ADAPTIVE CONTROL SYSTEM AND METHODS FOR WELL SERVICE PUMP SYSTEMS

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.

Claims

1. 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.

2. The well service pump system of claim 1, where the control system is configured to: 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 relative to the total number of working fluid pump assemblies.

3. The well service pump system of claim 2, where the control system comprises a processor or programmable logic controller (PLC) configured to sequentially actuate the working fluid pump assemblies such that the hydraulic ram cylinder of a first one of the working fluid pump assemblies is beginning its forward stroke as the hydraulic ram cylinder of a second one of the working fluid pump assemblies is ending its forward stroke.

4. The well service pump system of claim 3, where the processor or PLC is configured to sequentially actuate the working fluid pump assemblies such that the hydraulic ram cylinder of a third one of the working fluid pump assemblies is beginning its forward stroke when the hydraulic ram cylinder of the first one of the working fluid pump assemblies is a fraction of the way through its forward stroke, where the fraction equals 1/(n1), and n equals the number of operational working fluid end cylinders.

5. The well service pump system of claim 1, where the three or more working fluid pump assemblies comprises six or more of the working fluid pump assemblies, and the control system is configured to control the working fluid pump assemblies in two sets each with three or more working fluid pump assemblies.

6. The well service pump system of claim 5, where the control system is configured to: determine how many of the working fluid pump assemblies are operational in each set; and adjust the timing of actuation of each of the operational ones of the working fluid pump assemblies in each set based on the number of operational working fluid pump assemblies in the respective set, independently of the timing of the other set.

7. The well service pump system of claim 5, where the control system is further configured to, if one of the sets has fewer than a threshold number of operational working fluid pump assemblies, not adjust the timing of the sets independently, and instead treat all operational working fluid pump assemblies as a single set for purposes of adjusting the timing of actuation of the operational ones of the working fluid pump assemblies.

8-10. (cancelled)

11. The well service pump system of claim 3, where the processor or PLC is configured to actuate each of the working fluid pump assemblies, via adjustment of the source of pressurized working fluid, such that the duration of the forward stroke is twice the duration of the return stroke.

12. The well service pump system of claim 1, where the one or more sources of hydraulic fluid comprise: a plurality of bi-directional pumps, each coupled to a respective one of the working fluid pump assemblies such that the bi-directional pump is in fluid communication with the first hydraulic port and the second hydraulic port of the hydraulic ram cylinder to pump hydraulic fluid: from the second hydraulic port directly into the first hydraulic port to actuate the ram piston to drive the plunger rod in the first direction; and from the first hydraulic port directly into the second hydraulic port to actuate the ram piston to drive the plunger rod in the second direction.

13. The well service pump system of claim 12, comprising a fluid reservoir configured to be in fluid communication with each of the plurality of bi-directional pumps to compensate for leakage in the system.

14. (canceled)

15. The well service pump system of claim 12, comprising a motor configured to drive each of the bi-directional pumps to direct fluid to the first and second ports.

16. The well service pump system of claim 15, comprising a pump drive coupled to the motor and to each of the bi-directional pumps, the pump drive configured to transfer mechanical energy from the motor to each of the bi-directional pumps.

17. The well service pump system of claim 16, wherein at least one of the bi-directional pumps is mounted to the pump drive.

18-22. (canceled)

23. The well service pump system of claim 1, wherein at least one of the sources of hydraulic fluid comprises a fixed-displacement hydraulic pump.

24. (canceled)

25. (canceled)

26. 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.

27. The method of claim 26, further comprising: identifying a change in the number of the working fluid pump assemblies that are operational; and adjusting 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.

28. The method any of claim 26, where the timing of actuation of each of the operational ones of the working fluid pump assemblies is set or adjusted based on the number of operational working fluid pump assemblies relative to the total number of working fluid pump assemblies.

29. The method of claim 28, where the working fluid pump assemblies are actuated such that the hydraulic ram cylinder of a first one of the working fluid pump assemblies is beginning its forward stroke as the hydraulic ram cylinder of a second one of the working fluid pump assemblies is ending its forward stroke.

30. The method of claim 29, where the working fluid pump assemblies are actuated such that the hydraulic ram cylinder of a third one of the working fluid pump assemblies is beginning its forward stroke when the hydraulic ram cylinder of the first one of the working fluid pump assemblies is a fraction of the way through its forward stroke, where the fraction equals 1/(n1), and n equals the number of operational working fluid end cylinders.

