Granular Material Tank Measurement Using Depth Sensor Arrays
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Solution Overview
Problem
Maintaining adequate sand inventory levels during hydraulic fracturing operations is challenging due to the difficulty in ensuring consistent supply, as sand does not self-level like water, leading to uncertainties in delivery and usage.
Innovation Solution
A system and method using depth sensors to measure the elevation of granular material in a tank, calculating volumes based on notional cylinders, and aggregating data to determine the total volume of sand, facilitating improved inventory management through predictable sand delivery calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sand is stored in a tank for hydraulic fracturing operations, then the inventory can be maintained for use, but the sand does not self-level like water making it difficult to maintain levels and ensure adequate inventory
Solution Approach 1:
The tank interior is divided into multiple vertical zones or segments along the vertical axis. Depth sensors are positioned at different heights and radial locations to measure sand levels in each segment independently. This segmentation allows for comprehensive monitoring of sand distribution throughout the tank, overcoming the difficulty of measuring non-self-leveling granular material.
2Measurement precision
If multiple depth sensors are positioned at different radial locations and vertical heights to measure sand elevation, then accurate volume calculation is achieved, but the device complexity increases
Solution Approach 1:
Multiple depth sensors are deployed at different radial distances from the vertical axis and at different vertical heights. Each sensor serves multiple purposes: measuring local sand elevation, determining radial position, and contributing to overall volume calculation. This multi-functional sensor array achieves precise three-dimensional mapping of sand distribution while using standardized sensor components.
Solution Approach 2:
The measurement system transitions from single-point or single-line measurement to three-dimensional spatial measurement by positioning sensors at multiple radial distances and vertical heights. This dimensional expansion allows the system to capture the complex geometry of sand accumulation patterns and calculate accurate volumes despite the non-uniform distribution of granular material.
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
Enhances predictability in sand inventory management by providing accurate volume calculations, reducing uncertainties associated with sand delivery and usage in hydraulic fracturing operations.
Implementation Method 1
one or more devices disposed adapted to generate data representative of the elevation of the surface of any granular material in the tank
Data Source
AI summary
The system comprises: a tank having: an interior boundary; an upper portion defining a portion of the interior boundary and having an intake aperture for receiving the gravity flow; a lower portion defining a portion of the interior boundary and having a discharge aperture; and a vertical axis; and one or more devices disposed adapted to generate data representative of the elevation of the surface of any granular material in the tank, the data including data from a plurality of locations which substantially span the distance between the axis and the boundary at its widest point.