Battery-Powered Fuel Shutoff Valve for Automatic Tank Level Control
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Solution Overview
Problem
Conventional fuel delivery systems in the oil and gas industry, particularly in fracking operations, are prone to human error and have numerous potential failure points, leading to unreliable and unsafe fuel delivery, which can result in premature operation termination or equipment damage.
Innovation Solution
An electric fuel flow control device with a motorized valve and sensor system powered by a battery, which automatically controls fuel flow based on fuel level detection, eliminating the need for manual intervention and minimizing failure points by using a self-sufficient, battery-powered system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual fuel systems are used with personnel refueling equipment, then human operation is required, but human error increases and reliability decreases
Solution Approach 1:
The fuel system is designed to be self-regulating through the float mechanism. When the fuel tank reaches the desired level, the float automatically rises and shuts off the fuel flow without human intervention. This eliminates the need for personnel to monitor and manually control fueling operations, thereby removing human error while maintaining simplicity.
Solution Approach 2:
The patent replaces manual mechanical operation with an automated mechanical sensing system. The electric fuel sensor detects fuel presence and sends signals to the control circuitry, which then actuates the motorized valve. This substitution of manual control with automated sensing and control mechanisms improves reliability by eliminating human error while maintaining mechanical simplicity.
2Reliability
If conventional fuel pumps with multiple components are used, then fuel delivery capability is achieved, but the number of potential failure points increases
Solution Approach 1:
The patent extracts and eliminates unnecessary components from conventional fuel pump systems. Instead of using complex fuel pumps with multiple moving parts, seals, and mechanical connections, the invention uses a simplified system with a motorized valve controlled by an electric sensor and battery. This reduction in component count directly reduces potential failure points while maintaining fuel delivery capability.
Solution Approach 2:
The battery-powered system is self-sufficient and requires no external power sources or complex mechanical drive systems. The electric motor directly actuates the valve based on sensor input, eliminating the need for complex mechanical linkages, seals, and moving parts found in conventional fuel pumps. This self-contained design minimizes failure points.
3Reliability
If manual refueling operations are performed, then fuel delivery can be controlled, but human error and safety risks increase
Solution Approach 1:
The system performs self-monitoring and self-control through the electric fuel sensor and automated valve actuation. The sensor continuously detects fuel levels and the control circuitry automatically adjusts the valve position accordingly, eliminating the need for human operators to perform manual refueling tasks. This maintains operational simplicity while dramatically improving safety by removing human involvement from potentially hazardous fuel handling operations.
Solution Approach 2:
The electric fuel sensor provides continuous feedback to the control circuitry about fuel presence and levels. This feedback loop enables the system to automatically adjust fuel flow and shut off when the tank is full, preventing overfilling and spillage. The automated feedback-controlled operation eliminates human error while maintaining ease of operation through hands-free functionality.
4Extent of automation
If battery-powered automated control is implemented, then human intervention is eliminated, but power source requirements increase
Solution Approach 1:
The system uses a battery as the power source, which is a relatively simple, inexpensive, and maintenance-free energy storage device. While the battery will eventually need replacement, it eliminates the need for complex mechanical power transmission systems, external power connections, or frequent human intervention. The battery provides sufficient power for the low-energy electric motor and sensor operations, achieving high automation with minimal energy infrastructure requirements.
Data Source
AI summary
An electric fuel flow control device for use with oil and gas equipment, such as fueling systems for frac pumps. The electric fuel flow control device includes a battery, control circuitry, an enclosure that encloses the control circuity, and includes an electric fluid sensor, a valve, a beacon light, a status light, a button, an adapter cap enabling connection to a fuel tank, and a mandrel. The electric fuel flow control device may be used as a primary fuel flow control device or a backup fuel flow control device.