Note: Descriptions are shown in the official language in which they were submitted.
CA 02777284 2012-05-17
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MOBILE MATERIAL HANDLING AND METERING SYSTEM
FIELD OF THE INVENTION
[0002] The present invention pertains in general to material
handling systems and in
particular to a mobile material handling and metering system for storing and
delivering
granular material, and an associated method.
BACKGROUND
[0003] Granular material, such as sand, is used in bulk quantity in a
number of
applications. For example, in hydraulic fracture drilling by oil and gas and
other industries,
fracturing fluid, along with a granular proppant material such as sand and/or
ceramics, is
pumped into a drill well to create and prop open fractures in rock. Often,
activities requiring
large amounts of granular material are performed in a remote location,
requiring granular
material to be shipped in for example by road, rail or water.
[0004] For such activities, it is desirable to have sufficient and
often large amounts of
granular material readily available for adequately reliably carrying out
operations. For
hydraulic fracture drilling, storage facilities may be required, for example,
to hold 50,000
cubic feet of proppant, and hence must be adequately large, as well as capable
of supporting
the resulting weight of proppant. However, in many cases, granular materials
are only
required over a limited time period, for example during the drilling
operations. Thus, large,
permanent on-site storage facilities for the required granular materials are
often not
economical.
100051 Typically, proppant is stored at a well site in fixed
vertical silos and supplied by a
dry-bulk tanker and blown into the silo. This method of storage requires that
the silos are
transported on flat-deck trailers and hoisted into position using large
cranes. The set-up time
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for this type of operation may be extensive, for example lasting on the order
of days.
Additionally, the silo filling operation may require a dry-bulk blower, which
is costly, noisy
and creates an undesirably large amount of dust. Furthermore, limited site
space may place
restrictions on overall size of this type of system, and vehicle compliance
regulations may
limit overall dimensions of components, such as silos, of system which are to
be transported
by vehicles such as flat-deck trailers.
[0006] United States Patent Application Publication No. 2008/0008562
discloses a
method of transporting and storing an oilfield proppant, wherein proppant is
transported to
and accumulated at a storage facility. However, the storage facility is in the
form of a large
building which is not well-suited for portability.
[0007] United States Patent No. 6,293,689 discloses a multi-trailer
mobile concrete
batching and mixing plant, including a concrete silo trailer and an aggregate
trailer.
However, this plant comprises a specific, closed arrangement of trailers and
is limited in the
amount of material that can be stored and in the rate at which material can be
added or
removed from the plant.
[0008] United States Patent Application Publication No. 2008/0179054
discloses a
method and system for expandable storage and metering of proppant or other
materials. A
portable storage and metering device is transported to a well site and there
expanded and
filled with proppant, which is metered out as required. However, this approach
is limited in
scale of proppant material that can be stored and metered.
[0009] Therefore there is a need for a method and system for mobile
storage and delivery
of granular material that is not subject to one or more limitations of the
prior art.
[0010] This background information is provided for the purpose of making
known
information believed by the applicant to be of possible relevance to the
present invention.
No admission is necessarily intended, nor should be construed, that any of the
preceding
information constitutes prior art against the present invention.
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SUMMARY OF THE INVENTION
100111 An object of the present invention is to provide a method and
system handling
granular material. In accordance with an aspect of the present invention,
there is provided a
system for handling granular material, the system comprising: a delivery
module configured,
in a delivery module operational configuration, to receive said granular
material and to
convey said granular material to a predetermined delivery location; one or
more mobile
storage modules adjacent to the delivery module, each of the one or more
mobile storage
modules configured, in a mobile storage module operational configuration, to
hold and
dispense said granular material downward to the delivery module; and a remote
control
module configured to facilitate centralized, remote control of one or more
other portions of
the system, for example the delivery module and the one or more mobile storage
modules.
