Strategy to Manage Pump Interactions in Multi-Rig Applications

Abstract

A system for managing a pump arrangement is provided. The system may include at least one pressure sensor configured to generate a pressure signal indicative of a pump pressure of a targeted pump within the pump arrangement, and at least one controller in electrical communication with the pressure sensor. The controller may be configured to receive the pressure signal from the pressure sensor, apply a band pass filter on the pressure signal to filter frequencies associated with untargeted pumps, isolate at least a base frequency of the filtered pressure signal, and detect at least the pump pressure of the targeted pump based on the base frequency.

Description

TECHNICAL FIELD

The present disclosure relates generally to pump management systems, and more particularly, to systems and methods for managing interactions between pump sensors in a multi-rig application.

BACKGROUND

A hydraulic fracturing or fracking application generally involves the use of multiple rigs, each having a fracking fluid pump that is connected to a common manifold being supported by a missile trailer. The manifold is further configured to deliver the collective pressurized fluid to a wellhead and to equipment further downstream. Furthermore, each pump is provided with a pressure sensor which monitors the pump for existing or anticipated fault conditions. Pressure sensors may typically monitor pump health based on the discharge pressure or other pump attributes. In such fracking environments, or in any other multi-rig, multi-pump application where two or more pumps are situated in relatively close proximity to one another and share a common manifold, there may be noticeable unwanted interactions between the adjacent pump pressures, which may adversely affect and compromise the overall integrity of the management system.

In a typical multi-rig application, for instance, a pressure sensor that is designated for a particular, targeted pump may inadvertently detect or receive pressure fluctuations caused by or originating from adjacent and untargeted pumps, in addition to those pressures originating from the targeted pump. Although some of the undesired interferences may be filtered out using signal processes already built into the pressure monitoring system, this is only possible when the base and/or harmonic frequencies of the desired and undesired pressure signals, among others, are sufficiently distinguishable by the signal processes. More specifically, conventional pressure monitoring systems are unable to filter out undesired pressure readings or interference from untargeted pumps and isolating the desired pressure readings from the targeted pump if the base and/or harmonic frequencies coincide.

Although filtering schemes for use with pressure monitoring systems may be available, there is still room for improvement. For example, U.S. Pat. No. 7,830,749 (“Kyllingstad”) discloses a method of filtering that can be used with pressure gauges designed to measure the discharge pressure of a piston pump. Moreover, Kyllingstad is directed to filtering out noise attributed to the operation of the pump itself using mathematical noise models specific to the given pump, and thereby providing a cleaner reading of the pump condition. While the methods disclosed in Kyllingstad filter undesired noise, Kyllingstad is unable to filter and/or distinguish between signals originating from two or more pumps when the pumps are operating at similar pump speeds, such as in a multi-pump fracking site or other multi-rig application.

In view of the foregoing disadvantages associated with conventional pressure monitoring systems, a need therefore exists for a more reliable solution that can easily be implemented in any applicable multi-pump or multi-rig arrangement. Moreover, there is a need to provide a pressure monitoring system which efficiently and effectively accounts for undesired interactions between neighboring pumps within a multi-pump arrangement, such as in a fracking site, to provide more accurate indications of the condition of each of the plurality of pumps.

SUMMARY OF THE DISCLOSURE

In one aspect of the present disclosure, a system for managing a pump arrangement is provided. The system may include at least one pressure sensor configured to generate a pressure signal indicative of a pump pressure of a targeted pump within the pump arrangement, and at least one controller in electrical communication with the pressure sensor. The controller may be configured to receive the pressure signal from the pressure sensor, apply a band pass filter on the pressure signal to filter frequencies associated with untargeted pumps, isolate at least a base frequency of the filtered pressure signal, and detect at least the pump pressure of the targeted pump based on the base frequency.

