Trailer-Integrated Frac-Sand System with Pre-Assembled Safety Features
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Solution Overview
Problem
Current frac-sand handling systems lack versatility in loading options, integrated safety features, and portability, leading to safety hazards and inefficiencies in oil-field well sites.
Innovation Solution
A self-contained, trailer-integrated frac-sand conditioning and elevator system with pre-assembled safety features, including railings, a generator set, hydraulic elevation cylinders, and a fold-away sand funnel assembly, allowing for easy setup and operation at remote locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current frac-sand handling systems are assembled on site with multiple separate equipment pieces, then the system can be configured for specific operations, but worker safety is compromised and setup time increases
Solution Approach 1:
The patent combines multiple separate equipment pieces (conveyors, sifter, blender, generator, hydraulic system) into a single integrated trailer-mounted system. This merging eliminates the need for workers to assemble and connect separate components on-site, thereby improving safety while maintaining operational versatility through the integrated design.
Solution Approach 2:
The system is pre-assembled and pre-configured on the trailer before arrival at the work site. All connections, electrical wiring, hydraulic lines, and safety features are completed in advance during manufacturing, eliminating on-site assembly hazards and reducing setup time while maintaining adaptability to different operational requirements.
2Adaptability or versatility
If electrical generators and hydraulic pumps are delivered separately and connected on site, then the system can be adapted to different locations, but safety hazards increase due to strewn cables and hoses
Solution Approach 1:
The electrical generator, hydraulic pump, conveyors, and control systems are merged into a single integrated trailer unit with all electrical and hydraulic connections pre-made. This eliminates the need to deliver and connect separate equipment pieces, thereby removing the safety hazards of strewn cables and hoses while maintaining location flexibility.
Solution Approach 2:
All electrical wiring, hydraulic connections, and mechanical linkages are completed in advance during trailer assembly. The system arrives at the work site fully connected and configured, eliminating on-site connection hazards while adapting to different locations through the mobile trailer platform.
3Adaptability or versatility
If workers manually connect multiple separate equipment pieces, then the system can be customized for specific operations, but labor costs and setup time increase
Solution Approach 1:
Multiple equipment pieces are merged into a single integrated trailer system with all connections pre-established. This eliminates the labor-intensive process of manually connecting separate components on-site, thereby reducing setup time and labor costs while maintaining operational customization through the integrated design.
Solution Approach 2:
All connections and configurations are completed in advance during manufacturing. The system is delivered ready-to-operate, eliminating on-site assembly work and significantly reducing setup time while allowing operational customization through the integrated system's design capabilities.
4Reliability
If safety harnesses are required for workers climbing higher than six feet, then worker safety is improved, but the equipment lacks integrated safety features and requires additional gear
Solution Approach 1:
Safety features including harness anchor points, railings, and protective structures are integrated directly into the trailer and equipment design. This merging of safety features into the equipment itself eliminates the need for separate safety gear and provides consistent safety protection without adding complexity to the overall system.
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
The system enables quick and safe setup of frac-sand handling operations, reduces labor costs, and enhances worker safety by eliminating the need for on-site assembly and minimizing electrical and hydraulic hazards.
Implementation Method 1
hydraulic elevation (lifting) cylinders
Implementation Method 2
vibratory sifter located below the sand-liquid blender for removing debris from the frac-sand slurry
Implementation Method 3
generator set for powering the system
Implementation Method 4
sand-liquid blender for mixing a liquid containing water with the sand to form a frac-sand slurry
Data Source
AI summary
A self-contained single-trailer sand-conveyor and mixer system capable of being erected into an operational configuration and reconfigured into a compact highway-travel configuration, without the need for safety harnesses. The system, mounted on a single trailer, includes an input feed hopper for side-loading sand, first and second conveyors for material transport, a sand-liquid blender for producing frac-sand slurry, a vibratory sifter for debris removal, and a discharge funnel with a boot for precise slurry output. The system also integrates automated elevation actuators, and height-maintenance locks. Some embodiments include hydraulic mechanisms to ensure operational stability and worker safety. With pre-assembled components, OSHA-compliant safety features, and a generator-powered control system, this invention offers quick deployment, improved safety, and efficient frac-sand handling.