[0012] In accordance with another aspect of the present invention, there
is provided a
method for handling granular material, the method comprising: providing a
delivery module
configured to receive said granular material and to convey said granular
material to a
predetermined delivery location; providing one or more mobile storage modules
adjacent to
the delivery module, each of the one or more mobile storage modules configured
to hold and
dispense said granular material downward to the delivery module; and providing
a remote
control module configured to facilitate centralized, remote control of one or
more of: the
delivery module; and at least one of the one or more mobile storage modules.
BRIEF DESCRIPTION OF THE FIGURES
[0013] These and other features of the invention will become more
apparent in the
following detailed description in which reference is made to the appended
drawings.
[0014] Figures IA and 1B illustrate systems for handling granular
material, in accordance
with embodiments of the invention.
[0015] Figures 2A and 2B illustrate mobile storage modules in a
transportation
configuration, in accordance with embodiments of the invention.
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[0016] Figures 3A and 3B illustrate, in perspective view, mobile storage
modules in an
operational configuration, in accordance with embodiments of the invention.
[0017] Figures 4A and 4B illustrate, in elevation view, mobile storage
modules in an
operational configuration, in accordance with embodiments of the invention.
[0018] Figures 5A and 5B illustrates frames of a mobile storage module, in
accordance
with embodiments of the invention.
[0019] Figure 6 illustrates a flexible chute for fitting to an output
port of a mobile storage
module, in accordance with some embodiments of the invention.
[0020] Figure 7 illustrates a variable aperture device for operatively
coupling to an output
port of a mobile storage module, in accordance with some embodiments of the
invention.
[0021] Figure 8 illustrates a frame of a mobile storage module, in
accordance with
embodiments of the invention.
[0022] Figure 9 illustrates a top view of a delivery module, in
accordance with
embodiments of the invention.
[0023] Figure 10 illustrates an end view of a delivery module, in
accordance with
embodiments of the invention.
[0024] Figure 11 illustrates a discharge end of a delivery module in both
transportation
and operational configurations, in accordance with embodiments of the
invention.
[0025] Figure 12 illustrates a partial top view of a system for handling
granular material,
in accordance with embodiments of the invention.
[0026] Figures 13A and 13B illustrate a slide gate-style variable
aperture device for
operatively coupling to an output port of a mobile storage module, in
accordance with
embodiments of the invention.
[0027] Figure 14 illustrates a block diagram of a mobile support unit
module in
accordance with an embodiment of the present invention.
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[0028] Figure 15 illustrates an in-feed conveyor module arranged in a
transportation
configuration, in accordance with embodiments of the present invention.
[0029] Figure 16 illustrates the in-feed conveyor module of Figure 15,
arranged in an
operational configuration, in accordance with embodiments of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
Definitions
[0030] The term "granular material" is used to define a flow-able
material comprising
solid macroscopic particles, such as sand, gravel, or the like.
[0031] The term "proppant" is used to define a granular material used in
drilling, for
example by oil and gas industries. Proppant comprises appropriately sized and
shaped
particles which may be mixed with fracturing fluid to "prop" fractures open
after a hydraulic
fracturing treatment. Proppant may comprise naturally occurring sand grains of
a
predetermined size, or engineered materials, such as resin-coated sand,
ceramic materials,
sintered bauxite, or the like.
[0032] As used herein, the term "about" refers to a +1- 10% variation from
the nominal
value. It is to be understood that such a variation is always included in a
given value provided
herein, whether or not it is specifically referred to.
[0033] Unless defined otherwise, all technical and scientific terms used
herein have the
same meaning as commonly understood by one of ordinary skill in the art to
which this
invention belongs.