In another aspect of the present disclosure, a controller for managing a targeted pump in a pump arrangement is provided. The controller may include a receiver module, a filter module, and a detection module. The receiver module may be configured to receive a pressure signal from a pressure sensor associated with the targeted pump. The filter module may be configured to apply a band pass filter on the pressure signal to filter frequencies associated with untargeted pumps and isolate at least a base frequency of the targeted pump. The detection module may be configured to detect at least a pump pressure of the targeted pump based on the base frequency.

In yet another aspect of the present disclosure, a controller-implemented method for managing a pump arrangement having a targeted pump and one or more untargeted pumps is provided. The controller-implemented method may include receiving a pressure signal from a pressure sensor associated with the targeted pump; applying a band pass filter on the pressure signal configured to filter frequencies associated with the untargeted pumps; isolating at least a base frequency of the targeted pump based on the filtered pressure signal; and detecting at least a pump pressure of the targeted pump based on the base frequency.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a pictorial illustration of one exemplary pump management system that is implemented at a fracturing site;

FIG. 2 is a schematic illustration of one exemplary pump management system of the present disclosure;

FIG. 3 is a schematic illustration of one exemplary controller of a pump management system of the present disclosure;

FIG. 4 is a graphical illustration of a pressure signal corresponding to the discharge pressure of a targeted pump;

FIG. 5 is a graphical illustration of base and harmonic frequencies of the pressure signal of FIG. 4;

FIG. 6 is a graphical illustration of pressure signals corresponding to the discharge pressures of a targeted pump and untargeted pumps;

FIG. 7 is a graphical illustration of base and harmonic frequencies of the pressure signals of FIG. 6;

FIG. 8 is a graphical illustration of a band pass filter being applied onto pressure signals originating from targeted and untargeted pumps having sufficiently distinguishable pump speeds;

FIG. 9 is a graphical illustration of a band pass filter being applied onto pressure signals originating from targeted and untargeted pumps having substantially the same pump speeds; and

FIG. 10 is a flowchart illustrating one exemplary method of the present disclosure for managing pump interactions.

DETAILED DESCRIPTION

Referring now to FIG. 1, one exemplary pump management system 100 that may be implemented at a fracturing site 102 and used to manage interactions between pumps is provided. As shown, the fracturing site 102 may include a multi-rig application, or sets of rigs, trucks or trailers each performing a designated role necessary for fracking at a given wellhead 104. For example, a fracturing site 102 may generally include water supply rigs 106 for storing water, chemical storage rigs 108 for storing chemicals to be mixed with the water, mineral storage rigs 110 for storing sand or other minerals to be used for fracking, blender rigs 112 for mixing the chemicals and sand with water, pump rigs 114 which pump and pressurize the mixture to be discharged, and a manifold rig 116 which combines the mixture discharged by each of the pump rigs 114 and sends the pressurized mixture into the wellhead 104. The fracturing site 102 may further include a local data center 118 from which the fracking operations may be managed. Furthermore, the pump management system 100 may be implemented directly on the one or more of the pump rigs 114, within the data center 118, or combinations thereof. In still further alternatives, the pump management system 100 may be partially implemented and/or operated from a remote site via one or more wired and/or wireless networks.

Turning to FIG. 2, one exemplary embodiment of the pump management system 100 that is implemented in relation to a set of pump rigs 114 and an associated pump arrangement 120 is provided. In general, the pump management system 100 may include one or more pressure sensors 122 and one or more controllers 124 in electrical communication with the pressure sensors 122. Moreover, each individual pressure sensor 122 may be disposed in fluid communication with a discharge port of an associated or targeted hydraulic pump 126 and configured to generate a pressure signal indicative of at least pump pressure information of the targeted pump 126. Each pressure sensor 122 may also generate a pressure signal that is additionally indicative of pump failure information, or information relating to any detected or anticipated fault conditions or failures in the targeted pump 126. Pump pressure information may be monitored, measured or derived based on pump speed, discharge pressure, or the like, while pump failure information may be monitored, measured or derived based on pump speed, discharge pressure, vibrations in the pump 126, or the like.

