Mobile Fuel Distribution Station with Satellite Communication
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies due to frequent equipment shut-downs for refueling, which are costly and disrupt continuous operations, and hot-refueling methods are difficult to sustain reliably.
Innovation Solution
A mobile distribution station with a trailer-mounted pump, manifold, reels, valves, fluid level sensors, and a controller that manages fuel distribution continuously, along with a satellite dish for communication, allowing for remote operation and efficient fuel delivery to equipment during fracking, enabling continuous operation without shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If equipment operates continuously without refueling, then productivity is improved, but fuel supply reliability deteriorates
Solution Approach 1:
The fuel supply system is segmented into multiple independent fuel tanks (first fuel tank, second fuel tank, third fuel tank) with separate control valves and level sensors for each. This allows the system to switch between multiple fuel sources, ensuring continuous operation even when one tank is depleted or requires maintenance.
Solution Approach 2:
The system performs preliminary monitoring of fuel levels in all tanks using level sensors before operation continues. The controller proactively manages fuel distribution by opening/closing valves based on predicted fuel needs and current levels, preventing fuel exhaustion and ensuring uninterrupted supply to the pump.
2Reliability
If manual refueling operations are performed, then fuel supply reliability is improved, but loss of time increases
Solution Approach 1:
The system provides self-service fuel management through automated level monitoring and valve control. The controller automatically manages fuel distribution from multiple tanks to the pump based on real-time level sensor data, eliminating the need for manual refueling operations and reducing downtime.
Solution Approach 2:
The system implements continuous feedback through level sensors that monitor fuel levels in real-time and communicate with the controller. This feedback loop enables automatic adjustment of valve positions to maintain optimal fuel supply, eliminating manual intervention and reducing refueling time.
3Productivity
If hot-refueling is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The fuel distribution system is divided into multiple independent fuel tanks, each with its own control valve and level sensor. This segmentation allows the complex hot-refueling operation to be managed through simpler, independent control of each tank, reducing overall system complexity while maintaining continuous operation capability.
4Reliability
If multiple fuel tanks are used, then fuel supply reliability is improved, but device complexity increases
Solution Approach 1:
The control valve and level sensor assembly is designed as a universal, multi-functional unit that can be replicated for each fuel tank. Each valve serves multiple functions: controlling fuel flow, isolating depleted tanks, and enabling selective fuel source management. This standardized multi-functional design reduces complexity despite having multiple tanks.
Data Source
AI summary
A distribution station includes a mobile trailer, a pump on the mobile trailer, at least one manifold on the mobile trailer and fluidly connected with the pump, and a plurality of reels on the mobile trailer. A plurality of hoses are connected with different ones of the reels. A plurality of valves on the mobile trailer are situated between the manifold and respective different ones of the reels. A plurality of fluid level sensors are associated with different ones of the hoses. A controller is configured to individually open and close the valves responsive to the fluid level sensors, and a satellite dish is mounted on the mobile trailer. The satellite dish is moveable between a stowed position and a deployed position.