Rig management system for transmission control of a hydraulic fracturing rig

Patent metadata

Field	Value
Publication number	US-11028842-B2
Application number	US-201816051150-A
Country	US
Kind code	B2
Filing date	Jul 31, 2018
Priority date	Jul 31, 2018
Publication date	Jun 8, 2021
Grant date	Jun 8, 2021

Abstract

A rig management system is disclosed. The rig management system may be configured to receive information to be used to control shifting of a transmission to prevent cavitation during use of the hydraulic fracturing rig. The rig management system may be configured to determine a flow rate for a pump based on the information. The rig management system may be configured to determine an output torque of the transmission based on the flow rate. The rig management system may be configured to determine a transmission gear for the transmission based on the output torque and a fuel consumption map, wherein the fuel consumption map identifies a respective fuel consumption rate for different combinations of transmission gears and output torques. The rig management system may be configured to cause the transmission to shift into the transmission gear after determining the transmission gear.

First claim

What is claimed is:

1. A rig management system, comprising:
one or more memories; and
one or more processors, communicatively coupled to the one or more memories, configured to:
receive pump control information associated with controlling a pump of a hydraulic fracturing rig;
determine a modified flow rate to be used in association with the pump of the hydraulic fracturing rig based on the pump control information or a cavitation prediction map,
wherein the cavitation prediction map identifies a respective modified flow rate for different combinations of inlet pressures and fluid properties of a fluid to be used with the hydraulic fracturing rig;

determine an output torque of a transmission of the hydraulic fracturing rig based on the modified flow rate;
determine a transmission gear for the transmission based on the output torque and a fuel consumption map,
wherein the fuel consumption map identifies a respective fuel consumption rate for different combinations of transmission gears and output torques; and

cause the transmission to shift into the transmission gear after determining the transmission gear.

2. The rig management system of claim 1 , wherein the pump control information identifies at least one of:
an inlet pressure to be used for the hydraulic fracturing rig,
one or more fluid properties of the fluid to be used in association with the hydraulic fracturing rig,
a flow rate to be used in association with the hydraulic fracturing rig, or
an indication of a possible cavitation associated with use of the hydraulic fracturing rig.

3. The rig management system of claim 2 , wherein the one or more processors are further configured to:
detect the indication of the possible cavitation after receiving the pump control information; and
wherein the one or more processors, when determining the modified flow rate, are configured to:
determine the modified flow rate further based on detecting the indication of the possible cavitation.

4. The rig management system of claim 2 , wherein the one or more processors are further configured to:
determine a pump speed limitation for the pump based on the inlet pressure, the one or more fluid properties, and the cavitation prediction map; and
wherein the one or more processors, when determining the modified flow rate, are configured to:
determine the modified flow rate by modifying the flow rate based on the pump speed limitation.

5. The rig management system of claim 1 , wherein the one or more processors, when determining the output torque, are configured to:
determine the output torque based on a discharge pressure associated with an inlet pressure to be used for the hydraulic fracturing rig and the modified flow rate.

6. The rig management system of claim 1 , wherein the one or more processors, when causing the transmission to shift into the transmission gear, are configured to:
cause the transmission to shift into the transmission gear at a transmission input torque or a transmission speed,
wherein the transmission input torque or the transmission speed are based on the output torque.

7. The rig management system of claim 1 , wherein the one or more processors are further configured to:
determine an engine speed at which an engine associated with the hydraulic fracturing rig is to operate based on the output torque; and
cause the engine to operate at the engine speed in association with causing the transmission to shift into the transmission gear.

8. A hydraulic fracturing rig comprising:
a transmission;
a pump; and
a rig management system, wherein the rig management system is configured to:
receive information to be used to control shifting of the transmission to prevent cavitation during use of the hydraulic fracturing rig;
determine a flow rate for the pump based on the information;
determine an output torque of the transmission based on the flow rate;
determine a transmission gear for the transmission based on the output torque and a fuel consumption map,
wherein the fuel consumption map identifies a respective fuel consumption rate for different combinations of transmission gears and output torques; and

cause the transmission to shift into the transmission gear after determining the transmission gear.

9. The hydraulic fracturing rig of claim 8 , wherein the rig management system is further configured to:
monitor a set of sensors for the information,
wherein the information identifies a possible presence of a cavitation associated with use of the hydraulic fracturing rig.

10. The hydraulic fracturing rig of claim 8 , wherein the rig management system, when determining the flow rate, is configured to:
determine the flow rate based on the information and a cavitation prediction map,
wherein the cavitation prediction map identifies a respective modified flow rate for different combinations of inlet pressures and fluid properties of a fluid to be used with the hydraulic fracturing rig,
wherein the information identifies at least one of:
an inlet pressure to be used for the hydraulic fracturing rig,
one or more fluid properties of the fluid to be used in association with the hydraulic fracturing rig, or
the flow rate for the pump.

11. The hydraulic fracturing rig of claim 10 , wherein the rig management system, when determining the output torque, is configured to:
determine the output torque based on the flow rate and a discharge pressure associated with the inlet pressure.

12. The hydraulic fracturing rig of claim 8 , wherein the rig management system, when determining the transmission gear, is configured to:
determine an engine speed for an engine associated with the hydraulic fracturing rig based on the output torque; and
wherein the rig management system, when causing the transmission to shift into the transmission gear, is configured to:
cause the transmission to shift into the transmission gear at the engine speed for the engine.

13. The hydraulic fracturing rig of claim 12 , wherein the engine speed is associated with a transmission input torque and a transmission speed at which the transmission is to operate.

Assignees

• Caterpillar Inc

Inventors

• Zhang Yanchai
• Cai Zhijun
• Dust Maurice

Classifications

• E21B47/10

  Locating fluid leaks, intrusions or movements · CPC title

• E21B43/2607

  Surface equipment specially adapted for fracturing operations · CPC title

• F04B2205/04

  Pressure in the outlet chamber · CPC title

• E21B47/06

  Measuring temperature or pressure · CPC title

• F04B2201/1202

  Torque on the axis · CPC title