Mobile Distribution Station Pneumatic Valves Hot-Refueling
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies and increased costs due to the need for frequent equipment shut-downs for refueling, which can be mitigated by enabling continuous hot-refueling processes.
Innovation Solution
A mobile distribution station equipped with pneumatic valves, fluid level sensors, and a controller that manages air or gas flow to control fuel delivery, allowing for continuous operation by monitoring fuel levels and adjusting fuel supply accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If equipment operates continuously without shut-down for refueling, then productivity and efficiency are improved, but fuel supply reliability deteriorates due to inability to replenish fuel
Solution Approach 1:
The system performs preliminary action by storing multiple fuel tanks in advance on the mobile distribution station, enabling continuous fuel supply without shut-down. The fuel tanks are pre-positioned and can be rapidly exchanged during operation, eliminating the need to stop equipment for refueling while maintaining reliable fuel supply.
Solution Approach 2:
The mobile distribution station acts as an intermediary between the fuel source and the hydraulic fracturing equipment. It includes fuel tanks, a pump, and a distribution system that delivers fuel to the equipment continuously. This intermediary system enables hot-refueling operations where equipment can be refueled without shut-down, resolving the contradiction between continuous operation and fuel supply reliability.
2Productivity
If hot-refueling is implemented to avoid shut-downs, then productivity is improved, but operational complexity increases due to difficulty in sustaining hot-refueling
Solution Approach 1:
The fuel storage system is segmented into multiple separate fuel tanks rather than one large tank. This segmentation allows for easier fuel management, rapid exchange of fuel containers, and simplified hot-refueling operations. Each tank can be independently managed and replaced without affecting the entire fuel system, reducing operational complexity while maintaining productivity.
Solution Approach 2:
The system incorporates automatic fluid level sensors and a controller that automatically monitor fuel levels and activate pumps to transfer fuel between tanks and to the equipment. This self-service automation reduces the complexity of manual hot-refueling operations, allowing continuous operation without requiring complex manual intervention or specialized procedures.
3Duration of action of moving object
If multiple fuel tanks are used for continuous supply, then operational duration is improved, but device complexity increases due to additional components
Solution Approach 1:
The mobile distribution station is designed as a multi-functional unit that combines fuel storage (multiple tanks), fuel transfer (pump system), fuel distribution (manifold and hoses), and control (sensors and controller) into a single integrated system. This universal design allows the same system to handle multiple fuel tanks and serve multiple pieces of equipment simultaneously, extending operational duration without proportionally increasing complexity.
Solution Approach 2:
The system incorporates fluid level sensors that continuously monitor fuel levels in the tanks and provide feedback to the controller. The controller automatically activates pumps and manages fuel transfer based on this feedback, ensuring continuous fuel supply without manual intervention. This feedback mechanism simplifies the management of multiple fuel tanks by automating the complexity of coordinating fuel levels and transfers across multiple containers.
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
Enables prolonged continuous operation of hydraulic fracturing equipment, enhancing productivity, safety, and reducing costs by ensuring uninterrupted fuel supply during fracking operations.
Implementation Method 1
Pneumatic valves are situated between the manifold and hoses and are operable to control fluid flow through the fluid passages
Implementation Method 2
A plurality of fluid level sensors are associated with different ones of the hoses
Implementation Method 3
the pressurized gas source includes a compressor
Data Source
AI summary
A distribution station includes a plurality of pneumatic valves on a mobile structure. Each pneumatic valve is situated between a manifold and a reel of a plurality of reels. A plurality of secondary valves are connected by an air or gas line to corresponding ones of the pneumatic valves. Each secondary valve is operable between open and closed positions to permit air or gas flow to the corresponding pneumatic valve to open and close the pneumatic valve. A controller is configured to individually open and close the secondary valves responsive to fluid level sensors.