31. The method of claim 26, where the three or more working fluid pump assemblies comprises six or more of the working fluid pump assemblies, the working fluid pump assemblies are actuated in two sets each with three or more working fluid pump assemblies, and determining and setting comprises: determining how many of the working fluid pump assemblies are operational in each set; and timing actuation of each of the operational ones of the working fluid pump assemblies in each set based on the number of operational working fluid pump assemblies in the respective set, independently of the timing of the other set.

32. The method of claim 31, further comprising: detecting a change in the number of operational working fluid pump assemblies in each set; and adjusting the timing actuation of each of the operational ones of the working fluid pump assemblies in each set based on the number of operational working fluid pump assemblies in the respective set, independently of the timing of the other set.

33. The method of claim 31, where, if one of the sets has fewer than a threshold number of operational working fluid pump assemblies, treating all operational working fluid pump assemblies as a single set for purposes of adjusting the timing of actuation of the operational ones of the working fluid pump assemblies.

34. The method of claim 33, where the threshold number is 2.

35. The method of claim 32, where the working fluid pump assemblies in each set are actuated such that the hydraulic ram cylinder of a first one of the operational working fluid pump assemblies is beginning its forward stroke as the hydraulic ram cylinder of a second one of the operational working fluid pump assemblies is ending its forward stroke.

36. The method of claim 35, where the working fluid pump assemblies in each set are actuated such that the hydraulic ram cylinder of a third one of the working fluid pump assemblies is beginning its forward stroke when the hydraulic ram cylinder of the first one of the working fluid pump assemblies is a fraction of the way through its forward stroke, where the fraction equals 1/(n1), and n equals the number of operational working fluid end cylinders in the set.

37. The method of claim 29, where the working fluid pump assemblies are actuated such that the duration of the forward stroke is twice the duration of the return stroke.

38. The method of claim 26, where the one or more sources of hydraulic fluid comprise a plurality of bi-directional pumps, each fluidly coupled to a respective one of the working fluid pump assemblies, and actuating each ram piston comprises: directing hydraulic fluid, via a corresponding bi-directional pump: from the second hydraulic port directly into the first hydraulic port to actuate the ram piston to drive the plunger rod in the first direction; and from the first hydraulic port directly into the second hydraulic port to actuate the ram piston to drive the plunger rod in the second direction.

39-41. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] FIG. 1 depicts a first perspective view of one embodiment of the present well service pump systems.

[0046] FIG. 2 depicts a second perspective view of the system of FIG. 1.

[0047] FIGS. 3 and 4 depict perspective views of various components of the system of FIG. 1.

[0048] FIGS. 5 and 6 depict first and second perspective views of working pump assemblies suitable for use with some embodiments of the system of FIG. 1.

[0049] FIG. 7 depicts a cross-sectional side view of an embodiment of the working fluid pump assemblies of FIGS. 5 and 6.

[0050] FIG. 8 depicts a schematic of a closed-loop hydraulic circuit, suitable for use with some embodiments of the system of FIG. 1.

[0051] FIG. 9 depicts a flowchart of a methodology for timing the actuation of operational ones of a set of reciprocating pump assemblies, such as the working fluid pump assemblies depicted in FIG. 8, based on the number of operational pump assemblies.

[0052] FIG. 10 depicts a flowchart of a methodology for determining and adjusting the timing of actuation of operational ones of a set of reciprocating pump assemblies, such as the working fluid pump assemblies depicted in FIG. 8, based on the number of operational pump assemblies.

[0053] FIG. 11 depicts a flowchart of a methodology for determining whether to merge and merging operational ones of a set of reciprocating pump assemblies, such as the working fluid pump assemblies depicted in FIG. 8, based on the number of operational pump assemblies.

[0054] FIG. 12 depicts an exemplary actuation sequence for three operational reciprocating pump assemblies actuated as a single set in accordance with the present exemplary methodologies.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0055] The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale (unless otherwise noted), meaning the sizes of the depicted elements are accurate relative to each other for at least the embodiment depicted in the figures.

[0056] Referring now to the figures, and more particularly, to FIGS. 1 and 2, shown therein and designated by reference numeral 10 is an embodiment of the present well service pump systems for delivering working fluid at high pressure to a well. As shown, system 10 can be coupled to and carried by a vehicle 14 (e.g., a truck trailer) for transportation to and from work sites. In some embodiments, a system (e.g., 10) can be coupled to a skid frame that can then be loaded and offloaded from a vehicle (e.g., 14).

