Patent Publication Number: US-10759649-B2

Title: System and method for automatic fueling of hydraulic fracturing and other oilfield equipment

Description:
BACKGROUND 
     1. Field of the Invention 
     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. 
     2. Description of Related Art 
     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 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. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The novel features believed characteristic of the embodiments of the present application are set forth in the appended claims. However, the embodiments themselves, 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, wherein: 
         FIG. 1  is a diagram of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 2  is an end view of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 3  is a side view of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 4  is a generally downward perspective view of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 5  is a generally upward perspective view of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 6  is a diagram of a controller screen from a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 7  is a well site diagram of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; 
         FIG. 8  is a well site diagram of a system for automatically fueling hydraulic fracturing equipment with the ability to report fuel tank status, usage, and fill level according to the present application; and 
         FIG. 9  in the drawings is hereby amended in order to correct a clerical error and is submitted herewith. The Specification is hereby amended to recite a mobile fueling platform  402  having an onboard fuel supply tank  404 .  FIG. 9  is hereby amended to reflect this change in numbering. 
     
    
    
     While the assembly and method 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 invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present application as defined by the appended claims. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     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&#39;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. 
     Automatic frac pump and frac equipment fueling 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. 
     Referring now to  FIGS. 1-5  in the drawings, a preferred embodiment of mobile fueling platform for automatically providing fuel to a saddle tank of the frac equipment according to the present application is illustrated. System  101  is comprised of a fuel cap system  103 , a fuel input system  105 , a plurality of fuel output systems  107 , and a control system  109 . Fuel input system  105  is preferably comprised of an input fuel hose located on a hydraulically driven reel and is automatically retractable. As the user pulls the hose from the reel a spring is biased to provide the force to retract the input hose when needed. Alternatively, fuel input system  105  is comprised of a manifold on the platform wherein a fuel line is coupled to manifold. 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 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 from electrical conduit  110  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 hosing 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. 
     Fuel cap system  103  is comprised of a fuel cap  125  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 suspended above an upper surface  131  of the fuel within saddle tank  121  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 insure that the valve is closed when the fuel level in the tank approaches the tank&#39;s capacity. Low sensor  129  provides data to the system in order for the tank fill level to be reported. 
     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  149  that operates the hydraulic valves in control of the hydraulic motors  139 . With the remote control  149  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 . 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 an emergency stop both 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 and the valves using wireless antenna  114 . 
     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 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  FIG. 6  in the drawings, a preferred embodiment of display screen for automatically providing fuel to saddle tanks of hydraulic fracturing equipment according to the present application is illustrated. Control system  109  displays conditional information to a screen mounted to the platform. This allows users to glance at the platform and assess the condition of the system. Each tank is represented by a bar chart  201  scaled to the saddle tank capacity. High mark  203  displays the stop filling position of the system associated with tank  12 . Once the fuel level is at the high mark the valve  115  closes to stop fuel flow into the saddle tank. Low mark  205  displays the start filling position of the system associated with tank  12 . Once the fuel level is below the low mark the valve  115  opens and fuel flows into the saddle tank. Tank level  207  displays the relative position of the fuel level scaled. As an example, Tank  3  requires additional fuel to be added to the saddle tank because the fuel level is below the low mark as set by the user. Additionally indicators  209  display information such as pressure, flow, quantity, and valve position to the user. Each tank is separately controlled and monitored to allow users to customize the system based on the type of frac equipment, the type of saddle tank, the user&#39;s preferences, frac equipment issues or problems. 
     Referring now also to  FIGS. 7 and 8  in the drawings, embodiments of mobile cart layouts for automatically providing fuel to saddle tanks of hydraulic fracturing equipment according to the present application are illustrated. A frac site for oil and gas wells are a congested place during the time of fracturing the well. A well head  301  is connected to a plurality of frac pumps  305  and blender/chemical trailers  307 . To operate the various pumps and trailers require refueling of their diesel tanks. A mobile fueling platform  309  is located near the frac pumps  305 . Preferably the platform is moved into position by driving it into position as described above however the platform can be pulled or forked into position. 
     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 remote 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. 
     While the system as illustrated in  FIG. 7  is shown with two carts or platforms  309  and one supply tank  311 . An alternative embodiment combines the two platforms and the supply tank into a single trailer for providing automatic fueling to an entire well site. Additionally as shown in  FIG. 8  the system can be comprised of two carts or platforms  309  and two supply tanks  311 . 
     Referring now also to  FIG. 9  in the drawings, an embodiments of a mobile cart system for automatically providing fuel to saddle tanks of frac pumps with real time fuel reporting according to the present application is illustrated. Reporting system  401  is comprised of a plurality of carts  403 , a mobile fueling platform  402  having an onboard fuel supply tank  404 , server  405 , a cloud interface  407 , and a plurality of connected reporting devices  409 . Some connected reporting devices  409 , having a unique interface  413 , are combined into an enterprise system  415 . The plurality of connected reporting devices  409  is comprised of laptops, cellular phones, smartphones, tablets, desktop computers. Enterprise system  415  is configured for providing specialized information for an end user. For example, a first enterprise system can be configured for an operating company and a second enterprise system can be configured for a drilling company. Each enterprise system utilizes a different user interface to provide specific information required by the enterprise. The carts  403  are connected to the server  405  such that data from the sensors of each cart is transmitted to the server. The connection is preferably wireless, however wired connections are contemplated by this application. Furthermore, the plurality of connected reporting devices are connected to the server  405  by a cloud network  407 . Thereby a user can remotely track and monitor fuel status from several frac sites from a single place or check the other frac sites from a first frac site. 
     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. 
     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.