Controlling a discharge pressure from a pump for pressure testing a fluid system

Patent metadata

Field	Value
Publication number	US-12104587-B2
Application number	US-202217649531-A
Country	US
Kind code	B2
Filing date	Jan 31, 2022
Priority date	Jan 31, 2022
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

In some implementations, a controller may obtain a setting for a target discharge pressure associated with a fluid pump driven by a motor that is controlled by a variable frequency drive (VFD). The target discharge pressure may be for use in a pressure test of a system that includes the fluid pump. The controller may determine a target torque for the motor that achieves the target discharge pressure. The controller may cause, via the VFD and in connection with the pressure test, adjustment to a speed of the motor to achieve the target torque for the motor.

First claim

What is claimed is:

1. A system for hydraulic fracturing, comprising:
at least one fluid conduit;
a fluid pump in fluid communication with the at least one fluid conduit;
a motor configured to drive the fluid pump;
a variable frequency drive (VFD) configured to control the motor; and
a controller configured to:
receive an indication to initiate a pressure test of the system,
wherein the indication to initiate the pressure test is or is separate from an input that indicates a setting for a target discharge pressure associated with the fluid pump that is to be used for the pressure test;

determine a target torque for the motor, that achieves the target discharge pressure, based on a configuration of the fluid pump;
monitor, during the pressure test, a torque of the motor to identify a deviation from the target torque for the motor; and
cause, via the VFD and in connection with the pressure test, adjustment to a speed of the motor to achieve the target torque for the motor and based on the deviation from the target torque for the motor.

2. The system of claim 1 , wherein the controller, to cause adjustment to the speed of the motor, is configured to:
set a torque setting in a control mode for the VFD to the target torque.

3. The system of claim 1 , wherein the controller, to monitor the torque of the motor, is configured to:
determine an estimated torque of the motor, or
obtain a measurement of the torque of the motor.

4. The system of claim 1 , wherein the controller is further configured to:
determine whether the system has passed or failed the pressure test; and
generate information indicating whether the system has passed or failed the pressure test.

5. The system of claim 4 , wherein the controller, to determine whether the system has passed or failed the pressure test, is configured to:
obtain a measurement relating to a pressure in the at least one fluid conduit; and
determine whether the measurement is indicative of a leak in the system.

6. The system of claim 1 , wherein the configuration of the fluid pump includes one or more of:
a gear ratio of the fluid pump,
a stroke length of the fluid pump, or
a bore diameter of the fluid pump.

7. The system of claim 1 , wherein at least the fluid pump and the motor are mounted on a hydraulic fracturing trailer.

8. A method, comprising:
identifying, by a controller, target discharge pressure, associated with a fluid pump driven by a motor that is controlled by a variable frequency drive (VFD), for use in a pressure test;
determining, by the controller, a target torque for the motor that achieves the target discharge pressure;
monitoring, during the pressure test, a torque of the motor to identify a deviation from the target torque for the motor; and
causing, by the controller via the VFD and in connection with the pressure test, adjustment to a speed of the motor based on the deviation from the target torque for the motor.

9. The method of claim 8 , further comprising:
receiving an indication to initiate the pressure test; and
receiving an input that indicates a setting for the target discharge pressure,
wherein the indication to initiate the pressure test is separate from the input that indicates the setting for the target discharge pressure.

10. The method of claim 8 , wherein causing adjustment to the speed of the motor comprises:
causing the VFD to vary at least one of an input frequency or an input voltage to the motor.

11. The method of claim 8 , further comprising:
determining whether the system has passed or failed the pressure test; and
generating information indicating whether the system has passed or failed the pressure test.

12. The method of claim 11 , wherein determining whether the system has passed or failed the pressure test comprises:
determining whether fluctuations of a torque of the motor are indicative of a leak in the system.

13. The method of claim 8 , wherein the fluid pump is a hydraulic fracturing pump.

14. A controller, comprising:
one or more memories; and
one or more processors configured to:
identify a target discharge pressure for use in a pressure test of a system that includes a fluid pump driven by a motor that is controlled by a variable frequency drive (VFD);
determine a target torque, for the motor, that achieves the target discharge pressure;
monitor, during the pressure test, a torque of the motor to identify a deviation from the target torque for the motor; and
maintain or achieve, using the VFD and during the pressure test, the target torque for the motor based on the deviation from the target torque for the motor.

15. The controller of claim 14 , wherein the one or more processors, to determine the target torque for the motor, are configured to:
determine the target torque, for the motor, that achieves the target discharge pressure based on a configuration of the fluid pump that includes one or more of a gear ratio of the fluid pump, a stroke length of the fluid pump, or a bore diameter of the fluid pump.

16. The controller of claim 14 , wherein the one or more processors, to maintain or achieve the target torque for the motor, are configured to:
adjust a speed of the motor based on the deviation from the target torque for the motor.

17. The controller of claim 14 , wherein the one or more processors, to monitor the torque of the motor, are configured to:
obtain at least one of an estimated torque of the motor, a measurement of the torque of the motor, or a measurement of a discharge pressure associated with the fluid pump.

18. The controller of claim 14 , wherein the one or more processors are further configured to:
determine whether the system has passed or failed the pressure test; and
generate information indicating whether the system has passed or failed the pressure test.

19. The controller of claim 14 , wherein the one or more processors, to maintain or achieve the target torque for the motor, are configured to:
control, based on the deviation from the target torque for the motor, a rate of change of a speed of the motor.

20. The controller of claim 14 , wherein the one or more processors, to monitor the torque of the motor, are configured to:
determine an estimated torque of the motor based on one or more of a magnetic flux of the motor or a current of an armature of the motor, or
obtain, from a sensor of the motor, a measurement of the torque of the motor.

Assignees

• Caterpillar Inc

Inventors

• Publes Andy
• Paul Mark C
• Grimes Mark Francis
• Kabrich Todd Ryan
• Benguedda Riadh

Classifications

• F04B51/00

  Testing machines, pumps, or pumping installations · CPC title

• E21B43/2607 Primary

  Surface equipment specially adapted for fracturing operations · CPC title

• F04B2203/0202

  Voltage · CPC title

• F04B2203/0204

  Frequency of the electric current · CPC title

• F04B2203/0207

  Torque · CPC title