[0057] As shown, system 10 includes a motor 18, which is configured to drive a plurality of hydraulic pumps 22 (FIG. 3) to direct fluid as described in further detail below. Motor 18 can include one or more sources of mechanical energy, such as a diesel engine, gasoline engine, and/or an electric motor. In this embodiment, system 10 includes a pump drive 26, which is coupled to motor 18 (via driveline 30) and each pump 22. Pump drive 26 is configured to transfer mechanical energy from motor 18 to each pump 22 one at a time or two or more at a time. As shown, each pump 22 is mounted directly onto pump drive 26.

[0058] System 10 includes a plurality of working pump assemblies 34, each of which are coupled to and actuatable by a respective pump 22 to deliver working fluid at a high pressure to a well. As shown, system 10 can include any suitable number of working pump assemblies 34, such as two, three, four, five, six, seven, eight, nine, or ten assemblies. As shown, each assembly 34 can be mounted on a transport vehicle (e.g., 14) by one or more vibration-dampening mounts 38.

[0059] Referring additionally to FIGS. 5-7, one embodiment of the present working pump assemblies 34 is shown. As shown, assembly 34 includes a hydraulic ram cylinder 42 and a working fluid end cylinder 46. Working fluid end cylinder 46 includes a plunger rod 50 disposed within a chamber 54 defined by the fluid end cylinder. Plunger rod 50 is configured to reciprocate within chamber 54 to draw in working fluid into fluid end cylinder 46 via an inlet 58 and expel working fluid under high pressure to the well via an outlet 62. As shown in FIG. 7, hydraulic ram cylinder 42 has a ram piston rod 66 disposed within a chamber 70 defined by the ram cylinder. Ram piston rod 66 is coupled to plunger rod 50 to actuate the plunger rod and supply the working fluid under pressure. For example, assembly 34 includes a coupling member 74, such as a bracket, coupled between piston rod 66 and plunger rod 50 such that linear and/or rotational movement of the piston rod causes a matching linear and/or rotational movement of the plunger rod. Further, coupling member 74 is configured to connect piston rod 66 and plunger rod 50 such that the rods are axially aligned relative to one another.

[0060] Plunger rod 50 has an outer diameter that is smaller than an inner diameter of a cylindrical inner sidewall 78 of working fluid end cylinder 46. As such, plunger rod 50 is received in spaced-apart fashion from sidewall 78 so that abrasive fluids may be pumped without undue wear on the plunger rod and/or sidewalls. For example, an annular space between an outer surface of plunger rod 50 and inner sidewall 78 of working fluid end cylinder 46 is larger than the largest expected transverse dimension of any particle in the working fluid to prevent any single particle in the working fluid from simultaneously contacting the outer surface of the plunger and the inner sidewall of the working fluid end cylinder.

[0061] In the embodiment shown, plunger rod 50 is sealed within fluid end cylinder 46 by an end seal 82 that provides a tight seal around an outer surface of the plunger rod and assists with maintaining alignment of the plunger rod relative to the fluid end cylinder. For example, end seal 82 comprises a hydraulic seal that can be pressurized via a port extending through fluid end cylinder 46. Plunger rod 50 can have a length (measured from end seal 82 to a distal end of the plunger rod within chamber 54 of fluid end cylinder 46) that exceeds 12 inches (e.g., exceeds 40 inches and/or is between 50 inches and 60 inches, such as 48 inches). The maximum length of plunger rod 50 that extends into chamber 54 of fluid end cylinder 46 is termed a stroke length of the plunger rod.

