Patent Application
20210002124
Various types of machinery used at worksites need to be operated continuously over an extended period of time. Where the machinery is powered by a combustion engine with fuel supplied from a fuel tank with limited capacity, it may be necessary to refuel the machinery's fuel tank during the machinery's continued operation in order to prevent the fuel tank from running empty. Where worksites have multiple pieces of machinery running simultaneously, multiple fuel tanks may require refueling at the same time. Various systems for refueling these local fuel tanks have been developed.
However, when refilling these local tanks from a remote location, there is a risk that the tanks will be overfilled, potentially leading to a fire.
In one aspect, a fuel mixer includes a first compartment, a second compartment, a third compartment, a plurality of cooling tubes, and at least one flow pipe. The second compartment is in fluid communication with the first compartment and is at least partially above the first compartment. The third compartment is in fluid communication with the first compartment and is at least partially above the first compartment. The plurality of cooling tubes are disposed in the second compartment and extend between the first compartment and the third compartment, thereby allowing fuel to flow from the first compartment to the third compartment. The at least one flow pipe is disposed in the second compartment and has an open top end, thereby allowing fuel to flow from the second compartment to the first compartment.
In another aspect, a refueling system includes a fuel source supplying fuel at a source temperature and a fuel mixer. The fuel mixer includes a first compartment, a second compartment, a third compartment, and cooling tubes. The first compartment is fluidly coupled to an engine of a piece of fracking machinery supplying fuel at a return temperature to the fuel mixer, the return temperature greater than the source temperature. The second compartment is in fluid communication with the first compartment and fluidly coupled to the fuel source. The third compartment is in fluid communication with the first compartment. The cooling tubes are disposed in the second compartment and extend between the first compartment and the third compartment. During operation, fuel from the fuel source at least partially fills the second compartment and flows from the second compartment to the first compartment to mix with the fuel from engine such that fuel in the first compartment is at a mixed temperature that is intermediate the supply and return temperatures. The fuel from the first compartment flows through the cooling tubes to the third compartment and is further cooled such that the fuel in the third compartment is at a cooled temperature that is lower than the mixed temperature.
In another aspect, a method of refueling fracking equipment includes introducing a first fuel received from an engine of the fracking equipment to a first compartment of a fuel mixer, the first fuel at a first temperature. The method further includes filling, at least partially, a second compartment of the fuel mixer with a second fuel received from a fuel source, the second fuel at a second temperature lower than the first temperature. The method further includes mixing the first fuel and the second fuel in the first compartment. The method further includes passing the mixed fuel through cooling tubes disposed in the second compartment. The method further includes delivering the mixed fuel to the engine of the fracking equipment.
The features of the embodiments described herein will be more fully disclosed in the following detailed description, which is to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. The drawing figures are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat schematic form in the interest of clarity and conciseness. In the description, relative terms such as “horizontal,” “vertical,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing figure under discussion. These relative terms are for convenience of description and normally are not intended to require a particular orientation. Terms including “inwardly” versus “outwardly,” “longitudinal” versus “lateral” and the like are to be interpreted relative to one another or relative to an axis of elongation, or an axis or center of rotation, as appropriate. Terms concerning attachments, coupling and the like, such as “connected” and “interconnected,” refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The term “operatively connected” is such an attachment, coupling or connection that allows the pertinent structures to operate as intended by virtue of that relationship.
The fuel source selection devices and fuel mixers described herein can be used in a variety of applications. For example, they can be used to refuel machinery used in hydraulic fracturing. The fuel source selection device may allow an operator to select whether to refuel the machinery from a local fuel tank or, alternatively, directly fuel the machinery using a centralized refueling system configured to supply fuel to multiple pieces of equipment simultaneously. For example, the fuel source selection devices described herein can be used with the OCTOFUELER automated frac refueling system supplied by Global Engineering Solutions. Such centralized refueling systems allow for the safe refueling of multiple pieces of equipment without requiring a user to enter the “hot zone” where risk of injury is significantly increased. The fuel source selection devices described herein allow for the direct fueling of the machinery from the centralized fueling system, bypassing the machinery's local fuel tank. This reduces the risk of overfilling the local fuel tank and causing a spill.
