Frac Water Transfer Control Using Level Sensors and Valves
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Solution Overview
Problem
The process of monitoring and controlling water levels in hydraulic fracturing is labor-intensive, prone to human error, and costly, leading to potential damage to wells and formations if water supply is not adequately managed.
Innovation Solution
An automated system that includes a manifold, controllable valves, level indicators, flow meters, and controllers to remotely operate pumps and valves, ensuring precise water distribution and storage across multiple frac water storage containers, reducing the need for manual intervention and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring and controlling of water levels is used, then the system is simpler and cheaper, but it is labor-intensive, prone to human error, and costly
Solution Approach 1:
The system enables automatic self-monitoring and self-control of water levels through automated sensors and control mechanisms that operate without human intervention, allowing the system to manage its own water transfer operations reliably
Solution Approach 2:
Manual mechanical monitoring and control operations are replaced with automated electronic sensors, controllers, and actuated valves that provide reliable water level management while reducing human labor and error
2Productivity
If automated system is implemented, then labor costs are reduced and errors are minimized, but device complexity increases
Solution Approach 1:
The automated control system performs multiple functions including water level sensing, flow measurement, valve actuation, and data logging within a single integrated platform, improving productivity while managing complexity through consolidation
Solution Approach 2:
A centralized controller acts as an intermediary that coordinates between sensors, valves, and data systems, enabling efficient automated water transfer operations while simplifying the overall system architecture
3Reliability
If water supply is not adequately managed, then operational costs are saved, but potential damage to wells and formations occurs
Solution Approach 1:
The system continuously monitors water levels and flow rates, providing real-time feedback to the controller that automatically adjusts water transfer operations to ensure adequate supply management and prevent damage to wells and formations
Solution Approach 2:
The system proactively monitors water levels and predicts potential supply deficiencies before they occur, enabling preventive action to be taken to ensure adequate water supply and avoid harmful effects on wells and formations
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 automated system enhances the reliability and efficiency of water transfer during hydraulic fracturing, reducing labor costs, minimizing the risk of spills and overflows, and providing a historical operational record, thus ensuring cost savings and safer operations.
Implementation Method 1
a pump configured to be remotely operated to receive water from the water source and pump the water through a discharge to the manifold
Implementation Method 2
a plurality of controllable valves each configured to be in fluid communication between an input to one of the plurality of frac water storage containers and with one of the plurality of output openings of the manifold
Implementation Method 3
a plurality of level indicators configured to one of the plurality of frac water storage containers to determine a water level at each such one of the plurality of frac water storage containers
Implementation Method 4
a flow meter configured to measure a flow of water into the manifold
Data Source
AI summary
An exemplary automated system and method are provided for monitoring and controlling the transfer of water to water tanks or containers during a water transfer process. In one embodiment, the automated system includes a first manifold, a plurality of controllable valves, a plurality of level indicators, a pump, controller(s), storage device, and display. In one implementation, the controller is configured to control the opening/closing of the plurality of controllable valves based, at least in part, on the water levels of the frac water tanks. The controller(s) may include one or more control modes. In other implementations, the system may include a second manifold (or additional manifolds) and the capability to blend water from two or more sources, such as from an impaired water source, using either a single or multiple-manifold configuration. In other implementations, an assembly is provided, such as a skid or trailer mounted assembly, for use in a mobile automated system.