Remote Proppant Storage Control for Safer Fracturing Flow
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Solution Overview
Problem
In hydraulic fracturing operations, manual monitoring and control of proppant usage are inefficient, exposing workers to hazardous conditions, leading to operator errors, environmental hazards, and profit losses due to incorrect proppant flow and mixing.
Innovation Solution
A system for real-time remote monitoring and control of proppant usage using wireless sensors and software that connects proppant containers to a datavan, allowing for automated scheduling and flow management, reducing the need for manual intervention and minimizing exposure to silica dust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operators manually monitor and control proppant containers at the wellsite, then they can directly adjust proppant flow, but operators are exposed to hazardous conditions including silica dust, extreme weather, and must be stationed outside containers
Solution Approach 1:
A wireless remote control system acts as an intermediary between the operator and the proppant container. The operator controls the container gate and monitors proppant levels from a protected location using wireless communication, eliminating direct exposure to silica dust and hazardous environmental conditions while maintaining full operational capability
Solution Approach 2:
The patent replaces manual mechanical monitoring and control with an automated electronic system featuring wireless sensors for level detection and wireless remote controls for gate operation. This substitution eliminates the need for operators to physically presence at containers, removing them from hazardous environments while preserving control functions
2Reliability
If operators manually check proppant levels and adjust flow, then they can respond to container status, but it takes minutes to walk over and manually adjust, reducing productivity
Solution Approach 1:
Wireless sensors continuously monitor proppant levels in containers and transmit data in real-time to the control system. This continuous feedback eliminates the need for manual checking, providing immediate awareness of container status and enabling instantaneous response to level changes, thereby dramatically improving productivity while maintaining reliable control
Solution Approach 2:
The system enables self-monitoring of proppant levels through automated sensors that continuously track and report container status without human intervention. This self-service capability eliminates time-consuming manual checks and allows the system to automatically detect when intervention is needed, significantly improving response time and operational efficiency
3Ease of operation
If multiple personnel are stationed at containers for monitoring, then manual control can be performed, but it increases operational costs and is inconvenient when extra personnel are not available
Solution Approach 1:
The wireless monitoring and control system replaces the need for multiple personnel with automated electronic sensors and remote controls. A single operator can monitor multiple containers simultaneously from a protected location, eliminating the requirement for extra personnel while maintaining full manual control capability, thereby reducing operational costs and increasing convenience
4Productivity
If gates are left open for proppant flow, then proppant delivery is continuous, but it causes profit loss from spilling, environmental harm, and safety concerns
Solution Approach 1:
Wireless sensors provide real-time feedback on proppant levels and flow status to the control system. This continuous monitoring enables precise control of gate operation, allowing the system to maintain continuous delivery when needed while automatically closing gates when containers are empty or flow is complete, thereby preventing spills and environmental harm without sacrificing productivity
Solution Approach 2:
The automated control system independently manages gate operation based on sensor input, opening and closing gates as needed without human intervention. This self-service capability ensures continuous proppant delivery when containers have sufficient material while automatically preventing spills by closing gates at appropriate moments, eliminating environmental harm and safety concerns associated with manual gate control
5Adaptability or versatility
If operators manually determine which container to use, then they can select proppant types, but it leads to operator error and confusion about container scheduling
Solution Approach 1:
Wireless sensors continuously monitor and identify which containers are in use and their current status, providing real-time feedback to the control system and operators. This automated tracking eliminates confusion about container scheduling and prevents operator errors in selecting the wrong container, while maintaining the flexibility to choose different proppant types as needed
Solution Approach 2:
The system automatically tracks and identifies container usage status without requiring manual determination by operators. This self-service capability eliminates human error in container selection and scheduling while preserving the adaptability to select different proppant types, thereby improving reliability without sacrificing operational flexibility
Data Source
AI summary
A system and method that remotely monitors and controls proppant usage in a fracturing operation. The system and method allow operators to wirelessly monitor and control proppant storage units from inside a datavan through sensors and control mechanisms that interface with fracturing software to schedule the flow of the proppant. A sensor monitors the weight, container level, or volume of the proppant being used to keep the induced hydraulic fracture open. A serial to Ethernet converter converts this information and sends it wirelessly to a datavan. A user at the datavan controls the proppant usage through a display in the datavan of the storage units with the appropriate weight. The container monitoring software links with the fracturing software, providing real-time information about proppant usage so that the user can properly schedule proppant flow to the well through valves, conveyor belts, and other control mechanisms.