The present invention relates generally to fueling systems for hydraulic fracturing equipment, and more specifically to a system and method for automatically fueling equipment and reporting important information in a real time for fracing hydrocarbon wells.
The fracturing of hydrocarbon wells requires great amounts of pressure. Diesel, natural gas, and or a combination of those driven pumps are utilized in order to generate pressures sufficient to fracture shale deposits. This equipment is located remotely and require refueling several times during a frac job. Conventional systems for fueling hydraulic fracturing equipment use trucks and pump fuel into saddle tanks from the trucks as required to keep the saddle tanks full. Alternative conventional systems bypass the saddle tanks of the hydraulic fracturing equipment and provide a pressurized fuel line and a return line for each piece of equipment. Conventionally data is monitored on a per site basis typically relayed from the single sale pump to a user, therefore no one knows how much fuel each piece of equipment is using in relation to the rest of the fleet. Conventional systems and methods for fueling hydraulic fracturing equipment have disadvantages. First, stopping the frac to refill saddle tanks cost time and money. Second, different frac pump engines require different fuel pressures to operate, and keeping over a dozen pieces of equipment operating at different pressures is difficult. Third, the space at a fracturing site is limited and conventional systems require multiple hoses snaked in and around the pumps and various trailers. Thus, there exists significant room for improvement in the art for overcoming these and other shortcomings of conventional systems and methods for automatically fueling hydraulic fracturing equipment.
The novel features believed characteristic of the system of the present application are set forth in the appended claims. However, the system itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, in which the leftmost significant digit(s) in the reference numerals denote(s) the first figure in which the respective reference numerals appear, wherein:
While the system of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the method to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the application as defined by the appended claims.
Illustrative embodiments of the system and method for automatic fueling of hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level are provided below. It will, of course, be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with assembly-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
In the specification, reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper,” “lower,” or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.
Automatic fueling of frac pumps and frac equipment provides fuel to saddle tanks of hydraulic fracturing equipment as needed by the saddle tanks. The system for automatically fueling hydraulic fracturing equipment is comprised of a fuel input system, a fuel output system, and a control system for regulating the flow of fuel from the input system to the output system. Preferably the system is compact to reduce the footprint at fracturing sites. This system comes with the ability to report fuel tank status, usage, and fill level to users at the fracturing site and remote to the fracturing site, for example at the headquarters of the exploration company. Furthermore, the system provides self-propelled carts for distribution of fuel at a drilling site.
Referring now to
Fuel output system 107 is comprised of fuel hose 111, a reel 113, a remote actuated valve 115, a flow meter 117, and a ball valve 119. Reel 113 is retractable like a reel from the input fuel system but is manually driven and is configured to contain the fuel hose when the system does not require a long fuel hose and for when the system is unused. Adjacent the fuel hose 111 is electrical wiring connecting the control system 109 to the fuel cap system 103 located on the saddle tank 121. To facilitate the clarity of the illustrations the hoses between the reels 113 and the remote actuated valves 115 has been removed, however, it should be apparent that the valves 115 are coupled to the reels 113. The preferred embodiment of the reel 113 is a manual reel however due to the weight of some fuel lines a hydraulically driven reel is contemplated by this application. Flow meter 117 is configured to allow the system to report the fill status of the corresponding tank and the fuel tank usage over a stage level, a daily level, and a job level.
While the preferred embodiment utilizes electric valves wired directly to the controller, pneumatic valves controlled by air are contemplated by this application. Tubing would be utilized in place of wiring to air powered valves to open and close the supply of fuel to the pieces of equipment. This aspect increases the safety of the system by removing the proximity of fuel and electricity.
Fuel cap system 103 is comprised of a fuel cap with a male fluid coupling, a high sensor 127, and a low sensor 129. Male fluid coupling is configured to quickly allow the fuel hose 111 connect to the fuel cap system. Each saddle tank will utilize the fuel cap system 103. The high sensor 127 of the fuel cap system is configured to measure the amount of fuel in the saddle tank near the rated capacity of the tank. The low sensor 129 of the fuel cap system is configured to measure the entire amount of fuel in the saddle tank. The high sensor is preferably an ultrasonic sensor and alerts the system once the fluid level in the tank is high enough to break an ultrasonic beam. The low sensor is preferably a pressure sensor and is submerged into the fluid. As the tank is filled the pressure increases. The high sensor is a redundant sensor to ensure that the valve is closed when the fuel level in the tank approaches the tank's capacity. Low sensor 129 provides data to the system in order for the tank fill level to be reported. Alternatively, the fuel cap system further comprises an electric valve controlled by the control system 109 to stop the flow of fuel at the closest connection to the piece of equipment being filled. The additional electric valve also provides redundancy to the valve adjacent the reel.
