Fuel Supply Controller for Hydraulic Fracturing Turbines

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Solution Overview

Problem

The existing systems for managing fuel supply to gas turbine engines in hydraulic fracturing operations face inefficiencies, particularly when primary fuel levels drop, leading to interruptions and manual interventions, which can delay fracturing operations and expose personnel to hazards.

Innovation Solution

A system and method that include a controller to monitor fuel pressure and switch to secondary fuel sources when primary fuel levels fall below a set point, optimizing fuel distribution by identifying the gas turbine engine with the greatest secondary fuel availability and adjusting data sampling rates to ensure continuous operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual refueling procedures are used when primary fuel levels drop, then personnel can replenish fuel supplies, but operational delays occur and personnel are exposed to hazardous conditions

Engineering Contradiction:

Improvefuel supply continuityVSAvoidoperational delay

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by automatically detecting low primary fuel levels and switching to secondary fuel sources before manual intervention is required. The controller monitors fuel levels and pre-arranges the fuel switching sequence, eliminating the need for operators to manually intervene during critical fuel depletion scenarios.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fuel management system serves itself by automatically monitoring fuel levels, determining which engines should switch to secondary fuel, and executing the switching without human intervention. The controller autonomously manages the entire fuel supply optimization process, freeing personnel from hazardous manual refueling tasks.

Inventive Principle:

Principle #25Self-service

2Device complexity

If multiple gas turbine engines operate on a single primary fuel source, then fuel distribution can be simplified, but operational flexibility and reliability decrease when fuel levels drop

Engineering Contradiction:

Improvefuel distribution systemVSAvoidfuel supply flexibility

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The system dynamically adjusts fuel distribution by continuously monitoring primary fuel levels and automatically reconfiguring which engines receive primary versus secondary fuel. The controller can adapt the fuel supply configuration in real-time based on current fuel availability, maintaining operational flexibility without requiring complex manual intervention.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes operational parameters by switching engines between primary and secondary fuel sources based on fuel level conditions. The controller modifies the fuel supply parameters dynamically, allowing the fleet to adapt to varying fuel availability while maintaining simplified distribution infrastructure.

Inventive Principle:

Principle #35Parameter changes

3Loss of information

If manual monitoring and refueling procedures are implemented, then fuel levels can be tracked, but personnel exposure to hazards and operational interruptions increase

Engineering Contradiction:

Improvefuel level monitoringVSAvoidpersonnel hazard exposure

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The system implements continuous feedback by automatically monitoring fuel levels in the primary fuel source and using this information to trigger automated switching decisions. The controller receives real-time fuel level data and responds by redistributing fuel supplies, eliminating the need for personnel to manually monitor and respond to fuel depletion.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system replaces manual mechanical monitoring and refueling operations with an automated electronic control system. The controller electronically manages fuel distribution based on sensor inputs, substituting human operators with an automated system that eliminates personnel exposure to hazardous conditions while maintaining continuous fuel level monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11867118B2Methods and systems for supplying fuel to gas turbine engines

Publication Date: 2024.01.09 BJ ENERGY SOLUTIONS LLC

AI summary

Methods and systems for supply of fuel for a turbine-driven fracturing pump system used in hydraulic fracturing may be configured to identify when the supply pressure of primary fuel to a plurality of gas turbine engines of a plurality of hydraulic fracturing units falls below a set point, identify a gas turbine engine of the fleet of hydraulic fracturing units operating on primary fuel with highest amount of secondary fuel available, and to selectively transfer the gas turbine engine operating on primary fuel with the highest amount of secondary fuel from primary fuel operation to secondary fuel operation. Some methods and systems may be configured to transfer all gas turbine engines to secondary fuel operation and individually and/or sequentially restore operation to primary fuel operation and/or to manage primary fuel operation and/or secondary fuel operation for portions of the plurality of gas turbine engines.