Still referring to FIG. 2, the pump management system 100 may employ any one of a variety of different arrangements of controllers 124. As shown, a controller 124 may be provided for each individual pump rig 114, and configured to communicate with the pressure sensor 122 and/or pump 126 associated therewith. Alternatively, a central controller 124 may be provided and configured to communicate with multiple pressure sensors 122 and/or associated pumps 126. In other embodiments, two or more of controllers 124 may operate in conjunction with one another to collectively communicate with a single pressure sensor 122 and/or associated pump 126. Additionally, one or more of the controllers 124 may be remotely situated relative to the fracturing site 102 and configured to indirectly communicate with one or more of the pressure sensors 122 via networking devices, or the like. Furthermore, while the controllers 124 may be directly integrated into the electronic control module (ECM) or electronic control unit (ECU) of the associated pump rig 114, the controllers 124 may alternatively be implemented using any one or more of a processor, a microprocessor, a microcontroller, a field programmable gate array (FPGA), a programmable read-only memory (PROM), or any other device that can be operated in accordance with preprogrammed instructions and/or algorithms disclosed herein.

Turning to FIG. 3, one exemplary embodiment of a controller 124 that may be used in conjunction with the pump management system 100 is provided. As shown, for example, the controller 124 may be preprogrammed according to one or more algorithms generally categorized into a receiver module 128, a filter module 130, a detection module 132, a comparison module 134, and an adjustment module 136. The receiver module 128 may be configured to receive pressure signals 138, as shown in FIG. 4 for example, from one or more pressure sensors 122 associated with the targeted pump 126, where the pressure signals 138 may include pump pressure information, pump failure information, and any other relevant information the associated pressure sensor 122 is capable of reading. More particularly, as shown in FIG. 5, the pressure signals 138 may include a base frequency 140 and one or more harmonic frequencies 142, which may correspond to the pump speed, discharge pressure, and/or other attributes of the targeted pump 126. In other embodiments, the pressure signals 138 may similarly include a failure frequency that is indicative of any faults or failures in the targeted pump 126.

In actual practice, such as during a multi-rig fracking application, a given pressure sensor 122 and/or corresponding controller 124 may pick up on not only the pressure signals 138-1 from targeted pumps 126-1, but also pick up on unwanted pressure signals 138-2, 138-3 originating from untargeted pumps 126-2, 126-3, as illustrated in FIG. 2. As shown in FIG. 6, for example, the receiver module 128 of the controller 124 may receive pressure signals 138-2, 138-3 originating from one or more adjacent untargeted pumps 126-2, 126-3 in addition to the desired pressure signals 138-1 originating from the targeted pump 126-1. As further shown in FIG. 7, the interaction of pressure signals 138 received may reflect multiple base frequencies 140 and multiple sets of harmonic frequencies 142 corresponding to the pump speeds and/or discharge pressures of the untargeted pumps 126. Thus, the filter module 130 of FIG. 3 may apply the appropriate filters configured to filter out any unwanted base frequencies 140-2, 140-3 associated with untargeted pumps 126-2, 126-3 that may be included in the pressure signals 138 due to pump interactions, and isolate the base frequency 140-1 and any failure frequencies associated with the targeted pump 126-1.

As shown in FIG. 8, for example, the filter module 130 may be configured to apply a band pass filter 144 that is centered on at least the base frequency 140-1 of the targeted pump 126-1. By applying the band pass filter 144 on the pressure signals 138, the controller 124 may be able to filter out other undesired frequencies which may have been inadvertently received. Similarly, the filter module 130 may also be configured to center a band pass filter 144 on a failure frequency of the targeted pump 126-1 so as to filter out any other failure frequencies originating from untargeted pumps 126-2, 126-3. Based on the filtered pressure signals 138 and the isolated base frequency 140-1, the detection module 132 of the controller 124 may be configured to detect the discharge pressure of the targeted pump 126-1. The detection module 132 may also be configured to detect pump failures of the targeted pump 126-1 based on any failure frequencies that may be present in the filtered pressure signals 138. In certain situations, however, the band pass filter 144 may not be sufficient to isolate the base frequency 140-1 of a targeted pump 126-1 if, for instance, the base frequencies 140-2, 140-3, or corresponding pump speeds and/or discharge pressures, of the untargeted pumps 126-2, 126-3 are substantially the same as those of the targeted pump 126-1. Such situations may demand additional signal processes.