System 101 further comprises a propulsion system having a combustion motor 135, a hydraulic system 137, a plurality of hydraulic motors 139 coupled to the wheels 141 of the system, and a steering system 143. Steering system 143 is preferably a set of hydraulic valves connecting the hydraulic system 137 to the plurality of hydraulic motors 139. A user stands on foldable bracket 147 and can steer and move the system by moving the steering system. Foldable bracket 147 is configured that the user is able to see over a top of the system to drive it. The propulsion system is preferably both 2 wheel drive and four wheel drive capable by toggling a valve. Since wells sites are typically muddy having a four-wheel drive capable system facilitates moving the cart/platform near the hydraulic fracturing equipment. Furthermore, the unit can be moved by a remote control that operates the hydraulic valves in control of the hydraulic motors 139. With the remote control, the user can drive the unit around the job site and steer clear of obstacles in the confined spaces around a fracturing site.
Control system 109 is preferably a programmable logic controller with a display and assesses the amount of fuel to dispense based upon the low sensor 129. Control system 109 can be calibrated by entering in the distance from a bottom of the saddle tank to the max fill line to determine the relative expected pressures when the tank is near the max fill line. Alternatively, in addition to the low sensor, an ultrasonic distance sensor measures the amount of fuel in the saddle tank by ultrasonically measuring a distance between the ultrasonic distance sensor and the upper surface of the volume of fuel in the saddle tank. High sensor acts as a redundant stop where the valve 115 is closed whenever the top of the fuel is close to the high sensor. High sensor prevents fuel spills when the low sensor fails. Control system 109 is electrically coupled to the high sensor and the low sensor by wiring located adjacent the hose 111. Both the hose 111 and the wiring to the high and low sensor are contained in a common conduit. In the preferred embodiment, the reel 113 is continually coupled between the valve and the hose 111 while the electrical wiring has a disconnect. Alternatively, both the fuel line and the wiring to the high and low sensors have sliprings in the reel and are continually coupled. Control system 109 is also wired to flow meter 117. Control system 109 tracks fuel flow to each tank by the amount of fuel flowing through the flow meter 117 associated with each piece of equipment. This flow data provides users with feedback regarding how efficient the hydraulic fracturing equipment are operating. Furthermore, the control system provides manual control of the valve 115 by a series of switches for each reel. This allows a user to either prevent the remote activation, engage the remote valve, or allow the system to control the valve. Control system may further comprise an indicator tower and emergency stops located on the cart. While the preferred embodiment of the system uses wiring to connect the control system 109 to the sensors and valves, alternatively the control system is wirelessly connected to the sensors of the fuel cap system. Additionally, the controller is wired to electric valves located near the supply of fuel such as on the bobtail, the fuel shuttle, and or the transport. These electric valves are wired to stop the flow of fuel in an emergency by activation of an emergency stop located on the cart. Furthermore, the controller can close the electric valve on the supply of fuel as a redundant fuel stop in addition to the electric valves associated with each reel.
Typically the system 101 is comprised of twelve fuel output systems 107 connected to a single fuel input system 105. This configuration allows for a single platform to fuel a dozen saddle tanks concurrently. Typically the fuel line of the fuel output system is ½″ or ¾″ diameter and the diameter of the fuel input system is 1¼″ to 2″ diameter. In the preferred embodiment the control system is powered remotely, alternatively, the system further comprises a generator or solar system to supply voltage to the control system.
Referring now also to
Referring now also to
A fuel cap system is installed into each saddle fuel tank. A hose is extended from each reel as needed and coupled to the fuel cap system. Additionally, a hose is extended from the cart to the supply tank 311. Calibration of the sensors as needed is performed. The user then allows the controller to control the remotely controlled valve by flipping a switch or depressing a button. The system then autonomously fills the saddle tanks from the supply tank 311. A sale meter is located between the supply tank and the cart to document the volume of fuel sold. Once the frac job is complete the process is reversed. The extended hoses are decoupled and retracted into the cart. The fuel caps are removed from the saddle tanks. Additionally this orientation of carts exterior to the frac pumps allows for the removal of equipment during a fire and the fuel lines can be removed from the pieces of equipment and the cart and extended hoses driven away from the fire.
While the system as illustrated in
Referring now also to
The reporting system takes the data from the sensors and provides real-time tracking of fuel usage from the embedded sensors. The reporting system is also able to provide users with time histories of fuel usage such as an amount of fuel usage over a stage of a frac; an amount of fuel usage over a day; an amount of fuel usage over a job; and an amount of fuel in the saddle tank. Additionally, the reporting system can provide the amount of fuel in each of the saddle tanks and the supply tanks. Additionally, the reporting system allows a user remote control of the electric valves of the system. For example, a user can sit in their vehicle remotely viewing the fuel levels in a saddle from their laptop and open/close valves from the laptop to add or stop fuel from being added to the monitored tank. Furthermore, a semi-automatic mode is contemplated, such that the electric valve system closes once the fuel level reaches a selected high value in the tank or when the high sensor is activated. The operator would be alerted once the fuel level reached a selected low point and the operator would remotely activate the electric valve to open and start fuel flowing into the saddle tank of the piece of equipment.
