Autonomous Fueling System for Fracking Machinery
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Solution Overview
Problem
Manual refueling of diesel-powered machinery at fracking sites is hazardous and prone to interruptions due to the need for frequent refueling, which can damage operations and pose risks of fuel spillage and fire, and existing autonomous systems require on-site operators and suffer from single-point failures.
Innovation Solution
An autonomous fueling system with a main tank, multiple fuel pumps, and sensors for continuous operation, capable of monitoring fuel levels and flow, using wireless communication to manage refueling and alarm generation, and allowing for rapid customization and replacement of components, reducing the need for manual intervention and minimizing point-of-failure risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual refueling is used, then operators can control the refueling process, but operators are exposed to hazardous conditions including fuel spillage and fire risks
Solution Approach 1:
The refueling system operates autonomously without requiring human operators to be present in the hazardous refueling zone. The system self-monitors fuel levels, self-regulates fuel flow, and self-manages the refueling process, thereby eliminating operator exposure to fuel spillage and fire risks while maintaining reliable refueling operations
2Productivity
If traditional manual refueling is used, then the refueling process can be performed, but fracking operations are interrupted and productivity is reduced
Solution Approach 1:
The autonomous refueling system enables continuous operation by eliminating interruptions in the fracking process. Fuel level monitoring is continuous, and refueling occurs automatically without stopping machinery operations, ensuring that the useful action of fracking continues uninterrupted while fuel needs are met
3Object-affected harmful factors
If autonomous fueling system is implemented, then operator safety is improved and manual intervention is eliminated, but system complexity increases
Solution Approach 1:
The system replaces manual mechanical refueling operations with automated electronic control systems. Sensors, microprocessors, and automated valves substitute for human operators performing manual tasks, thereby eliminating operator exposure to hazards while managing complexity through electronic automation rather than mechanical complexity
4Device complexity
If single fuel tank system is used, then the system is simple, but single point of failure risks are high
Solution Approach 1:
The fuel storage system is segmented into multiple separate fuel tanks instead of a single large tank. This segmentation creates redundancy so that if one tank fails or runs out of fuel, other tanks can continue to supply fuel, thereby improving system reliability and availability while maintaining relatively simple individual tank structures
Data Source
AI summary
Method for autonomously fueling machinery operating at fracking sites. A fuel tank with a plurality of fuel lines individually coupled to a fuel tank are used. Pumps are connected to some of the fuel lines. Pump outputs are coupled to hoses extending to machinery tanks to be refueled. A cap is detachably connected to the hoses and machinery tanks to be fueled. The fuel tank includes an intake filter capable of blocking approximately 10 micron contaminants with about 250 gallon per minute flow rate. The methodology of the present invention includes measuring the duration of machinery tank fuelings and the interval between fuelings. A first alarm is generated if the duration of fuelings is longer than a first interval. A second alarm is generated if the interval between fuelings is longer than a second interval.