During the operation of typical diesel machinery used in the hydraulic fracturing process, only a portion of the fuel supplied to the engine is used during the combustion cycle. The remainder of the fuel is circulated through various portions of the engine to cool the engine and maintain its operating temperature. Typically, as shown in
In one embodiment, shown in
Turning to
In one embodiment, first compartment 108, second compartment 110, and third compartment 112 are stacked vertically, one on top of another. In such embodiments, first compartment 108 and second compartment 110 may be separated by a first bulkhead 114. Further, second compartment 110 and third compartment 112 may be separated by a second bulkhead 116. First bulkhead 114 and second bulkhead 116 may be constructed of any appropriate material. For example, first bulkhead 114 and second bulkhead 116 may be constructed of aluminum, steel, stainless steel, or any other appropriate material. The bulkheads 114, 116 can be joined to body 104 using any appropriate method. For example, in one embodiment, bulkheads 114, 116 are welded to body 104. In various embodiments, the perimeters of bulkheads 114, 116 are sealed to body 104 such that fuel cannot flow from one compartment to another around the perimeter of bulkheads 114, 116. For example, the perimeters of bulkheads 114, 116 can be sealed using a gasket, adhesive, caulk, or any other appropriate material.
First compartment 108, second compartment 110, and third compartment 112 can have any appropriate geometries. In various embodiments, second compartment 110 has a height that is greater than the height of either first compartment 108 or second compartment 110. This allows for increased heat transfer, as will be described further herein. Further, first compartment 108, second compartment 110, and third compartment 112 may have any appropriate volumes. In some embodiments, the volume of second compartment 110 is greater than the volume of either first compartment 108 or third compartment 112.
As best shown in
Flow pipes 120 are disposed in second compartment 110 and have an open top end 122 within second compartment 110. As will be described further herein, during operation, fuel in second compartment 110 flows through open top end 122, through flow pipe 120, and into first compartment 108. Flow pipes 120 may have any appropriate length. Further, flow pipes 120 may have any appropriate inner diameter. In various embodiments, the inner diameter of flow pipes 120 is greater than the inner diameter of cooling tubes 118.
As shown, for example, in
As shown in
The fuel supplied by fuel source 206 is at a source temperature, Ts. Engine 202 supplies fuel to fuel mixer 102 at a return temperature, TR. The return temperature, TR, being greater than the source temperature, Ts.
During operation, fuel from fuel source 206 at least partially fills second compartment 110 and flows into open top end 122 of flow pipe 120, through flow pipe 120, and into first compartment 108 where it mixes with the fuel from engine 202. The fuel within first compartment 108 is, therefore, at a mixed temperature that is intermediate the source, Ts, and return, TR, temperatures. Further, the fuel from first compartment 108 flows through cooling tubes 118 to third compartment 112. Cooling tubes 118 are surrounded by fuel at the source temperature. Hence, as the fuel flows through cooling tubes 118 it is further cooled such that the fuel in third compartment 112 is at a cooled temperature that is lower than the mixed temperature.
In one embodiment, fuel mixer 102 also includes a purge valve 130 configured to allow air to exit mixing chamber 106. As shown best in
The fuel mixer 102 may further include various gauges. For example, as shown in
In various embodiments, the fuel source selection device 100 further includes one or more valves that allow a user to control whether fuel is supplied to engine 202 from fuel source 206 or local fuel tank 208. As will be described herein, fuel source selection device 100 is configured to operate in either a first mode, in which fuel is supplied from fuel source 206 to engine 202, or a second mode, in which fuel is supplied from local fuel tank 208 to engine 202.
For example, as shown in
When operating in the first mode of operation, the one or more valves of fuel source selection device 100 are configured such that engine supply hose 210 and fuel source hose 214 are in fluid communication (e.g., via mixing chamber 106). Further, in the first mode of operation, the one or more valves are configured such that engine return hose 212 is in fluid communication with mixing chamber 106 such that hot return fuel may mix with fuel from fuel source 206, as described above.
When operating in the second mode of operation, the one or more valves of fuel source selection device 100 are configured such that engine supply hose 210 and local fuel tank supply hose 216 are in fluid communication to supply engine 202 with fuel from local fuel tank 208. Further, in the second mode of operation, the one or more valves are configured such that engine return hose 212 is in fluid communication with local fuel tank filling hose 218 to supply hot return fuel from engine 202 to local fuel tank 208.
In at least one embodiment, fuel source selection device 100 includes a diverter valve 136, as shown in
When operating in the first mode, return fuel from engine 202 passes through first valve inlet 138 and out through second valve outlet 148 and into first compartment 108 of mixing chamber 106 via hot fuel hose 150 and first mixer inlet 124. In addition, fuel from fuel source 206 passes into second compartment 110 of mixing chamber 106 via fuel source hose 214 and second mixer inlet 126. As described above, the fuel from engine 202 and fuel source 206 mix in mixing chamber 106. The mixed fuel in third compartment 112 of mixing chamber 106 passes through mixer outlet 128, mixed fuel hose 142, second valve inlet 140, first valve outlet 146, and engine supply hose 210 to engine 202. This process continues as machinery 204 is operated.