[0034] An aspect of the present invention provides for a system for
handling granular
material, for example for storage and delivery of proppant for use in
hydraulic fracturing at a
drill well site. The system comprises a delivery module configured to receive
said granular
material at a reception area thereof and to convey said granular material to a
predetermined
delivery location. The delivery module may comprise one or more mobile powered
conveyor
systems, for example at least partially for substantially horizontal
conveyance of the granular
material. The system further comprises one or more mobile storage modules,
each
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CA 02777284 2012-05-17
configured to hold said granular material and to dispense said granular
material downward to
the delivery module. In an operational configuration, the mobile storage
modules are
arranged adjacent to the delivery module. In a transportation configuration,
the mobile
storage modules may be configured and towed as semi-trailers and may comprise
a container
pivotably connected to a base, which may be raised into position for gravity-
assisted
dispensing of granular material. The delivery module may also further be
configured in a
transportation configuration for towing as a semi-trailer. The system further
comprises a
remote control module configured to facilitate centralized, remote control of
one or more
other portions of the system, such as the mobile storage modules and delivery
modules.
[0035] The system may further comprise one or more mobile support unit
modules, each
mobile support unit module configured to provide power, control signals, or
both to one or
more other system components, including the delivery module and the one or
more mobile
storage modules. Power provided by the one or more mobile support unit modules
may be
used for operation, deployment, or the like, or a combination thereof. A
mobile support unit
module may comprise portions or all of the remote control module, or the
mobile support
unit module may be substantially separate from the remote control module.
[0036] The system may further comprise one or more mobile in-feed
conveyor modules,
each in-feed conveyor module configured to convey material such as proppant to
the mobile
storage modules when in the operational configuration. The in-feed conveyor
module may
be provided as a remotely-controlled, self-propelled vehicle. The in-feed
conveyor module
further comprises an elevator or conveyor for raising granular material from a
source to an
input port of a mobile storage module. The conveyor or elevator may be
reconfigurable
between a transportation configuration and an operational configuration.
[0037] In some embodiments, a mobile module may be provided having
selected
attributes and functionalities of both a mobile support unit module and an in-
feed conveyor
module. Thus, for example, an in-feed conveyor module may be configured to
provide
hydraulic power, heating, starting power, control signals, and the like, to
one or more other
modules such as mobile storage modules and delivery modules. Similarly, a
mobile power
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CA 02777284 2012-05-17
module may additionally or alternatively be configured to convey material to
the mobile
storage modules via a conveyor or elevator operatively coupled thereto.
[0038] Another aspect of the present invention provides for a delivery
module for
handling granular material, the delivery module as described above. Another
aspect of the
present invention provides for a mobile storage module for handling granular
material, the
mobile storage module as described above.
[0039] Another aspect of the present invention provides for a mobile
support unit module
for providing power to components of a system, the mobile support unit module
as described
above.
[0040] Figure IA illustrates a system 100 for handling granular material in
accordance
with embodiments of the present invention. The system 100 is illustrated as
arranged in an
operational site configuration, with a plurality of mobile storage modules
110, 115 arranged
around a delivery module 120. As shown, there are five mobile storage modules
110 in a
first bank on one side of the delivery module 120, and five mobile storage
modules 115 in a
second bank on another side of the delivery module 120 opposite the first
bank. However,
this number may be reduced or increased. If the number is increased, the
delivery module
portion 120 may be expanded in length, for example by adding one or more
additional
conveyors arranged end-to-end. Other arrangements, such as providing plural
delivery
modules in parallel, may also be used. The mobile storage modules 110, 115 are
arranged so
that they may individually discharge granular or flow-able material such as
proppant onto
one or more, centrally located main conveyors of the delivery module 120. The
granular
material is conveyed by the main conveyors to one or more discharge conveyors
130, which
convey the material to a height appropriate to allow the material to feed one
or more blender
modules 140. Each blender module 140 may be a mobile unit used to blend
fracking
chemicals, proppant and bulk fluid. Alternatively, the discharge conveyors 130
may be
configured for delivering granular material to another appropriate location or
equipment, for
example to re-load a bulk tanker during well-site decommissioning.
[0041] Figure I B illustrates a system 102 for handling granular material
in accordance
with embodiments of the present invention, also arranged in an operational
site configuration,
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CA 02777284 2012-05-17
with banks 112, 117 of mobile storage modules arranged around a delivery
module 122.
