US20130078114A1 - Phase shift controller for a reciprocating pump system - Google Patents
Phase shift controller for a reciprocating pump system Download PDFInfo
- Publication number
- US20130078114A1 US20130078114A1 US13/639,929 US201113639929A US2013078114A1 US 20130078114 A1 US20130078114 A1 US 20130078114A1 US 201113639929 A US201113639929 A US 201113639929A US 2013078114 A1 US2013078114 A1 US 2013078114A1
- Authority
- US
- United States
- Prior art keywords
- pump
- phase shift
- phase
- control device
- shift control
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 230000010363 phase shift Effects 0.000 title claims abstract description 66
- 238000006073 displacement reaction Methods 0.000 claims abstract description 42
- 230000007246 mechanism Effects 0.000 claims description 5
- 238000000034 method Methods 0.000 claims description 5
- 230000009467 reduction Effects 0.000 claims description 3
- 230000010349 pulsation Effects 0.000 abstract description 15
- 239000012530 fluid Substances 0.000 description 9
- 239000002002 slurry Substances 0.000 description 9
- 229910052500 inorganic mineral Inorganic materials 0.000 description 7
- 239000011707 mineral Substances 0.000 description 7
- 238000005065 mining Methods 0.000 description 6
- 238000012545 processing Methods 0.000 description 6
- 238000010586 diagram Methods 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- 230000006872 improvement Effects 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 238000005086 pumping Methods 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007257 malfunction Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000010355 oscillation Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B11/00—Equalisation of pulses, e.g. by use of air vessels; Counteracting cavitation
- F04B11/005—Equalisation of pulses, e.g. by use of air vessels; Counteracting cavitation using two or more pumping pistons
- F04B11/0075—Equalisation of pulses, e.g. by use of air vessels; Counteracting cavitation using two or more pumping pistons connected in series
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B23/00—Pumping installations or systems
- F04B23/04—Combinations of two or more pumps
- F04B23/06—Combinations of two or more pumps the pumps being all of reciprocating positive-displacement type
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B15/00—Pumps adapted to handle specific fluids, e.g. by selection of specific materials for pumps or pump parts
- F04B15/02—Pumps adapted to handle specific fluids, e.g. by selection of specific materials for pumps or pump parts the fluids being viscous or non-homogeneous
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/007—Installations or systems with two or more pumps or pump cylinders, wherein the flow-path through the stages can be changed, e.g. from series to parallel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
- F04B49/20—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00 by changing the driving speed
Definitions
- Disclosed embodiments relate generally to pumps and more particularly to multiple reciprocating positive displacement pumps for handling mineral slurries.
- Reciprocating positive displacement pumps are used for pumping fluid against relatively high pressure, when compared to single stage centrifugal pumps, for example. Further characteristics of such positive displacement pumps include high efficiency and an accurate flow output, but a relatively low flow capacity when compared to centrifugal pumps.
- more positive displacement pumps can be arranged in parallel such that their suction and/or discharge connections are connected into a single suction and/or discharge line. This means that the sum flow of the individual pumps can meet the total flow requirements of the application.
- the combination of the individual pumps and the interconnecting suction and discharge lines forms a pump system.
- a displacement element such as a piston or plunger makes a reciprocating motion inside a cylinder liner enabling the positive displacement the fluid to be pumped.
- the reciprocating motion of the displacement element is generated by a mechanism which transfers the rotating motion of the pump drive into a reciprocating motion of the displacement element.
- this mechanism may include crankshaft, eccentric shaft, camshaft or cam disc mechanisms.
- Disclosed embodiments provide a solution for the described shortcomings of the phase shift control systems of the prior art crankshaft-driven positive displacement pumps.
- a real pump is used as a master in a master/slave control scheme for controlling the phase shift between the master and slave pump.
- the drawbacks included the complex master/slave scheduling procedures, the reduced reliability of the pump system as it depends on the reliability of a single master pump, and the reduced performance of the entire pump system in case of an unstable master pump operation.
- a pump system using multiple-reciprocating, positive displacement pumps which phase shift is controlled by a phase shift controller.