[0062] Hydraulic ram cylinder 42 includes a ram piston 86 (FIG. 7) coupled to ram piston rod 66 and disposed within hydraulic ram cylinder 42. Contrary to plunger rod 50, ram piston 86 includes an outer diameter that fits closely and in a substantially sealed relationship with a cylindrical inner sidewall 90 of hydraulic ram cylinder 42. Ram piston 86 is configured to be actuatable to reciprocate within ram cylinder 42 such that the piston, via its connection to piston rod 66, can cause plunger rod 50 to move accordingly within fluid end cylinder 46. For example, ram cylinder 42 comprises a first hydraulic port 94 on a first side of ram piston 86 and a second hydraulic port 98 on a second side of the piston. Each hydraulic port 94, 98 is configured to receive hydraulic fluid from a respective pump 22 to actuate ram piston 86 such that the piston (via piston rod 66 and coupling member 74) move plunger rod 50 in a first direction 102 to expel working fluid from fluid end cylinder 46 during a forward stroke of the plunger rod and in a second direction 106 to draw working fluid into the fluid end cylinder during a return stroke of the plunger rod. For example, in the depicted embodiment, when plunger rod 50 is in the forward stroke, the plunger rod occupies a majority of the volume of chamber 54, thereby reducing the volume available for working fluid within the chamber and thus forcing the working fluid out of fluid end cylinder 46 via outlet 62.

[0063] Ram piston 86 has a piston surface area 110 upon which hydraulic fluid in chamber 70 can act to move the ram piston, and thus piston rod 66, in first direction 102 and plunger rod 50 has a piston surface area 114 upon which working fluid in chamber 54 can act to move the plunger rod in second direction 106. In this embodiment, piston surface area 110 of at least one ram piston 86 is greater than, such as approximately two or more times greater than, piston surface area of plunger rod 50.

[0064] Each pump 22 is configured to be driven by motor 18 to supply a hydraulic fluid under high pressure to first hydraulic port 94 and second hydraulic port 98 of a respective ram cylinder 42. As shown in FIG. 8, each pump 22 can be fluidly coupled to a respective working fluid pump assembly 34 using a closed-loop hydraulic circuit 118. Further, each pump 22 can operate bi-directionally to actuate ram piston 86 in both first direction 102 and second direction 106. For example, each pump 22 is coupled to a respective ram cylinder 42 such that the pump is in fluid communication with each of first hydraulic port 94 and second hydraulic port 98 of the ram cylinder to pump hydraulic fluid from the second hydraulic port directly into the first hydraulic port to actuate ram piston 86 to drive plunger rod 50 in first direction 102 (forward stroke) and from the first hydraulic port directly into the second hydraulic port to actuate the ram piston to drive the plunger rod in second direction 106 (return stroke). By using a closed-loop hydraulic circuit 118 to actuate ram piston 86, and thereby actuate plunger rod 50, less hydraulic fluid is required for actuating assembly 34, as compared to a system (e.g., 10) having an open-loop hydraulic circuit.

[0065] At least one pump 22 can comprise a fixed-displacement hydraulic pump. In some embodiments, at least one pump (e.g., 22) can comprise a variable-displacement hydraulic pump. Each pump 22 direct fluid to ports 94, 98 at a variable flow rate.

[0066] In some embodiments, system 10 may include a hydraulic fluid reservoir 122 configured to be in fluid communication with each pump 22 to compensate for leakage and/or other operational losses of hydraulic fluid in the system.

[0067] As shown, system 10 includes a working fluid end block 126 that comprises, for each assembly 34, an inlet 58 having an inlet check valve 130 fluidly coupled to chamber 54 of fluid end cylinder 46 and configured to permit working fluid to be drawn into the fluid end cylinder but prevent working fluid from exiting the fluid end cylinder through the inlet check valve. In this embodiment, for at least one assembly 34, working fluid directed to inlet 58 can flow from an elevated tank and/or through a pump, such that the working fluid is pressured when it enters chamber 54 of fluid end cylinder 46 through inlet valve 130, thereby urging plunger rod 50 in its return stroke. In operation, inlet check valve 130 prevents working fluid from exiting chamber 54 through inlet 58, thereby enabling working fluid to be pressurized in chamber 54 of fluid end cylinder 46 during the forward stroke of plunger rod 50.

[0068] In this embodiment, end block 126 comprises, for each assembly 34, outlet 62 having an outlet check valve 218 fluidly coupled to chamber 54 of fluid end cylinder 46 and configured to permit working fluid to exit the fluid end cylinder while preventing working fluid from being drawn into the fluid end cylinder through the outlet check valve. In operation, outlet check valve 134 prevents working fluid that is pressurized downstream of the outlet check valve from entering chamber 54 of fluid end cylinder 46 during the return stroke of plunger rod 50 of assembly 34 and during the forward stroke of a plunger rod (e.g., 50) of one or more of the other working fluid pump assemblies (e.g., 34) of system 10.