The mobile storage modules discharge granular or flow-able material such as
proppant onto
one or more centrally located main conveyors. The granular material is
conveyed by the
main conveyors to two discharge conveyors 132 and from there to a blender
module 142.
Alternatively, the discharge conveyors 132 may be configured for delivering
granular
material to another appropriate location.
[0042]
Figure 1B further illustrates a mobile support unit module 160 of the system
102.
Although a single mobile support unit module is illustrated, plural mobile
support unit
modules may be provided. The mobile support unit module 160 is configured as a
four-
wheeled module configured to provide power to the mobile storage modules,
delivery
modules, or both. Power may be used for deployment, operation, or both, or the
like, of the
various modules. The mobile support unit module may be configured for towing
various
modules into position. The mobile power unit may contain one or more hydraulic
power
packs for providing power to other modules of the system. The hydraulic power
pack may
be operatively coupled to the other modules via hydraulic transmission lines
or hoses (not
shown).
[0043]
Figure 1B further illustrates an optional mobile in-feed conveyor module 170
of
the system 102. The mobile in-feed conveyor module 170 is provided as a mobile
vehicle
having a conveyor or elevator 172 configured for delivery of granular material
to a mobile
storage module which the module 170 is located adjacent to.
[0044]
Figure 113 further illustrates a remote operator module 180, which comprises a
remote operator interface and a remote radiofrequency transceiver, in
accordance with an
embodiment of the present invention. The
remote operator module 180 may be
communicatively coupled to the mobile support unit module and optionally may
be coupled
to one or more other modules of the system for control thereof. In some
embodiments, the
remote operator module may further be a remote control module which directly
executes
centralized control of the system, for example manual, automatic (autonomous)
or semi-
automatic (semi-autonomous) control. In some embodiments, the remote operator
module
indirectly executes such centralized control of the system, and thus functions
as a portion of a
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CA 02777284 2012-05-17
remote control module. For example, the remote operator module may be used to
command,
direct and/or configure a central controller housed aboard a mobile support
unit module or
another module. In such embodiments, the remote operator module and portions
of the
mobile support unit module may operate together as the remote control module.
[0045] In some embodiments, there may be a substantially independently
variable number
of mobile storage modules provided on each side of the mobile storage module.
For
example, between zero and ten mobile storage modules may be arranged in a
first bank along
one side of a delivery module, and between zero and ten mobile storage modules
may be
arranged in a second bank along another side of a delivery module opposite the
first bank.
The number of mobile storage modules in the first and second bank need not be
even. For
example, two, three or four mobile storage modules may be arranged in the
first bank, and
five or six mobile storage modules may be arranged in the second bank.
[0046] An aspect of the present invention provides for a method for
handling granular
material. The method comprises providing a delivery module configured to
receive said
granular material and to convey said granular material to a predetermined
delivery location.
The delivery module may be transported to a desired site in a transportation
configuration
and then converted to an operational configuration for receiving and conveying
the granular
material. The method further comprises providing one or more mobile storage
modules
adjacent to the delivery module, each of the one or more mobile storage
modules configured
to hold and dispense said granular material downward to the delivery module.
The mobile
storage modules may be transported to a desired site in a transportation
configuration and
then converted to an operational configuration for holding and dispensing the
granular
material. The method further comprises providing a remote control module
configured to
facilitate centralized, remote control of one or more other portions of the
system, such as the
mobile storage modules and delivery modules.
[0047] The method may further comprise providing one or more mobile
support unit
modules. Each mobile support unit module may be configured to provide
operating power to
one or more other system components, including the delivery module and the one
or more
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CA 02777284 2012-05-17
mobile storage modules. Each mobile support unit module may additionally or
alternatively
be configured to provide control signals to one or more other system
components.
[0048] Embodiments of the present invention provide for robustness to
component failure
or mechanical breakdown by providing redundancies for one or more components.