As described above, when operating in the first mode, hot return fuel from engine 202 is not supplied to local fuel tank 208. Instead, the return fuel is continuously cooled and recycled via fuel mixer 102. This eliminates the risk of over-filling local fuel tank 208, thereby significantly reducing the risk of accidents or fires.
When operating in the second mode, return fuel from engine 202 passes through engine return hose 212, first valve inlet 138, third valve outlet 152, local fuel tank filling hose 218, and into local fuel tank 208 where the hot fuel from engine 202 is able to mix with the cooler fuel contained therein. In addition, fuel from the local fuel tank 208 passes through local fuel tank supply hose 216, third valve inlet 144, first valve outlet 146, local fuel tank supply hose 216, and to engine 202.
As a result, the user is able to select one of the fuel sources from which to supply fuel to engine 202 of machinery 204. Hence, fuel source selection device 100 may be permanently installed as a portion of the refueling system. When a central refueling source (e.g., fuel source 206) is being used, fuel source selection device 100 is used in the first mode of operation. When a central refueling source is not being used, fuel source selection device 100 is used in the second mode of operation. This allows for safe switching between multiple fuel sources.
Diverter valve 136 may include any appropriate fitting for connection to the various hoses. For example, diverter valve 136 may include quick-connect type fittings, threaded fittings, cam-and-groove fittings, or any other appropriate type of fitting.
In various embodiments, as shown in
Diverter valve 136 can be any appropriate diverter valve. For example, in one embodiment, diverter valve 136 is a six-way closed center flow diverter valve. Diverter valve 136 may be operated by actuator 154. As shown in
Alternatively, in other embodiments, fuel source selection device 100 includes multiple valves. For example, in one embodiment, a first valve may allow selection of whether engine supply hose 210 is in fluid communication with fuel source 206 (via fuel mixer 102) or with local fuel tank supply hose 216. Further, a second valve may allow selection of whether engine return hose 212 is in fluid communication with fuel mixer 102 or with local fuel tank filling hose 218. In such embodiments, a user may operate the first and second valves to change the mode of operation of fuel source selection device 100.
In at least one embodiment, refueling system 200 includes a pre-filter 220 in line with engine supply hose 210. Pre-filter 220 removes particulates and other foreign matter from the fuel before the fuel is supplied to engine 202.
When installed, fuel source selection device 100 may be mounted directly to machinery 204. In other embodiments, fuel source selection device 100 may be mounted to a stand 222, as shown in
The fuel source selection devices and fuel mixers described herein can be used to supply fuel to any type of machinery. For example, they can be used to supply machinery used in hydraulic fracturing such as pumpers, blenders, sand units, or any other appropriate machinery. Further, the fuel source selection devices and fuel mixers described herein can be used to supply any appropriate fuel to such machinery. For example, the fuel source selection devices and fuel mixers described herein can be used to supply diesel fuel. Alternatively, the fuel source selection devices and fuel mixers can be used to supply gasoline.
In various embodiments, a method of refueling fracking equipment includes introducing a first fuel received from engine 202 of machinery 204 to first compartment 108 of fuel mixer 102. The first fuel is at a return temperature. The method further includes filling, at least partially, second compartment 110 of fuel mixer 102 with a second fuel received from fuel source 206. The second fuel is at a source temperature that is lower than the return temperature. The method further includes mixing the first fuel and the second fuel in first compartment 108. The method further includes passing the mixed fuel through cooling tubes 118 disposed in second compartment 110. The method further includes delivering the mixed fuel to engine 202 of machinery 204 via third compartment 112 of fuel mixer 102.
While the foregoing description and drawings represent preferred or exemplary embodiments of the present invention, it will be understood that various additions, modifications and substitutions may be made therein without departing from the spirit and scope and range of equivalents of the accompanying claims. In particular, it will be clear to those skilled in the art that the present invention may be embodied in other forms, structures, arrangements, proportions, sizes, and with other elements, materials, and components, without departing from the spirit or essential characteristics thereof. One skilled in the art will further appreciate that the invention may be used with many modifications of structure, arrangement, proportions, sizes, materials, and components and otherwise, used in the practice of the invention, which are particularly adapted to specific environments and operative requirements without departing from the principles of the present invention. The presently disclosed embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being defined by the appended claims and equivalents thereof, and not limited to the foregoing description or embodiments. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the invention, which may be made by those skilled in the art without departing from the scope and range of equivalents of the invention. All patents and published patent applications identified herein are incorporated herein by reference in their entireties.