- the phase shift controller uses a virtual master pump inside the phase shift controller which is used as a phase reference against which the phase shifts of the individual pumps is calculated.
- the phase shift controller adjusts the speed reference set-point for the variable speed drives of the individual pumps such that a desired phase shift is obtained and maintained.
- the operation of multiple reciprocating pumps using phase shift control can significantly reduce the pressure pulsation levels in the pump system.
- the use of a virtual master pump eliminates master slave scheduling and increases system reliability and availability as is the operating of the phase control is not depending on the reliability of a real master pump as is the case in prior art phase shift controllers.
- the virtual master pump creates a phase reference signal within the phase shift controller based on a single pump system reference speed set-point just as a real master pump would do. All the real pumps in the pump system act as slaves in the phase shift controller. The phase of each individual pump is compared to the phase of the virtual master pump inside the controller which is then used as an input for the phase shift control.
- FIG. 4 a control flow diagram for the virtual master phase shift controller is shown.
- a virtual master pump can provide some operational improvements over the known prior art crankshaft-driven, positive displacement phase shift control systems.
- the slave pumps are always referenced against the same virtual master pump, hence no scheduling is required.
- the virtual master pump is considered to be available at all times as it does not require maintenance and has a much higher reliability than a real mechanical pump.
- the speed of the master pump is stable at all times since it is not influenced by the performance of a single master pump, which is especially useful when a positive displacement pump is used for pumping abrasive slurries in the mining and mineral processing industry.
- the disclosure is not limited to triplex single acting positive displacement pumps but applies to all single or multi cylinder single and double acting positive displacement pumps.
- FIG. 1 illustrates a schematic cross section of a prior art triplex single acting positive displacement pump, also showing a disclosed embodiment using an intermediate fluid and an additional flexible displacement element;
- FIG. 2 illustrates a triplex single acting positive displacement pump flow pulsation of the prior art
- FIG. 3 illustrates a prior art control flow diagram of reciprocating pump phase control with a master-slave control scheme using a real pump as master
- FIG. 4 illustrates a control flow diagram of reciprocating pump phase control with a master-slave control scheme using a virtual master, in accordance with disclosed embodiments.
- crankshaft driven positive displacement pump a schematic cross section of a 3-cylinder or triplex single acting crankshaft driven positive displacement pump is shown.
- the displacement element can directly displace the pumped fluid or displace an intermediate fluid which displaces a flexible displacement element which displaces the pumped fluid, such as an abrasive slurry.
- the disclosure applies to an embodiment of a positive displacement pump, but as the improvement is of particular interest to positive slurry pumps as described below, the embodiment using an intermediate fluid and flexible displacement as specifically shown in FIG. 1 .
- crankshaft-driven positive displacement pump A typical characteristic of the crankshaft-driven positive displacement pump is the non-constant reciprocating velocity of the displacement element. Crankshaft-driven positive displacement pumps therefore inherently generate a non-constant flow or flow pulsation each crankshaft revolution.
- FIG. 2 a typical flow pulsation generated during one crankshaft revolution or pump cycle of a triplex single-acting positive displacement pump is shown.
- these flow pulsations can result in pressure pulsations in the pumped fluid which can result in vibration of the piping and its support structure through which the fluid is flowing, and the pressure pulsations can create an unbalanced load in the piping system.
- crankshaft-driven positive displacement pump When more than one crankshaft-driven positive displacement pump is connected to a single suction and/or discharge inlet or outlet, an interaction between the flow pulsations generated by the individual pumps can occur. This interaction can cancel out or increase the total level of flow and pressure pulsations in the pump system, again depending on the hydraulic response of the connected system. Also, hydraulic resonances present in the pump system can be excited by the flow pulsations generated by each individual pump.
- An important parameter which determines the total flow and pressure pulsation in a given pump system is the phase shift between the crankshafts of the individual pumps. Controlling this phase shift can therefore help in controlling the flow and pressure pulsation in a given pump system using crankshaft-driven positive displacement pumps.
