Mobile Distribution Station Bypass Line for Hot-Refueling
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies due to equipment shut-downs for refueling, which can be costly and disrupt continuous operations, and hot-refueling methods are challenging to sustain reliably.
Innovation Solution
A mobile distribution station with a bypass line, fluid level sensors, and a controller to manage valve operation, allowing continuous fuel delivery without relying on the pump, and incorporating an auxiliary generator for power redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hot-refueling is used to avoid shut-downs, then productivity is improved, but reliability deteriorates because hot-refueling is difficult to reliably sustain
Solution Approach 1:
The patent implements a bypass line that allows fuel to reach the manifold without passing through the pump, creating a redundant fuel delivery path. This backup mechanism ensures that if the pump fails or requires maintenance, fuel delivery can continue uninterrupted through the bypass line, thereby cushioning against potential failures and maintaining refueling reliability during continuous operations.
2Quantity of substance
If pump is used for fuel delivery, then fluid flow is improved, but reliability worsens due to single point of failure
Solution Approach 1:
The bypass line acts as an intermediary fuel delivery path that bypasses the pump. It includes a bypass valve that can redirect fuel flow from the fuel source directly to the manifold, independent of the pump's operation. This intermediary path provides system redundancy, ensuring fuel delivery continues even when the pump fails, thus improving reliability without compromising the primary fuel delivery capability.
3Reliability
If fluid level sensors and controller are added, then reliability is improved through automated control, but device complexity increases
Solution Approach 1:
The patent incorporates fluid level sensors that monitor the fuel level in the manifold and provide feedback to a controller. The controller automatically adjusts the bypass valve based on this feedback, opening the valve when fuel level is low and closing it when the level is adequate. This feedback mechanism automates the control process, improving reliability by ensuring proper fuel levels without requiring constant manual intervention, while the simplicity of the feedback loop keeps the added complexity manageable.
Data Source
AI summary
A distribution station includes a mobile trailer, a pump, a manifold, a fluid line connecting the pump to the manifold, and a bypass line leading into the fluid line between the pump and the manifold. The bypass line permits fluid to be provided to the manifold without use of the pump. Reels on the mobile trailer are individually connected with the manifold, and hoses are connected with a different one of the reels. Valves on the mobile trailer are situated between the manifold and different ones of the reels. Fluid level sensors are connectable to the ends of different ones of the hoses. A controller is configured to individually open and close the valves responsive to the fluid level sensors.