Mobile Fuel Distribution Station for Continuous Hot Refueling
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Solution Overview
Problem
Hydraulic fracturing operations face inefficiencies due to equipment shut-downs for refueling, and maintaining continuous operation through hot-refueling is challenging.
Innovation Solution
A mobile distribution station equipped with a controller that manages fluid delivery through hoses, valves, and sensors, ensuring continuous fuel supply by monitoring fuel levels and activating/deactivating pumps and valves based on real-time data, with fail-safes to prevent overfilling or unsafe conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hot-refueling is used to maintain continuous operation, then productivity is improved, but reliability deteriorates due to difficulty in sustaining the operation
Solution Approach 1:
The system divides the refueling operation into multiple independent hose lines (first hose line, second hose line, etc.) that can operate separately. This segmentation allows the refueling system to maintain continuous operation by switching between or simultaneously using multiple hoses, thereby improving reliability while sustaining productivity.
Solution Approach 2:
The system changes the operational parameters by implementing automated control mechanisms that monitor fuel levels and dynamically adjust refueling operations. This includes using sensors to detect fuel levels and controllers to manage the refueling process, enabling sustained continuous operation with improved reliability through parameter-based control.
2Device complexity
If manual refueling monitoring is used, then device complexity is reduced, but loss of time increases due to shut-downs
Solution Approach 1:
The system implements feedback mechanisms through sensors that continuously monitor fuel levels in equipment tanks. This feedback is transmitted to controllers that automatically initiate refueling operations when fuel levels drop, eliminating the need for manual monitoring and preventing shut-downs, thus reducing time loss while maintaining manageable system complexity.
Solution Approach 2:
The refueling system is designed to operate autonomously by using sensors to detect fuel levels and automatically controlling the refueling process. The system serves itself by initiating and managing refueling operations without human intervention, thereby reducing time loss due to shut-downs while keeping the control mechanism relatively simple.
3Reliability
If automated control with sensors is implemented, then reliability is improved, but device complexity increases
Solution Approach 1:
The system uses sensors as intermediary devices that bridge the gap between manual operation and full automation. These sensors provide reliable fuel level detection and trigger automated responses through controllers, improving refueling reliability while adding only moderate complexity through the introduction of intermediate sensing and control components.
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 with enhanced reliability and safety by preventing equipment shut-downs and managing fuel distribution efficiently, reducing the risk of overfilling or leaks.
Implementation Method 1
A non-limiting example of a sensor includes a fluid level sensor that can be hard-wired to a controller through a communication line routed through the reel.
Implementation Method 2
A pump is configured to deliver fluid to the at least one manifold
Implementation Method 3
Each valve is situated between the at least one manifold and a respective different one of the reels, and each fluid level sensor is paired with a different one of the hoses. A controller is configured to individually open and close the valves responsive to the fluid level sensors.
Data Source
AI summary
A fluid delivery apparatus includes a mobile distribution station, at least one manifold on the mobile distribution station, a pump configured to deliver fluid to the at least one manifold, a plurality of reels fluidly connected with the at least one manifold, a plurality of hoses, a plurality of valves, and a plurality of fluid level sensors. Each hose is fluidly connected with a different one of the reels. Each valve is situated between the at least one manifold and a respective different one of the reels, and each fluid level sensor is paired with a different one of the hoses. A controller is configured to individually open and close the valves responsive to the fluid level sensors.