Bulk Material Container Sequencing for Continuous Blender Feed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bulk material handling systems for oil and gas well operations face inefficiencies due to the need for frequent container changes and manual operation of discharge gates, leading to potential timing errors and disruptions in the continuous flow of materials during wellbore treatment processes.
Innovation Solution
A method and computer system for sequencing the opening and closing of bulk material containers, utilizing a control system and graphical user interface to automate the actuation of discharge gates, ensuring a continuous flow of materials to the blender by identifying the next container to open and providing active notification for container replacement, thereby reducing operator errors and maintaining a steady supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple portable containers are used to transport bulk material, then the material can be delivered to the well site, but the containers must be changed out frequently causing disruptions in continuous supply
Solution Approach 1:
The system segments the bulk material storage into multiple portable containers (12) that can be independently managed. Each container serves as a separate module that can be filled, emptied, and replaced independently, allowing continuous operation while maintaining manageable individual units.
Solution Approach 2:
The control system (90) performs preliminary sequencing of container operations. Containers are pre-positioned and the system pre-determines the optimal sequence for opening and closing discharge gates (36), ensuring that the next container is ready before the current one is depleted, thereby eliminating idle time.
2Ease of operation
If manual coordination of container movement and material release is used, then operators can manage the process, but timing errors and disruptions occur
Solution Approach 1:
The control system continuously monitors the status of bulk material in containers through sensors (94) and automatically adjusts the sequencing of discharge gate operations. This closed-loop feedback ensures that containers are switched at the optimal moment to maintain continuous flow, eliminating the timing errors associated with manual coordination.
Solution Approach 2:
The system enables self-service automation where the control system (90) autonomously manages the sequencing of container discharge operations without requiring constant operator intervention. The automated gate actuators (40) and sequencing logic allow the system to self-regulate material flow, reducing human error while maintaining operational simplicity through the graphical user interface (100).
3Reliability
If automated sequencing control is implemented, then continuous material flow is ensured, but system complexity increases
Solution Approach 1:
The control system (90) is designed as a multi-functional universal controller that handles container sequencing, gate actuation, material level monitoring, and operator interface functions. This consolidation of multiple functions into a single integrated system reduces overall complexity compared to having separate dedicated systems for each function.
Solution Approach 2:
The graphical user interface (100) serves as an intermediary layer between the operator and the complex automated sequencing control system. It provides intuitive interaction while shielding the operator from underlying system complexity, and the controller acts as an intermediary that translates high-level operational requirements into precise automated actions.
Data Source
AI summary
In accordance with presently disclosed embodiments, systems and methods for sequencing portable containers of bulk material to provide continuous bulk material usage at an outlet are provided. The disclosed sequencing techniques may involve identifying a sequence for opening different portable containers of bulk material (or identifying the “next” portable container to open) and automatically actuating the discharge gates of the portable containers in the desired sequence to provide a continuous flow of bulk material to the outlet (e.g., blender unit). The identified sequence may be executed through a control system communicatively coupled to actuators used to open/close the discharge gates of the portable bulk material containers. A GUI may be communicatively coupled to the control system to allow an operator to select the desired sequence for execution by the control system and to display information regarding the portable bulk material containers.