For
example, the delivery module may comprise plural conveyor systems, and the
system may be
configured to facilitate continued operation in the event that one or more
conveyor systems
break down. As another example, each of the mobile storage modules may include
interchangeable components, such as hydraulic power packs, which may be
connected for
use in another mobile storage module should that component of the other mobile
storage
module fail or break down. Plural components may be also used in series or
parallel to
augment specific operations. As another example, each of the mobile support
unit modules
may be interchangeably connectable to different delivery modules, storage
modules, or a
combination thereof. Hydraulic power packs aboard the mobile support unit
modules may
thereby be interchangeably connectable in the case of failover, or to provide
increased
hydraulic power by connecting plural hydraulic power packs to a single load.
[0049] Embodiments of the present invention may provide for one or more
mechanical
features facilitating operation of mobile storage modules and/or delivery
modules. For
example, one or more modules may comprise a rock-over chassis, which may
operate as a
semi-trailer chassis in the transportation configuration and as a support
structure engaging
ground over an adequately large surface area in the operational configuration.
[0050] In embodiments of the present invention, some or all of the mobile
storage
modules, delivery modules, mobile support unit modules and in-feed conveyor
modules, are
reconfigurable between transportation and operational configurations. In the
transportation
configuration, each module may be separately transportable in an adequately
compact
configuration. In the operational configuration, plural modules may be
configured and
arranged together for accepting, storing, conveying and delivering granular
material.
[0051] Embodiments of the present invention are modular and expandable,
which enables
a configurable storage capacity for granular material such as proppant, and/or
a configurable
capacity for adding and/or removing granular material. The number of mobile
storage
CA 02777284 2012-05-17
modules may be adjusted as required, to provide the appropriate capacity. In
some
embodiments, additional delivery modules or delivery module expansion units
may also be
provided as desired. Excess storage modules may remain unused or may be used
at another
site to improve operational efficiencies. Each mobile storage module provides
its own
storage capacity, and plural mobile storage modules may be loaded with
granular material at
the same time, thereby facilitating quicker loading or reloading. In some
embodiments,
plural storage modules may further feed the delivery module at the same time,
thereby
providing granular material to the delivery module at a higher rate than from
a single storage
module. Additional mobile support unit modules may be provided and operatively
interconnected with the system as required to provide sufficient power,
sufficient towing
facility, sufficient heating facility, or the like, or a combination thereof.
[0052] At
least some embodiments of the present invention may provide improvements in
terms of operational efficiency, set-up time, transportation requirements,
storage and asset
tracking requirements, and the like, for example by requiring a relatively
small number of
component modules when compared with some prior art solutions.
[0053]
Embodiments of the present invention provide a system comprising a self-
erecting,
and largely self-sufficient, method of proppant storage and handling. The
system can be
delivered to site and be operational within hours rather than days and without
the current
reliance upon specialized plant and equipment.
Mobile Storage Module
[0054] The
present invention comprises one or more mobile storage modules for holding
and dispensing granular material. The number of storage modules utilized may
be adjusted
as needed for a given operation, from one to a predetermined maximum number
which may
depend at least in part on delivery module capacity. Each of the mobile
storage modules may
be reconfigurable between a transportation configuration and an operational or
site
configuration. In the transportation configuration, each mobile storage module
may be
configured as a separately transportable trailer or semi-trailer. In
the operational
configuration, each mobile storage module may be configured as a granular
material storage
container or silo.
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[0055] In embodiments of the present invention, each mobile storage
module comprises a
frame and a container portion, such as an enclosed box, supported by the frame
and pivotably
coupled thereto. The mobile storage module frame may be referred to and/or
associated with
a chassis. The container portion is configured, for storing granular material
and comprises an
input port for receiving the granular material and an output port for
dispensing the granular
material. The container portion may be substantially enclosed on all sides,
except for the
input port and output port, which may comprise controllably-sized apertures.
The mobile
storage module may further comprise an actuating system configured to pivot
the container
between a lowered position and a raised position. In the raised position, the
input port is
located above the output port to allow the granular material to flow from
input to output with
assistance of gravity. The mobile storage module may further comprise a
loading system,
such as an in-feed elevator, conveyor, bucket conveyor, or the like,
operatively coupled to the
input port to facilitate loading of granular material into the container
portion. In some
embodiments, the loading system may be provided at least in part by a separate
component,
such as a mobile in-feed conveyor module as described herein.