- phase shift control also referred to as pump synchronization
- the phase shift control requires pumps equipped with variable speed drives (VSD) which can be used to adjust and maintain the phase shift between the pumps by speed adjustments of the individual drives.
- VSD variable speed drives
- the individual pump and/or their drives are equipped with a phase sensor which indicates the position of the pump cycle of the individual pump, further referred to as phase of the individual pump.
- phase information is then used by the phase shift calculator to calculate the phase shifts between the individual pumps, which then is used by the phase shift controller to adjust the speed of the individual pumps such that the phase shift is adjusted towards or maintained at the desired phase shift.
- one pump in the pump system is assigned as the master pump.
- This master pump follows the pump system speed reference set-point without any adjustments for phase shift control.
- the other pumps are assigned as slaves who have to follow the master pump.
- the phase shift controller calculates the phase difference between the master and each slave pump and generates a speed set-point for each individual slave pump which is based on the phase shift between the master and the individual slave pump, such that a the constant and desired phase shift between the master and slave pump is obtained and maintained.
- Embodiments known and used in prior art are normally limited to three or four pumps per pump system, and for which the master/slave scheduling procedures are relatively easy. Furthermore the total flow rate of prior art pump systems with phase shift control are limited so that the system can still operate reliably because unbalanced loads generated by the pressure pulsations are relatively low and can still be acceptable in some applications.
- the present disclosure includes several embodiments for the individual parts of the phase shift controller. For completeness, a listing of some embodiments is given:
- variable speed drive is not limited to a particular embodiment of the used variable speed drive, however the following embodiments are mentioned in particular:
- phase shift controller is not limited to a particular embodiment of the phase shift controller, however, the following embodiments are mentioned in particular:
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Control Of Positive-Displacement Pumps (AREA)
- Reciprocating Pumps (AREA)
- Control Of Transmission Device (AREA)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US13/639,929 US20130078114A1 (en) | 2010-04-07 | 2011-04-05 | Phase shift controller for a reciprocating pump system |
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US32160110P | 2010-04-07 | 2010-04-07 | |
| NL2004979 | 2010-06-28 | ||
| NL2004979A NL2004979C2 (en) | 2010-04-07 | 2010-06-28 | Phase shift controller for a reciprocating pump system. |
| PCT/NL2011/050230 WO2011126367A2 (en) | 2010-04-07 | 2011-04-05 | Phase shift controller for a reciprocating pump system. |
| US13/639,929 US20130078114A1 (en) | 2010-04-07 | 2011-04-05 | Phase shift controller for a reciprocating pump system |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US20130078114A1 true US20130078114A1 (en) | 2013-03-28 |
Family
ID=43971690
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US13/639,929 Abandoned US20130078114A1 (en) | 2010-04-07 | 2011-04-05 | Phase shift controller for a reciprocating pump system |
Country Status (11)
| Country | Link |
|---|---|
| US (1) | US20130078114A1 (zh) |
| CN (1) | CN102893028B (zh) |
| AR (1) | AR080839A1 (zh) |
| AU (1) | AU2011239051B2 (zh) |
| CA (1) | CA2795538C (zh) |
| DE (1) | DE112011101269B4 (zh) |
| MX (1) | MX2012011512A (zh) |
| PE (1) | PE20130791A1 (zh) |
| RU (1) | RU2012147256A (zh) |
| TW (1) | TW201207236A (zh) |