[0069] As shown, system 10 comprises a suction manifold 138 fluidly coupled to each inlet check valve 130 of end block 126 to distribute working fluid to each of the inlet check valves in parallel. System 10 comprises a discharge manifold 142 coupled to each outlet check valve 134 of end block 126 to collect working fluid from each of the outlet check valves in parallel.

[0070] System 10 comprises a control system 146 having at least one processor or programmable logic controller (PLC) 150 and corresponding memory from which instructions can be retrieved and executed, one or more of which is configured to control the operation of each pump 22 (e.g., by executing instructions from the corresponding memory). Control system 146, and thus processor(s) 150 can be electronically coupled to each pump 22 via wired or wireless connection. Processor(s) 150 can be configured to control a flowrate and/or direction of hydraulic fluid flowing between each pump and its respective ram cylinder 42. For example, processor(s) 150 can be configured to control each pump 22 such that it directs hydraulic fluid, at any suitable flowrate, in a first direction from second hydraulic port 98 to first hydraulic port 94 and a second direction from the first hydraulic port to the second hydraulic port. Processor(s) 150 can be configured to control the frequency and sequence at which each pump 22 alternates the direction hydraulic fluid between the first and second directions such that system 10, via collective operation of the pumps, delivers a continuous and pulseless output flow of working fluid from fluid end cylinders 46 to the well, as described in paragraphs [0067]-[0069] and FIG. 16 of U.S. Publication US 2015/0192117, which is hereby incorporated by reference in its entirety.

[0071] In this embodiment, the length and rate at which each ram piston 86 completes its forward and return strokes can be adjusted by one or more parameters of system 10. For example, with the aid of one or more sensors 154 configured to collect data indicative of the position of ram piston 86 relative to ram cylinder 42, the length and rate of the forward and return strokes of each ramp piston can be adjusted by control system 146, which can vary the pressure and/or the rate at which hydraulic fluid is delivered to and removed from each ram cylinder 42. For example, assuming that hydraulic fluid is delivered at a pressure that is sufficient to move ram piston 86, the faster the hydraulic fluid is delivered to first hydraulic port 94 and/or removed from chamber 70 via second hydraulic port 98 by pump 22, the faster the ram piston will complete its forward stroke. Conversely, if it is more advantageous for the return stroke to be completed faster (have a shorter duration) than the forward stroke, pump 22 can be controlled to more quickly deliver hydraulic fluid to second hydraulic port 98 and/or remove hydraulic fluid from chamber 70 via first hydraulic port 94.

[0072] The length and rate of the forward and return strokes of each ramp piston 86 can be adjusted to increase pump efficiency and/or reduce cyclic fatigue. For example, to increase pump efficiency, ram cylinder 42 and/or fluid end cylinder 46 can be elongated to permit ram piston 86 and/or plunger rod 50 additional travel within respective chambers 70, 54, thereby allowing for more working fluid to be drawn into fluid end cylinder's chamber and for more working fluid to be expelled from the fluid end chamber into the well for every stroke, as compared to shorter ram cylinders and/or fluid end cylinders. Further, the longer stroke length can significantly reduce the number of strokes required to pump a given volume, and thereby reduce the rate at which plunger rod 50 must cycle, reducing fatigue and extending fluid end life. For further example, the return and forward stroke of each ram piston 86 can be controlled (e.g., by control system 146) to prevent contact between the ram piston and opposing interior end walls 158 of ram cylinder 42. That is, when ram piston 86 reciprocates within ram cylinder 42 during and between the forward and return strokes, the ram piston is, at all times, spaced a distance from a first interior end wall 158 of the ram cylinder and a second interior end wall 158 of the ram cylinder opposite the first end wall.