[0056] In some embodiments, the mobile storage module may comprise a
discharge chute,
gate valve, and/or variable discharge aperture valve, operatively coupled to
the output port to
facilitate controlled and metered flow of granular material from the container
portion. The
collective flow from container plural mobile storage modules may also be
controlled and
metered by controlling and metering flows from plural mobile storage modules.
The variable
discharge chute, metering iris or aperture may facilitate remote, or manual,
and ultimately
combined, control of the rate of discharge from one or more storage units. A
variable
aperture at an output port may allow for a substantially continuous control of
granular
material flow from zero flow to a predetermined maximal flow.
[0057] In some embodiments, the mobile storage module may further comprise
a
hydraulic power pack for powering components such as the actuating system,
loading
system, and output port valves. In some embodiments, the mobile storage module
may be
configured into a transportation configuration corresponding to a trailer or
semi-trailer
complying with predetermined laws, regulations and/or and height and weight
requirements,
for transportation by a road tractor or other appropriate on-road, off-road,
rail or water
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vehicle. Additionally or alternatively, the mobile storage module may comprise
a hydraulic
interconnection port for coupling to an external hydraulic power pack, for
example provided
aboard a mobile support unit module.
[0058] Figures 2A and 2B illustrate a mobile storage module 200 arranged
in a
transportation configuration, as a semi-trailer mounted on a road tractor 210,
in accordance
with embodiments of the present invention. The semi-trailer may be configured
to comply
with applicable laws and regulations regarding size, length, weight, and the
like. In some
embodiments, for example as illustrated in Figures 2A and 2B, the container
portion 225 of a
mobile storage module 200 is formed as a rigid box of a generally rectangular
structure,
tapered from front to rear so that the container top is at maximum allowable
vehicle height
when in the transportation configuration, in accordance with predetermined
laws and/or
transportation regulations. Other features illustrated in Figures 2A and 2B
are also described
herein.
[0059] Figures 3A, 3B, 4A and 4B illustrate, in perspective and elevation
views,
respectively, a mobile storage module 200 arranged in a site configuration as
an erected silo,
in accordance with embodiments of the present invention. The mobile storage
module 200 is
detached from a road tractor and set up at an appropriate location, for
example adjacent to a
delivery module and possibly one or more other mobile storage modules. A
loading system
such as an elevator 310 or other conveyor is connected to an input port 320.
The elevator
310 or other conveyor may be provided as part of a separate in-feed conveyor
module, rather
than part of the mobile storage module 200. Granular material may be loaded
onto the
elevator 310 from an appropriate container vehicle. The elevator 310
transports the material
to the input port 320, where it may be stored in the container portion 225,
and/or flowed
therethrough to an output port. The mobile storage module 200 comprises, at
its base, a
frame 235 or 235b, which may be substantially rigid and may span approximately
the unit's
full length and width. The container portion 225 is raised into position by a
actuating system,
for example in the form of a hydraulic actuator 350, for example comprising a
set of one or
more hydraulic piston-cylinder assemblies, which are coupled to the container
portion 225
and the frame 235 or 235b and controllably powered by a hydraulic power pack
or other
source of pressurized hydraulic fluid. The hydraulic actuators may be
attached, via pin joints
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or other pivotable joints, at one end to the container portion 225 and at the
other end to the
frame 235 or 235b, such that expansion of the hydraulic actuators 350 effects
differential
movement between the container portion 225 and frame 235 or 235b in an arc,
thereby
raising and pivoting the container portion 225 from the trailer chassis to a
desired or
predetermined angle. In some embodiments, the hydraulic actuators are attached
to the
frame via a pin joint and to the container portion via a trunnion. Embodiments
of the present
invention may be configured for pivoting the container portion to one or more
predetermined
or selectable angles, adequate for facilitating flow of material from the
input port to the
output port under gravity. Such an angle may depend on factors such as the
material
involved, material grain size. flow-ability, height availability, weight
distribution
requirements, and the like. In some embodiments, the container portion may be
pivoted at an
angle of about 40 degrees relative to the frame. In some embodiments, an
agitator may be
provided for agitating the container portion, thereby controllably increasing
flow-ability of
granular material at one or more predetermined angles.