| WO (1) | WO2011126367A2 (zh) |
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|---|---|---|---|---|
| US20190195020A1 (en) * | 2016-09-16 | 2019-06-27 | Robert Bosch Gmbh | Rotary Electrohydraulic Actuator |
| US10705554B2 (en) | 2017-04-28 | 2020-07-07 | Graco Minnesota Inc. | Solenoid valve for a portable hydraulic power unit |
| US11149725B2 (en) | 2016-01-20 | 2021-10-19 | Weir Minerals Netherlands B.V. | Hydraulic pump system for handling a slurry medium |
| US11306707B2 (en) * | 2018-09-13 | 2022-04-19 | Nuovo Pignone Tecnologie—S.R.L. | Method for reducing the pulsation level in a multi-compressor plant employing reciprocating compressors |
| US11434737B2 (en) | 2017-12-05 | 2022-09-06 | U.S. Well Services, LLC | High horsepower pumping configuration for an electric hydraulic fracturing system |
| US11451016B2 (en) | 2012-11-16 | 2022-09-20 | U.S. Well Services, LLC | Switchgear load sharing for oil field equipment |
| US11449018B2 (en) | 2012-11-16 | 2022-09-20 | U.S. Well Services, LLC | System and method for parallel power and blackout protection for electric powered hydraulic fracturing |
| US11454170B2 (en) | 2012-11-16 | 2022-09-27 | U.S. Well Services, LLC | Turbine chilling for oil field power generation |
| US11454079B2 (en) | 2018-09-14 | 2022-09-27 | U.S. Well Services Llc | Riser assist for wellsites |
| US11459863B2 (en) | 2019-10-03 | 2022-10-04 | U.S. Well Services, LLC | Electric powered hydraulic fracturing pump system with single electric powered multi-plunger fracturing pump |
| US11476781B2 (en) | 2012-11-16 | 2022-10-18 | U.S. Well Services, LLC | Wireline power supply during electric powered fracturing operations |
| US11506126B2 (en) | 2019-06-10 | 2022-11-22 | U.S. Well Services, LLC | Integrated fuel gas heater for mobile fuel conditioning equipment |
| USD977426S1 (en) | 2019-12-13 | 2023-02-07 | Graco Minnesota Inc. | Hydraulic power pack |
| US11578577B2 (en) | 2019-03-20 | 2023-02-14 | U.S. Well Services, LLC | Oversized switchgear trailer for electric hydraulic fracturing |
| US11674352B2 (en) | 2012-11-16 | 2023-06-13 | U.S. Well Services, LLC | Slide out pump stand for hydraulic fracturing equipment |
| US11713661B2 (en) | 2012-11-16 | 2023-08-01 | U.S. Well Services, LLC | Electric powered pump down |
| US11728709B2 (en) | 2019-05-13 | 2023-08-15 | U.S. Well Services, LLC | Encoderless vector control for VFD in hydraulic fracturing applications |
| US11850563B2 (en) | 2012-11-16 | 2023-12-26 | U.S. Well Services, LLC | Independent control of auger and hopper assembly in electric blender system |
| US11959533B2 (en) | 2017-12-05 | 2024-04-16 | U.S. Well Services Holdings, Llc | Multi-plunger pumps and associated drive systems |
| US12078110B2 (en) | 2015-11-20 | 2024-09-03 | Us Well Services, Llc | System for gas compression on electric hydraulic fracturing fleets |
| US12092095B2 (en) | 2016-12-02 | 2024-09-17 | Us Well Services, Llc | Constant voltage power distribution system for use with an electric hydraulic fracturing system |
| US12116875B2 (en) | 2018-10-09 | 2024-10-15 | U.S. Well Services, LLC | Electric powered hydraulic fracturing pump system with single electric powered multi-plunger pump fracturing trailers, filtration units, and slide out platform |
| US12142928B2 (en) | 2018-06-15 | 2024-11-12 | U.S. Well Services, LLC | Integrated mobile power unit for hydraulic fracturing |
| US12152711B2 (en) | 2019-12-27 | 2024-11-26 | U.S. Well Services, LLC | System and method for integrated flow supply line |
| US12221872B2 (en) | 2014-10-14 | 2025-02-11 | U.S. Well Services, LLC | System and method for parallel power and blackout protection for electric powered hydraulic fracturing |
| US12241353B2 (en) | 2019-12-31 | 2025-03-04 | U.S. Well Services, LLC | Self-regulating frac pump suction stabilizer/dampener |