As shown in FIG. 9, for example, the base frequency 140-1 of the targeted pump 126-1 may be the substantially the same as the base frequencies 140-2, 140-3 of an untargeted pumps 126-2, 126-3. Moreover, the two base frequencies shown may be indistinguishable by the band pass filter 144 provided. In order to prevent such interactions from causing inaccurate pressure readings, the detection module 132 may also be configured to monitor pump speeds of the targeted pump 126-1 and the untargeted pumps 126-2, 126-3. For example, the detection module 132 may detect for situations where the pump speeds of the targeted pump 126-1 and one or more untargeted pumps 126-2, 126-3 are substantially the same, or for any other situation that could potentially result in overlapping or substantially similar base frequencies 140 as shown in FIG. 9. While adjustments to the band pass filter 144 may be one way to isolate the base frequency 140-1 of the targeted pump 126-1, the controller 124 may implement amplitude-based techniques for isolating the base frequency 140-1 of the targeted pump 126-1.

If the detection module 132 detects that the pump speeds of the targeted pump 126-1 and one or more untargeted pumps 126-2, 126-3 are substantially the same, the comparison module 134 of the controller 124 may compare the amplitudes of the base frequencies 140 provided in the pressure signals 138 to a theoretical amplitude or threshold 146 as shown in FIG. 9. The comparison module 134 may determine or lookup the theoretical amplitude or threshold 146 based on the given pump speed of the targeted pump 126-1 by referring to a theoretical pump model, map, lookup table, or any other set of relationships between the pump speed and pressure signal amplitudes that may be preprogrammed into the controller 124. Additionally, the adjustment module 136 of the controller 124 may be configured to apply an adjustment factor to the pressure signals 138 based on the comparisons assessed by the comparison module 134, so as to eliminate or reduce any existing base frequencies 140-2, 140-3 originating from the untargeted pumps 126-2, 126-3. In alternative embodiments, the controller 124 may be preprogrammed according to other combinations or arrangements of modules configured to collectively provide comparable results. For instance, the controller 124 may be programmed to perform amplitude-based assessments other than those performed by the comparison module 134 and the adjustment module 136 in order to isolate the base frequency 140 of the targeted pump 126.

INDUSTRIAL APPLICABILITY

In general terms, the present disclosure sets forth techniques for managing a pump arrangement, or more particularly, systems and methods for managing interactions between an arrangement of pumps simultaneously operating in fluid communication with one another. Although applicable to any type of pump monitoring or management system, the present disclosure may be particularly applicable to pump arrangements in a multi-rig application, such as in a fracturing application, where multiple hydraulic pumps are used to discharge pressurized fluids into a common manifold and where the individual pump pressures are susceptible to influence by pressures from neighboring pumps. In general, the present disclosure employs a combination of band pass filters and theoretical pump models to manage pump interactions. More specifically, the band pass filters are used to filter out unwanted pressure signals originating from untargeted pumps, and isolate the desired pressure signals originating from the targeted pump. In the event an untargeted pump is operating at a pump speed that is substantially the same as that of the targeted pump, the theoretical pump model is used a reference, which can further be used to compare the respective amplitudes of the pressure signals at the appropriate frequencies, and distinguish between pressure signals belonging to the targeted pump and more attenuated pressure signals belonging to any untargeted pumps.

