Fuel Consumption Optimization in Well Site Motorized Equipment
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Solution Overview
Problem
Current systems for monitoring and optimizing fuel consumption in motorized equipment at well sites are inefficient, as they do not accurately account for the complex interplay between hydraulic horsepower, external parasitic load, and internal parasitic load, leading to excessive fuel usage and increased costs.
Innovation Solution
The development of systems and methods to monitor, calculate, and optimize fuel consumption by determining the total parasitic fuel consumption rate, internal parasitic fuel consumption rate, and external parasitic load as functions of engine speed, allowing for real-time adjustments to optimize engine operation and reduce fuel usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If traditional fuel monitoring systems are used, then simplicity of operation is maintained, but fuel consumption efficiency deteriorates due to inaccurate accounting of parasitic loads
Solution Approach 1:
The patent segments fuel consumption into distinct components: hydraulic horsepower fuel consumption, external parasitic load fuel consumption, and internal parasitic load fuel consumption. This segmentation allows for precise measurement and optimization of each component separately, improving overall fuel efficiency without requiring complete system redesign.
Solution Approach 2:
The system continuously monitors engine speed, hydraulic horsepower, and calculated fuel consumption rates, providing real-time feedback to operators. This feedback mechanism enables dynamic adjustment of operations to optimize fuel efficiency while maintaining manageable system complexity through automated calculations.
2Loss of energy
If real-time fuel consumption optimization is implemented, then fuel costs are reduced, but measurement precision requirements increase
Solution Approach 1:
The patent introduces calculated intermediate values (total parasitic fuel consumption rate, internal parasitic fuel consumption rate, external parasitic load) that serve as mediators between raw sensor data and final fuel efficiency metrics. These intermediaries simplify the measurement chain while maintaining precision by breaking down complex measurements into manageable computational steps.
Solution Approach 2:
The system transforms physical parameters (engine speed, hydraulic horsepower) into fuel consumption rates through established relationships and formulas. This parameter transformation allows optimization based on readily measurable quantities while achieving precise fuel consumption accounting without direct complex measurement.
3Productivity
If engine speed optimization is performed, then fuel consumption is minimized, but operational flexibility may be reduced
Solution Approach 1:
The patent enables dynamic optimization of engine speed based on real-time operating conditions. Rather than fixed speed settings, the system continuously adjusts optimal engine speed according to actual hydraulic horsepower requirements and parasitic load conditions, maintaining operational flexibility while improving fuel efficiency.
Solution Approach 2:
The system allows operators to change operational parameters (engine speed, load distribution) based on calculated fuel consumption rates. This parameter adaptability enables optimization across different operating scenarios without sacrificing versatility, as the system recalculates optimal settings for each condition.
Data Source
AI summary
Systems and methods for monitoring, calculating, and/or optimizing the consumption of fuel in operating motorized equipment in well site operations or other jobs are provided. In one embodiment the methods comprise: calculating a set of fuel consumption rates for one or more engines at a job site as a function of a speed of each engine, a hydraulic horsepower load to be provided by each engine, and an external parasitic load to be provided by each engine; identifying one or more operating speeds for the one or more engines during an operation at the job site based at least in part on the set of fuel consumption rates for the one or more engines; and operating the one or more engines at the one or more operating speeds during an operation at the job site.