| US12359548B2 (en) | 2019-12-30 | 2025-07-15 | U.S. Well Services, LLC | Electric motor driven transportation mechanisms for fracturing blenders |
| US12509974B2 (en) | 2019-12-27 | 2025-12-30 | U.S. Well Services, LLC | Systems and methods for fluid end health monitoring |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2016229643B2 (en) * | 2015-03-09 | 2020-10-01 | Weir Minerals Netherlands B.V. | Hydraulic pump system for handling a slurry medium |
| NL2019357B1 (en) | 2017-07-27 | 2019-02-18 | Weir Minerals Netherlands Bv | Pump system for handling a slurry medium |
| CN112727752B (zh) * | 2020-12-28 | 2022-10-14 | 广东拓斯达科技股份有限公司 | 一种多泵合流的流量脉动消除方法和装置 |
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| US5259731A (en) * | 1991-04-23 | 1993-11-09 | Dhindsa Jasbir S | Multiple reciprocating pump system |
| US20120057991A1 (en) * | 2010-02-23 | 2012-03-08 | Artemis Intelligent Power Limited | Fluid-working machine and method of operating a fluid-working machine |
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2011
- 2011-04-05 PE PE2012001999A patent/PE20130791A1/es active IP Right Grant
- 2011-04-05 DE DE112011101269.1T patent/DE112011101269B4/de active Active
- 2011-04-05 CA CA2795538A patent/CA2795538C/en active Active
- 2011-04-05 AU AU2011239051A patent/AU2011239051B2/en active Active
- 2011-04-05 US US13/639,929 patent/US20130078114A1/en not_active Abandoned
- 2011-04-05 MX MX2012011512A patent/MX2012011512A/es unknown
- 2011-04-05 CN CN201180022244.4A patent/CN102893028B/zh active Active
- 2011-04-05 WO PCT/NL2011/050230 patent/WO2011126367A2/en not_active Ceased
- 2011-04-05 RU RU2012147256/06A patent/RU2012147256A/ru not_active Application Discontinuation
- 2011-04-06 TW TW100111875A patent/TW201207236A/zh unknown
- 2011-04-07 AR ARP110101161A patent/AR080839A1/es active IP Right Grant
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| US5259731A (en) * | 1991-04-23 | 1993-11-09 | Dhindsa Jasbir S | Multiple reciprocating pump system |
| US20120057991A1 (en) * | 2010-02-23 | 2012-03-08 | Artemis Intelligent Power Limited | Fluid-working machine and method of operating a fluid-working machine |
Cited By (39)
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|---|---|---|---|---|
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| US11449018B2 (en) | 2012-11-16 | 2022-09-20 | U.S. Well Services, LLC | System and method for parallel power and blackout protection for electric powered hydraulic fracturing |
| US11850563B2 (en) | 2012-11-16 | 2023-12-26 | U.S. Well Services, LLC | Independent control of auger and hopper assembly in electric blender system |
| US11674352B2 (en) | 2012-11-16 | 2023-06-13 | U.S. Well Services, LLC | Slide out pump stand for hydraulic fracturing equipment |
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| US11451016B2 (en) | 2012-11-16 | 2022-09-20 | U.S. Well Services, LLC | Switchgear load sharing for oil field equipment |
| US12221872B2 (en) | 2014-10-14 | 2025-02-11 | U.S. Well Services, LLC | System and method for parallel power and blackout protection for electric powered hydraulic fracturing |
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Also Published As
| Publication number | Publication date |
|---|---|
| MX2012011512A (es) | 2012-11-29 |
| CA2795538C (en) | 2018-02-20 |
| WO2011126367A2 (en) | 2011-10-13 |
| DE112011101269B4 (de) | 2021-05-06 |
| DE112011101269T5 (de) | 2013-05-02 |
| CN102893028A (zh) | 2013-01-23 |
| AU2011239051B2 (en) | 2015-12-24 |
| AU2011239051A1 (en) | 2012-11-01 |
| RU2012147256A (ru) | 2014-05-27 |
| WO2011126367A3 (en) | 2015-07-02 |
| CA2795538A1 (en) | 2011-10-13 |
| PE20130791A1 (es) | 2013-07-25 |
| TW201207236A (en) | 2012-02-16 |
| CN102893028B (zh) | 2016-09-28 |
| AR080839A1 (es) | 2012-05-09 |
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