Conveyor Sled Assembly for Proppant Delivery
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Solution Overview
Problem
Conventional proppant delivery systems in hydraulic fracturing operations face challenges with spillage and inefficient pod replacement due to lack of automated controls, leading to stress and inefficiency in large-scale proppant delivery.
Innovation Solution
A conveyor sled assembly with close-tolerance components and sequential discharge mechanism, featuring programmatically controlled gate valves and sensors for precise proppant delivery and pod status monitoring, along with a touchscreen for operator control, ensures reduced spillage and predictable pod replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional proppant delivery systems are used, then the system is simple in structure, but proppant spillage occurs and pod replacement is inefficient
Solution Approach 1:
The conveyor sled assembly is divided into multiple discrete loading stations positioned at different locations along the sled. Each loading station has its own gate valve assembly and receives proppant from separate pods, allowing independent control and sequential discharge of proppant from different locations without requiring a complex centralized system
Solution Approach 2:
The gate valve assemblies are positioned at predetermined locations along the conveyor sled assembly before operation begins. The system is pre-configured with multiple loading stations at specific positions, allowing for controlled sequential discharge of proppant from different pods in a predetermined order, eliminating the need for real-time complex control adjustments
2Productivity
If multiple pods are placed on the conveyor sled, then proppant delivery capacity increases, but determining which pods have discharged all proppant becomes difficult
Solution Approach 1:
The system incorporates sensors at each loading station that detect when a pod has discharged all of its proppant. This feedback mechanism automatically identifies which pods are empty and need replacement, eliminating the need for manual inspection and making it easy to monitor pod status across multiple loading stations simultaneously
Solution Approach 2:
The system uses visual indicators such as colored lights or color-coded tags at each loading station to indicate pod status. Different colors signal whether a pod is full, discharging, or empty, providing immediate visual feedback to operators about which pods need replacement without requiring manual inspection
3Reliability
If gate valve assembly is positioned close to conveyor belt, then proppant spillage is reduced, but precise positioning tolerance is required
Solution Approach 1:
The gate valve assembly is segmented into multiple components with adjustable positioning mechanisms. The valve body, gate, and actuator are separate elements that can be independently positioned and adjusted, allowing for precise alignment with the conveyor belt while maintaining ease of installation and tolerance compensation
Solution Approach 2:
The system incorporates adjustable positioning parameters for the gate valve assembly, allowing the vertical and horizontal position to be modified during installation or operation. This adjustability compensates for manufacturing tolerances and ensures proper alignment with the conveyor belt without requiring extremely tight manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces proppant spillage and simplifies pod replacement by ensuring sequential discharge and precise control over proppant delivery, enhancing the efficiency and reliability of large-scale hydraulic fracturing operations.
Implementation Method 1
The proppant pod has a gravitational discharge opening
Data Source
AI summary
A conveyor sled assembly is utilized to supply proppant in support of oilfield hydraulic fracturing operations. The conveyor sled assembly includes precisely positioned components where tolerances between components are so small as to prevent significant spillage at component junction boundaries. This manner of fitting proppant pods onto the conveyor sled assembly increases predictability of which pods will discharge their proppant load first. This enhances reliability of the overall proppant delivery system.