comprises de-powering the engine.

14. The safety shutdown system of claim 12 , further comprising the steps of:

(g) verifying, via an input, a safe operational condition of the system prior to repowering the system;

(h) resetting the pressure relief valve;

(i) activating the engine to produce the flowrate; and

(j) repeating steps (b)-(i).

15. The system of claim 14 , further comprising the steps of:

(k) upon the non-occurrence of step (g), maintaining the swashplate at the neutral position and the reduced power to the engine.

16. The safety shutdown system of claim 12 , wherein the pressure sensor is a plurality of pressure sensors.

17. The safety shutdown system of claim 12 , wherein the control system further comprises a networking device, and wherein the input/output device is a mobile device configured to communicate with the control system over a network.

18. The safety shutdown system of claim 12 , wherein the hydraulic pump is hydraulically driven via hydraulic fluids.

19. The safety shutdown system of claim 12 , further comprising a second sensor in communication with the control system, wherein the second sensor is selected from the list consisting of: a temperature sensor, a level sensor, a flow rate meter, and a particulate matter sensor.

20. A method of controlling a high-pressure system comprising an engine, and a hydraulic pump having a swashplate and a hydraulically driven reciprocating cylinder operable to drive a reciprocating piston in a fluid end of the pump, the method comprising:

(1) inputting a maximum discharge pressure, a maximum allowable equipment pressure, a pressure relief valve setting, a flowrate, a maximum positive rate of change of pressure, and a maximum negative rate of change of pressure;

(2) setting a work value of the high-pressure system to required power to the engine;

(3) setting a first position of the swashplate as a function of flowrate;

(4) determining:

(a) if a discharge pressure is greater than the pressure relief valve setting;

(b) if the discharge pressure is greater than the maximum allowable equipment pressure;

(c) if a rate of change of pressure is greater than the maximum positive rate of change of pressure; and

(d) if the rate of change of pressure is greater than the maximum negative rate of change of pressure;

(5) upon the occurrence of any of steps 4(a)-4(d):

(e) activating a pressure relief valve in the system;

(f) setting the swashplate position to neutral; and

(g) reducing the engine power to zero.