[0073] Some embodiments of the present methods include delivering a working fluid to a well with a well service pump system (e.g., 10) comprising: at least two working fluid pump assemblies (e.g., 34), each comprising: a working fluid end cylinder (e.g., 46) having a plunger rod (e.g., 50) configured to reciprocate within the fluid end cylinder; and a hydraulic ram cylinder (e.g., 42) having a ram piston (e.g., 86) configured to reciprocate within the hydraulic ram cylinder and a piston rod (e.g., 66) 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 (e.g., 94) on a first side of the ram piston and a second hydraulic port (e.g., 98) on a second side of the ram piston; a plurality of bi-directional pumps (e.g., 22), each fluidly coupled to a respective one of the working fluid pump assemblies (e.g., 34); wherein delivering the working fluid comprises: actuating the ram piston of the hydraulic ram cylinder to move the plunger rod of the working fluid end cylinder: in a first direction (e.g., 102) to expel working fluid from the fluid end cylinder during a forward stroke of the plunger rod, and in a second direction (e.g., 106) to draw working fluid into the fluid end cylinder during a return stroke of the plunger rod; and directing hydraulic fluid, via the bi-directional pump: from the second hydraulic port directly into the first hydraulic port to actuate the ram piston to drive the plunger rod in the first direction; and from the first hydraulic port directly into the second hydraulic port to actuate the ram piston to drive the plunger rod in the second direction. Some embodiments of the present methods additionally include actuating a motor (e.g., 18) to drive each of the bi-directional pumps to direct fluid to the first and second ports. In some embodiments of the present methods, the motor comprises an electric motor and/or a combustion engine. In some embodiments of the present methods, at least one of the hydraulic pumps comprises a fixed-displacement hydraulic pump.

[0074] FIG. 9 depicts a flowchart of a methodology 200 for timing the actuation of operational ones of a set of reciprocating pump assemblies, such as the working fluid pump assemblies described above and depicted in FIG. 8, based on the number of operational pump assemblies (i.e., the number of pump assemblies that are operating as intended, or at least acceptably, for example within a window of acceptable operational parameters within which the overall system exhibits acceptable performance). The methodology can be implemented manually or in an automated or semi-automated fashion via a processor or PLC (e.g., 150). In the depicted example, a step 204 involves determining how many of the working fluid pump assemblies are operational (e.g., and identifying a change in the number of operational ones of the pump assemblies). For example, while a set may include three pump assemblies, one or more of the pump assemblies may cease to be operational (e.g., due to binding, corrosion, or the like) such that the non-operational pump assembly/ies may need to be taken off line. In prior control methodologies, this typically would require taking an entire set of pump assemblies offline. However, in the present methodologies, the timing of actuation of the operational pump assemblies can be set and/or adjusted based on the number of operational pump assemblies (e.g., relative to the total number of working fluid pump assemblies, such as increasing the interval between actuation of respective pumps to account for a decrease in the number of operational pumps), such as at a step 208 as shown in FIG. 9. Once set and/or adjusted, the operational pump assemblies can begin or continue being sequentially actuated in accordance with the determining timing, such as at step 212.

[0075] FIG. 10 depicts a flowchart of a methodology 220 for determining and adjusting the timing of actuation of operational ones of a set of reciprocating pump assemblies, such as the working fluid pump assemblies depicted in FIG. 8, based on the number of operational pump assemblies. In the depicted example, the timing of actuation between individual pumps is selected such that a first one of the working fluid pump assemblies is beginning its forward stroke as the hydraulic ram cylinder of a second one of the working fluid pump assemblies is ending its forward stroke (e.g., as shown in FIG. 12). This timing can be accomplished by beginning the forward stroke of the hydraulic ram cylinder of a third one of the working fluid pump assemblies when the hydraulic ram cylinder of the first one of the working fluid pump assemblies is a fraction of the way through its forward stroke, where that fraction equals 1/(n1), and n equals the number of operational working fluid end cylinders. Thus, in a set of three such working fluid pump assemblies, the third piston begins its forward stroke when the first piston is halfway through its forward stroke and the second piston is at the end of its forward stroke. Similarly, in a set of four such working fluid pump assemblies, the third piston begins its forward stroke when the first piston is one third through its forward stroke; a fourth piston is two thirds through its forward stroke, and the second piston is at the end of its forward stroke. Thus, the depicted example methodology 220 includes a step 254 that involves determining a target interval stroke, and a step 258 of comparing that target interval stroke to the current interval stroke. If the two strokes are the same, the methodology proceeds to step 262 of maintaining the current stroke interval and may then loop back to step 254. If the two strokes are not the same, then the methodology 220 proceeds to step 266 of modifying the current stroke interval to the target stroke interval, and may then loop back to step 254.

