Mobile Fuel Distribution Station for Continuous Hot-Refueling
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies due to frequent equipment shut-downs for refueling, which can be costly and disrupt continuous operations.
Innovation Solution
A mobile distribution station equipped with a trailer containing pumps, manifolds, hoses, valves, fluid level sensors, and a controller that allows for continuous hot-refueling by individually managing fuel distribution to equipment, ensuring uninterrupted operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If equipment operates semi-continuously with shutdowns for refueling, then refueling operations are simpler and safer, but operational efficiency and productivity decrease
Solution Approach 1:
The system divides the refueling operation into multiple independent hose lines (first hose line, second hose line, etc.) that can operate simultaneously or independently. This segmentation allows continuous refueling of multiple tanks without requiring complete shutdowns, thereby improving productivity while maintaining refueling reliability through distributed operation.
Solution Approach 2:
The system enables continuous refueling operations by providing multiple hose lines that can service multiple tanks simultaneously. The controller manages fuel distribution continuously across different tanks via different hoses, eliminating the need to shut down equipment for refueling and maintaining uninterrupted operational action.
2Productivity
If hot-refueling is implemented to avoid shutdowns, then operational continuity is improved, but system complexity and difficulty of reliable operation increase
Solution Approach 1:
The system incorporates automatic fluid level sensors in each tank that communicate with the controller to enable self-regulating refueling operations. The controller automatically opens or closes valves based on sensor feedback, allowing the system to manage its own refueling process without complex manual intervention, thereby maintaining operational continuity while managing system complexity.
Solution Approach 2:
The system uses fluid level sensors in each tank that provide real-time feedback to the controller. The controller adjusts valve positions based on this feedback to maintain proper fuel levels, enabling continuous hot-refueling operations with automated control that manages system complexity through intelligent regulation.
3Productivity
If multiple hose lines are used for simultaneous refueling, then refueling speed and productivity increase, but control complexity and fluid management difficulty increase
Solution Approach 1:
The system replaces manual fluid management with an automated electronic control system. The controller receives signals from fluid level sensors and automatically actuates valves on each hose line, eliminating the need for manual coordination of multiple hoses and significantly improving ease of operation while maintaining high refueling speed.
Solution Approach 2:
Each hose line is equipped with its own fluid level sensor and valve that operate autonomously under controller management. The system self-regulates fuel distribution across multiple lines based on real-time tank levels, enabling fast simultaneous refueling without complex manual fluid management.
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 continuous hydraulic fracturing operations by maintaining fuel supply without shutdowns, enhancing operational efficiency and reducing costs through reliable and controlled fuel management.
Implementation Method 1
a pump, first and second manifolds fluidly connected with the pump
Implementation Method 2
Each fluid level sensor is associated with a different one of the hoses
Implementation Method 3
Each valve is situated between one of the first or second manifolds and a respective different one of the reels. The controller is configured to individually open and close the valves responsive to the fluid level sensors
Data Source
AI summary
A distribution station includes a container, a pump, first and second manifolds fluidly connected with the pump, reels, hoses, valves, fluid level sensors, and a controller. Each hose is connected with a different one of the reels. A portion of the reels are connected to be fed from the first manifold and another portion of the reels are connected to be fed from the second manifold. Each valve is situated between one of the first or second manifolds and a respective different one of the reels. Each fluid level sensor is associated with a different one of the hoses. The controller is configured to individually open and close the valves responsive to the fluid level sensors.