Floating Load Cell Hopper for Automated Proppant Flow Control
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Solution Overview
Problem
The demand for a reliable and continuous supply of proppant at well sites for hydraulic fracturing operations is high and often challenging due to irregular deliveries and the need for significant human intervention, which can lead to system downtime and increased costs.
Innovation Solution
A proppant handling system with a discharge box supported by load cells and a conveyor system that monitors weight and adjusts speed automatically, combined with level sensors for storage containers, ensuring a continuous supply to the blender hopper through automated control and high-capacity storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a proppant handling system uses manual monitoring and intervention, then the system can operate with simpler equipment, but it results in increased human intervention, more system downtime, and higher costs
Solution Approach 1:
The system uses load cells to continuously monitor the weight of proppant in the discharge box and provides feedback to the control system. This automated feedback loop enables the system to adjust conveyor speed and detect low proppant conditions without human intervention, resolving the contradiction by implementing automation through intelligent monitoring and control
Solution Approach 2:
The system is designed to automatically monitor its own proppant levels and adjust operations without requiring operator intervention. The load cells and control system work together to self-regulate the proppant supply, eliminating the need for manual checking and intervention while maintaining reliable operation
2Reliability
If the system uses load cells to monitor proppant weight, then it can achieve automated control and reduced downtime, but it increases the complexity of the equipment
Solution Approach 1:
Load cells are integrated into the discharge box support structure to provide continuous weight feedback to the control system. This enables automated detection of proppant levels and conveyor speed adjustment, improving reliability through real-time monitoring while the feedback mechanism handles the complexity automatically
Solution Approach 2:
The load cells serve multiple functions: they support the discharge box structurally and simultaneously provide weight measurement for proppant monitoring. This multi-functionality reduces the need for separate monitoring equipment, improving reliability without proportionally increasing system complexity
3Measurement precision
If the discharge box is physically supported by load cells, then weight monitoring is enabled, but the structural support becomes more complex
Solution Approach 1:
The load cells are integrated into the existing support structure for the discharge box, serving both as structural supports and as weight measurement devices. This multi-functional integration enables precise weight monitoring while avoiding the need for separate, complex measurement apparatus
Solution Approach 2:
The support function and measurement function are merged into a single integrated structure. The load cells are positioned to bear the discharge box weight while simultaneously providing the electrical signal for proppant level detection, combining structural and monitoring functions in one element
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
The system provides a robust, reliable, and cost-effective proppant supply with reduced human intervention, minimizing downtime and maintaining a steady flow to the blender hopper, even in the face of irregular deliveries.
Implementation Method 1
repeatedly obtaining signals from a first plurality of load cells physically supporting the discharge box while the proppant moves through the discharge box, wherein each of the signals represents a weight, at a corresponding moment, of the discharge box and the proppant inside the discharge box
Implementation Method 2
enabling the continuing supply of proppant to move through the discharge box on one or more surfaces within the discharge box between the inlet and the outlet of the discharge box
Data Source
AI summary
Systems and methods are disclosed for receiving a continuing supply of proppant from a proppant conveyor through an inlet of a discharge box; enabling the continuing supply of proppant to move through the discharge box on one or more surfaces within the discharge box between the inlet and the outlet of the discharge box; repeatedly obtaining signals from a first plurality of load cells physically supporting the discharge box while the proppant moves through the discharge box, wherein each of the signals represents a weight, at a corresponding moment, of the discharge box and the proppant inside the discharge box; and controlling a speed of the proppant conveyor automatically based on the signals from the first plurality of load cells.