Referring now to
Fuel is removed from the fuel tank 507 by first hose 519 being fluidly coupled to a port 521 of a multiport on the trailer and fluidly coupled to the pair of pumps 513. Pumps 513 are preferably mechanically driven by a power take-off system of the truck cab 503 and can be electrically or mechanical switched on and off. Alternatively, the pumps can be electrically driven by a local power supply or a remote power supply. Furthermore, a fuel meter is located between the fuel tank 507 and the reels to measure the amount of fuel removed from the tank 507. Second hose 523 fluidly couples the pumps to the fuel manifold 515. Fuel manifold 515 and the first plurality of reels 509 is similar to that of system 101 and used to fuel tanks of frac pumps directly with electronic valves controlled by controller 517 located between the reels and the manifold. System 501 can be driven to the well site and located adjacent the frac pumps. System 501 provides metered and controlled fuel to each saddle tank of the frac pumps and additionally provide fuel to the carts as described above. The compact nature of the truck and tank combined make transport easier around a congested well site.
Referring now also to
Referring now also to
Pump station 711 is comprised of a pair pf redundant systems, each system having a fuel reel, a meter, and a series of fittings to fluidly couple the tank 707 to the reel and ultimately to the cart. The cabin is comprised of a structure that the users can be located inside of during use and provides electrical connections and data connections for laptop control of system 101. Folding platforms surround the cabin and are unloaded at the well site. Additional controls are located in the cabin such as breaker panel for the generator 709 and switches for pumps 713. A battery system can be located on the shuttle for storage of energy to the various connected subsystems.
Generator 709 is a diesel driven three phase and single phase electrical providing system. Generator 709 electrically powers pumps 713 and cabin 705 along with lighting as necessary on the shuttle. Furthermore, generator 709 can power carts 101 with an extension cable. A pair of actuated struts 715 supports the system 701 when the cab of the truck has left system 701 at a well site.
Referring now also to
The base retainment member 819 is placed where the fuel tank cap would normally be located on the saddle tank of the frac pump. The base retainment member 819 is strapped in place by a strap that goes around the circular tank and picks up openings in the base retainment member 819, the tension of the strap holds the base retainment member 819 in place relative to the saddle tank. The base retainment member 819 has a gasket for sealing with the saddle tank. The base retainment member 819 has a pair of cam-style levers to retain the base 803 in place. The base retainment member 819 also has a gasket for sealing with the base 803.
The base 803 is comprised of machined aluminum and features a series of passages from the exterior of the saddle tank to the interior of the saddle tank, as well as, a groove located around a circumference of the base to engage the levers of the base retainment member. A first portion of the hydraulic coupler is located on the base. A first portion of the electrical coupler is located on the base, for example, the electrical receptacle. A fill pipe is coupled to the base to be inserted into the saddle tank. Fuel comes out of the hose through the hydraulic coupler, the base, and the fill pipe and into the saddle tank.
Both the high sensor 813 and the low sensor 815 are electrically connected to the controller across the electrical coupler 807. The high sensor 813 of the fuel cap system is configured to measure the amount of fuel in the saddle tank near the rated capacity of the tank. The low sensor 815 of the fuel cap system is configured to measure the entire amount of fuel in the saddle tank. The high sensor is preferably an ultrasonic sensor and alerts the system once the fluid level in the tank is high enough to break an ultrasonic beam. The low sensor is preferably a pressure sensor and is submerged into the fluid. As the tank is filled the pressure increases. The high sensor is a redundant sensor to ensure that the valve is closed when the fuel level in the tank approaches the tank's capacity. Low sensor 815 provides data to the system in order for the tank fill level to be reported.
Plate 809 rigidly retains a second portion of the hydraulic coupler and a second portion of the electrical coupler. Plate 809 features a set of handles or openings to allow the user to easily grab the plate and couple and decouple the fuel and electrical connections.
Referring now also to
System 901 further comprises a propulsion system having an electric motor mechanically driving a pair of the wheels 915 with a drivetrain, a mechanical actuator coupled to the wheels 915 of the system of the front wheel steer system. Furthermore, the unit can be moved by a remote control that operates the electric motor and the actuator to steer the wheels 915. With the remote control, the user can drive the unit around the job site and steer clear of obstacles in the confined spaces around a fracturing site.
Calibration vessel 913 is typically a fuel filled tube having a depth similar to the depth of typical saddle tanks. The user inserts the fuel cap system into the calibration vessel to verify operation of all sensors associated with the fuel cap system and to calibrate a portion of the sensors or all the sensors associated with the fuel cap system. Each fuel cap system for each saddle tank is verified and calibrated with the wiring associated with the specific fuel cap or stinger.
System 901 further comprises a light tower 917 attached to the cart for displaying conditional information regarding the fueling to users all around the cart and the frac site. System 901 further comprises a plurality of drain pan sensors located near the wheels 915 inside the cart. The drain pan sensors detect leaking liquid from the cart and are wired to the controller to act as an emergency stop upon detection of leaking fluid in the drain pan of the cart.
Referring now also to
It is apparent that a system with significant advantages has been described and illustrated. The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is, therefore, evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the application. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments but are amenable to various changes and modifications without departing from the spirit thereof.
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PCT/US2017/029173 | 4/24/2017 | WO | 00 |
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WO2017/185094 | 10/26/2017 | WO | A |
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Number | Date | Country | |
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Parent | 15135761 | Apr 2016 | US |
Child | 16094810 | US |