Adaptive control system and methods for well service pump systems
OwnerTom GABLE, George DALEKOS +2inventors
InventorsTom GABLE, George DALEKOS, Shelton BURNETT, Sean HODGSON
Life of this patent
Estimating the term…
Abstract
A well service pump system supplies high pressure working fluid to a well. The pump system includes a closed-loop hydraulic circuit for actuating a plurality of working pump assemblies. The pump system is powered by a motor, which transfers mechanical energy to a plurality of pumps, which, in turn, provide hydraulic fluid to operate hydraulic ram cylinders, and thereby operate the working pump assemblies. Each of the polished rods of the hydraulic ram cylinders is connected axially to a plunger rod end of the working fluid end cylinder to operate the working pump assembly.
Claims33
A well service pump system for delivering fracturing fluid at high pressure to a well, the pump system comprising:
- three or more working fluid pump assemblies, each comprising:
- a working fluid end cylinder having an end cylinder housing, a plunger rod configured to reciprocate in the end cylinder housing;
- and
- a hydraulic ram cylinder having a ram cylinder housing, a ram piston configured to reciprocate in the ram cylinder housing, and a piston rod coupled to the ram piston and coupled to the plunger rod of the working fluid end cylinder such that piston of the hydraulic ram cylinder can be actuated to move the plunger rod of the working fluid end cylinder:
- in a first direction to expel working fluid from the end cylinder housing during a forward stroke of the plunger rod, and
- in a second direction to draw working fluid into the end cylinder housing during a return stroke of the plunger rod;
- and
- a sensor configured to detect a parameter indicative of the position of the plunger rod of the working fluid end cylinder and/or the position of the ram piston of the hydraulic ram cylinder;
- one or more sources of hydraulic fluid configured to selectively direct pressurized hydraulic fluid to each of the hydraulic ram cylinders to drive the respective ram piston in at least one of the first and second directions;
- a control system coupled to the sensors and configured to sequentially actuate the hydraulic ram cylinders to deliver a continuous output flow of the working fluid from the pump system to the well, the control system further configured to:
- determine how many of the working fluid pump assemblies are operational;
- and
- adjust the timing of actuation of each of the operational ones of the working fluid pump assemblies based on the number of operational working fluid pump assemblies.
8-10. (cancelled)
(canceled)
18-22. (canceled)
(canceled)
(canceled)
A method comprising:
- delivering a working fluid to a well with a well service pump system comprising:
- at least three working fluid pump assemblies, each comprising:
- a working fluid end cylinder having a plunger rod configured to reciprocate within the fluid end cylinder;
- and
- a hydraulic ram cylinder having a ram piston configured to reciprocate within the hydraulic ram cylinder and a piston rod coupled to the ram piston and coupled to the plunger rod of the working fluid end cylinder;
- wherein the hydraulic ram cylinder includes a first hydraulic port on a first side of the ram piston and second hydraulic port on a second side of the ram piston;
- one or more sources of hydraulic fluid configured to selectively direct pressurized hydraulic fluid to each of the hydraulic ram cylinders to drive the respective ram piston in at least one of the first and second directions;
- wherein delivering the working fluid comprises, for each operational one of the working fluid pump assemblies:
- actuating the ram piston of the hydraulic ram cylinder to move the plunger rod of the working fluid end cylinder:
- in a first direction to expel working fluid from the fluid end cylinder during a forward stroke of the plunger rod, and
- in a second direction to draw working fluid into the fluid end cylinder during a return stroke of the plunger rod;
- and
- determining how many of the working fluid pump assemblies are operational;
- and
- timing actuation of each of the operational ones of the working fluid pump assemblies based on the determined number of operational working fluid pump assemblies.
39-41. (canceled)
Dependencies are inferred from the claim text.