One exemplary algorithm or controller-implemented method 148 for managing interactions between hydraulic pumps 126 within a multi-pump arrangement 120 is diagrammatically provided in FIG. 10. As shown, the controller 124 in block 148-1 may be configured to continuously, periodically or intermittently receive pressure signals 138 from a pressure sensor 122 of a targeted pump 126, where the pressure signals 138 may include information pertaining to the pump speed, discharge pressure, fault events, and the like. In block 148-2, the controller 124 may be configured to monitor the pump speed of the targeted pump 126 relative to the pump speeds of adjacent untargeted pumps 126 to determine if the pump speeds are substantially the same. If the pump speed of the targeted pump 126 is sufficiently distinguishable from those of other surrounding pumps 126, the controller 124 may proceed to block 148-3 and apply one or more band pass filters 144 onto the pressure signals 138. Moreover, the band pass filter 144 may be centered on the base frequency 140, one or more harmonic frequencies 142 thereof, and any failure frequencies of the targeted pump 126, so as to filter out undesired frequencies belonging to untargeted pumps 126 which may have been inadvertently received. Based on the filtered pressure signals 138, the base frequency 140 and any harmonic frequency 142 and/or failure frequency associated therewith, the controller 124 in block 148-4 may be configured to extract information related to the discharge pressure, fault or failure events, and any other information relevant to the targeted pump 126.

If, however, the controller 124 in block 148-2 of FIG. 10 determines that the pump speed of the targeted pump 126 is not sufficiently distinguishable from an untargeted pump 126, the controller 124 may proceed to block 148-5. More specifically, the controller 124 in block 148-5 may apply one or more band pass filters 144 onto the pressure signals 138 in a manner configured to filter out undesired frequencies belonging to any untargeted pumps 126. The controller 124 in block 148-6 may additionally compare the amplitudes of the pressure signal 138 at the appropriate frequencies, such as at the base frequency 140, harmonic frequencies 142 and/or the failure frequency, with theoretical amplitudes which may be derived from a preprogrammed theoretical pump model, or the like. Based on the amplitude comparisons, the controller 124 may be able to distinguish between amplitudes belonging to pressure signals 138 originating from the targeted pump 126, and more attenuated amplitudes belonging to pressure signals 138 originating from untargeted pumps 126. Furthermore, the controller 124 in block 148-7 may apply the appropriate adjustment factors to the pressure signals 138 based on the previous comparisons in a manner configured to eliminate or sufficiently reduce the undesired remnants in the pressures signals 138 originating from the untargeted pumps 126, and extract information related to the discharge pressure, fault or failure events, and any other information relevant to the targeted pump 126.

The controller 124 may thus obtain or determine the desired pump information, such as information related to the discharge pressure, fault or failure events, and any other information relevant to the targeted pump 126, via either block 148-4 or block 148-7 of FIG. 10. The controller 124 in block 148-8 may additionally process the extracted information for further diagnostics and prognostics, which may be used for managing the pump arrangement 120. Alternatively, the controller 124 may forward any extracted information to a central controller 124 and/or a data center 118 where more suitable resources for performing the diagnostics and prognostics may be available. From the foregoing, it will be appreciated that while only certain embodiments have been set forth for the purposes of illustration, alternatives and modifications will be apparent from the above description to those skilled in the art. These and other alternatives are considered equivalents and within the spirit and scope of this disclosure and the appended claims.

Claims

1. A system for managing a pump arrangement, comprising:

at least one pressure sensor configured to generate a pressure signal indicative of a pump pressure of a targeted pump within the pump arrangement; and

at least one controller in electrical communication with the pressure sensor, the controller being configured to receive the pressure signal from the pressure sensor, apply a band pass filter on the pressure signal to filter frequencies associated with untargeted pumps, isolate at least a base frequency of the filtered pressure signal, and detect at least the pump pressure of the targeted pump based on the base frequency.

