Automated Fuel Transfer Unit for Hydraulic Fracturing Safety

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Solution Overview

Problem

Hydraulic fracturing operations require prolonged high-pressure pumping, leading to substantial fuel consumption and increased safety risks due to the 'hot zone' around well sites, where fuel line hookups are hazardous and time-consuming, posing risks to personnel.

Innovation Solution

A compact fuel supply system comprising an engine unit, fuel supply unit, and transfer unit with multi-way valves and a housing, allowing for efficient fuel distribution and return within the system, keeping personnel outside the hot zone during operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fuel line hookups are performed manually in the hot zone, then fuel can be supplied to the engine unit, but personnel safety is compromised due to explosion and fire dangers

Engineering Contradiction:

Improvepersonnel safetyVSAvoidfuel line hookup operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent introduces an automated fuel transfer system that acts as an intermediary between the fuel supply unit and the engine unit. This system includes automated coupling mechanisms, transfer pumps, and control systems that enable fuel transfer without direct personnel intervention in the hot zone, thereby maintaining safety while ensuring operational capability

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The fuel supply system is designed with self-service capabilities where the system automatically performs fuel line hookups, fuel transfer, and disconnection operations. The automated coupling mechanisms and control systems enable the system to service itself without requiring personnel to enter the hazardous hot zone, thus improving safety while maintaining ease of operation

Inventive Principle:

Principle #25Self-service

2Productivity

If manual fuel line hookups are performed, then fuel supply can be established, but the process is time-consuming and reduces operational efficiency

Engineering Contradiction:

Improveoperational efficiencyVSAvoidfuel line hookup time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by pre-positioning fuel supply units near engine units and pre-configuring automated coupling mechanisms before fuel transfer is needed. This preparation enables rapid automated fuel line hookups when fuel transfer is required, significantly reducing hookup time and improving operational efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual mechanical fuel line hookup operations with automated mechanical and electronic systems. Automated coupling mechanisms, transfer pumps, and control systems substitute for manual labor, enabling rapid and efficient fuel transfer operations that reduce time loss and improve productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11519369B1Fuel supply system

Publication Date: 2022.12.06 DELTA FUEL CO LLC

AI summary

A remote fuel supply system comprising a fuel transfer unit for managing the flow of fuel from a remote fuel tank and onboard auxiliary tank to an engine. The system may include an engine unit comprising an onboard auxiliary tank, a remote fuel supply unit comprising a remote fuel tank, and a fuel transfer unit. The fuel transfer unit may include a housing featuring multiple inlets for receiving fresh fuel from the fuel supply unit and unburnt fuel from the engine unit, and the housing may include multiple outlets connected to diverter valves for selectively transferring fuel to the engine unit from the fuel supply sources; namely, the fresh fuel from the fuel supply unit and/or the unburnt fuel from the engine unit.