[0076] In some instances, a system may include a sufficient number of pump assemblies for the pump assemblies to be actuated in sets. For example, such a system may include six or more of the working fluid pump assemblies that can be actuated in two sets, each with three or more pump assemblies. In system configurations with multiple sets of pumps, it may be advantageous to time the actuation of pumps in each set independently, for example in accordance with the methodologies described above, e.g., two sets of three pump assemblies each in which (as long as all pump assemblies are operational) the first pump assemblies of the two sets are actuated simultaneously, the second pump assemblies of the two sets are actuated simultaneously, and the third pump assemblies of the two sets are actuated simultaneously. Of course, given the present control methodologies, the sets may be actuated differently if one of the pump assemblies in one of the sets ceases to be operational. Additionally, independent actuation of separate may become difficult or impracticable (e.g., due to increasing variations in flow pattern) if one of the sets falls below a threshold number of operational working fluid pump assemblies.

[0077] FIG. 11 depicts a flowchart of a methodology 380 for determining whether to merge and merging operational ones of a set of reciprocating pump assemblies, such as the working fluid pump assemblies depicted in FIG. 8, based on the number of operational pump assemblies. In the depicted example, methodology 280 includes a step 284 that involves determining the number of operational pump assemblies in each set. At a step 288, the number of operational fluid pump assemblies is compared to a threshold (e.g., minimum number of operational pump assemblies to that will achieve acceptable performance in a set) to determine whether the number of operational fluid pump assemblies has fallen below the threshold. The threshold number may, for example, be two, three, four, or more operational pump assemblies. If not below the threshold, the current sets can be maintained, as shown at step 292, and may then loop back to step 284. If below the threshold, the independent sets (or at least two of the sets) can be functionally merged at step 296 such that the pump assemblies of the merged sets are thereafter actuated as a single set (e.g., 3 operational pump assemblies in first set+1 operational pump assembly in second set=4 operational pump assemblies in merged set), and may then loop back to step 284.

[0078] FIG. 12 depicts an exemplary actuation sequence for three operational reciprocating pump assemblies actuated as a single set (e.g., one of multiple sets) in accordance with the present exemplary methodologies. As shown, at time A, a first ram cylinder (e.g., 42), represented by line 42a, is halfway through its forward stroke and a second ram cylinder (e.g., 42), represented by line 42b, begins its forward stroke. At time B, second cylinder 42b is halfway through its forward stroke and a third ram cylinder (e.g., 42), represented by line 42c beings its forward stroke. At time C, first cylinder 42a has returned to top dead center (TDC) and is beginning a subsequent forward stroke. In use, the relative position of ram piston 86 in each respective ram cylinder (e.g., 42) is maintained during its forward stroke such that, at any given point in time at which one or more of the ram pistons are at TDC, one or more of the other ram pistons are at bottom dead center (BDC), and the any remaining ram pistons are half way in between TDC and BDC. In use, these relative positions result in a relatively smooth and pulseless delivery of fluid to discharge manifold 142 and to a well. For example, in the positions illustrated in FIG. 8, counting from left to right, the third and sixth ram cylinders (e.g., 42) are shown to have caused their respective fluid end cylinders (e.g., 46) to stop expelling working fluid into the discharge manifold 238, the first and fourth ram cylinders (e.g., 42) are shown to have begun to cause their respective fluid end cylinders (e.g., 46) to start expelling working fluid into the discharge manifold, and the second and fifth ram cylinders (e.g., 42) are shown to be causing their respective fluid end cylinders (e.g., 46) to expel working fluid into the discharge manifold at a substantially constant rate. To facilitate these relative relationships between the pistons, the return stroke must be equal to or less than one half of the duration of the forward stroke. For example, when the second and fifth ram cylinders (e.g., 42) reach BDC, the first and fourth ram cylinders (e.g., 42) will be halfway through their forward stroke, and the third and sixth ram cylinders (e.g., 42) must be at BDC and ready to begin their forward stroke. Processor or PLC 150 can be configured to actuate each assembly 34 (e.g., via adjustment of the source of pressurized working fluid, such that the duration of the forward stroke is twice the duration of the return stroke. For example, each ram piston 86 can be paused momentarily at TDC to enable the re-synchronization of the other ram pistons (e.g., at any suitable frequency, such as, at every stroke). The illustrated relationship corresponds to a stroke length of 1/(n1); specifically, with three pumps: 1/(31)= such that each piston begins its forward stroke when the immediately preceding piston is one-half through its forward stroke.

[0079] The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. For example, embodiments of the present methods and systems may be practiced and/or implemented using different structural configurations, materials, ionically conductive media, monitoring methods, and/or control methods.

[0080] The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) means for or step for, respectively.