2. The system of claim 1, wherein the pressure sensor is configured to generate pressure signals including pump pressure information measured in terms of pump speed.

3. The system of claim 1, wherein the pressure sensor is configured to generate pressure signals including pump failure information measured in terms of vibrations in the pump.

4. The system of claim 1, wherein the controller is configured to apply the band pass filter to isolate at least the base frequency of the targeted pump.

5. The system of claim 1, wherein the controller is configured to apply the band pass filter to isolate a failure frequency of the targeted pump, and detect a pump failure of the targeted pump based on the failure frequency.

6. The system of claim 1, wherein the controller is configured to detect when pump speeds of the targeted pump and one or more untargeted pumps are substantially the same, compare amplitudes of the detected base frequencies to a theoretical amplitude of the base frequency of the targeted pump at the given pump speed, and apply an adjustment factor to the pressure signal based on the amplitude comparison to exclude base frequencies of untargeted pumps.

7. A controller for managing a targeted pump in a pump arrangement, comprising:

a receiver module configured to receive a pressure signal from a pressure sensor associated with the targeted pump;

a filter module configured to apply a band pass filter on the pressure signal to filter frequencies associated with untargeted pumps and isolate at least a base frequency of the targeted pump; and

a detection module configured to detect at least a pump pressure of the targeted pump based on the base frequency.

8. The controller of claim 7, wherein the receiver module is configured to receive pressure signals including pump pressure information measured in terms of pump speed.

9. The controller of claim 7, wherein the receiver module is configured to receive pressure signals including pump failure information measured in terms of vibrations in the pump.

10. The controller of claim 7, wherein the filter module is configured to center the band pass filter on at least the base frequency of the targeted pump.

11. The controller of claim 7, wherein the filter module is configured to apply the band pass filter to isolate a failure frequency of the targeted pump, and the detection module is configured to detect a pump failure of the targeted pump based on the failure frequency.

12. The controller of claim 7, wherein the detection module is configured to detect when pump speeds of the targeted pump and one or more untargeted pumps are substantially the same.

13. The controller of claim 12, further comprising:

a comparison module configured to compare amplitudes of the detected base frequencies to a theoretical amplitude of the base frequency of the targeted pump at the given pump speed; and

an adjustment module configured to apply an adjustment factor to the pressure signal based on the amplitude comparison to exclude base frequencies of untargeted pumps.

14. A controller-implemented method for managing a pump arrangement having a targeted pump and one or more untargeted pumps, comprising:

receiving a pressure signal from a pressure sensor associated with the targeted pump;

applying a band pass filter on the pressure signal configured to filter frequencies associated with the untargeted pumps;

isolating at least a base frequency of the targeted pump based on the filtered pressure signal; and

detecting at least a pump pressure of the targeted pump based on the base frequency.

15. The controller-implemented method of claim 14, wherein the pressure signal includes at least pump pressure information measured in terms of pump speed.

16. The controller-implemented method of claim 14, wherein the pressure signal includes pump failure information measured in terms of vibrations in the pump.

17. The controller-implemented method of claim 14, wherein the band pass filter is centered on the base frequency and a failure frequency of the targeted pump.

18. The controller-implemented method of claim 17, further comprising:

isolating at least the failure frequency of the targeted pump based on the filtered pressure signal; and

detecting at least a pump failure of the targeted pump based on the failure frequency.

19. The controller-implemented method of claim 14, further comprising:

detecting when pump speeds of the targeted pump and one or more untargeted pumps are substantially the same;

comparing amplitudes of the detected base frequencies to a theoretical amplitude of the base frequency of the targeted pump at a given pump speed; and

applying an adjustment factor to the pressure signal based on the amplitude comparison to exclude base frequencies of untargeted pumps.

20. The controller-implemented method of claim 19, wherein detected failure frequencies caused by interactions with pressure sensors associated with one or more untargeted pumps are also excluded based on amplitude comparisons and adjustment factors.