[0060] As also illustrated in Figures 3A, 3B, 4A and 4B, the container
portion 225 may
comprise a fully enclosed rigid box approximately dimensionally equal to the
frame 235 or
235b in length and width. The container portion 225 may be attached to the
frame 235 or
235b by way of a hinge 230, for example located rearward of the wheel axles
370. In
another embodiment, the wheel axles 370 may be coupled to both the container
portion 225
and the frame 235 or 235b and may act as a hinge therebetween.
[0061] In some embodiments, one or more hydraulic piston-cylinder
assemblies or other
substantially linear hydraulic actuators 350 are configured such that, in
their collapsed state
corresponding to the transportation configuration, one end is substantially
higher than the
other end. Thus, at commencement of expansion, the actuators can generate a
sufficient
vertical axis component of thrust to initiate movement of the container
portion 225. For a
given size of hydraulic actuator, this may be effected by positioning the
upper end of the
hydraulic actuator, for example a piston rod end thereof, substantially above
the frame 340
and possibly into a region located within the convex hull of the container
portion 225. In
this arrangement, volume which could otherwise potentially be occupied by
usable granular
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payload within the container portion 225 may, in some embodiments, be
sacrificed to make
room for a portion of the hydraulic actuator or actuators 350.
[0062] In some embodiments, the main hydraulic actuators 350 are
configured so as to be
substantially parallel and within the frame 235 or 235b when in the
transportation
configuration, with a first end of the main hydraulic actuators 350 connected
to the frame 235
or 235b and a second end coupled to a bottom surface of the container portion
225, for
example by way of a yoke or lug extending below the container portion 225. In
this
arrangement, the hydraulic actuators 350 may then substantially lie outside of
the convex hull
of the container portion 225, thereby increasing potential granular material
storage capacity
thereof. A second set of one or more initiating hydraulic actuators, for
example piston-
cylinder assemblies oriented substantially vertically, may be provided,
permanently or as
needed, for initially raising the container portion 225 to an orientation at
which the main
hydraulic actuators 350 are able to provide sufficient vertical thrust to
raise the box to its full
height. At this point, the main hydraulic actuators 350 may take over the
container portion
load.
[0063] For example, as illustrated in Figures 2A and 2B, the initiating
hydraulic actuators
220 may be located at an end of the container portion 225 opposite the hinge
230, the
hydraulic actuators 220 supported by the frame 235 or 235b. In some
embodiments, the
initiating hydraulic actuators 220 may be pin-jointed to the frame 235 or 235b
at a lower end
and bear, for example non-rigidly, against a box-mounted cup structure 240 at
an upper end.
At the point at which the main hydraulic actuators 350 take over lifting duty,
the initiating
hydraulic actuators 220 may reach maximum stroke and loose contact, at their
upper ends,
with the box-mounted cup structure 240.
[0064] In some embodiments, deployable rigid bracing 380, as illustrated
in Figures 3A,
3B, 4A and 4B, may be provided. The bracing 380 may be, for example, hinged at
one end
and free sliding at the other end. The bracing 380 may facilitate supporting
the container
portion 225 of a mobile storage unit 200 in a raised, operational
configuration, thereby
reducing or eliminating the need to maintain hydraulic power after the
container portion is
raised and the rigid bracing 380 locked into place.
CA 02777284 2012-05-17
[0065] In some embodiments, a rigid brace 380 may be provided for bracing
the container
portion 225 when in the raised position. As illustrated in Figures 3 and 4, a
first end of the
brace 380 may be pin jointed to the underside of the container portion 225 at
a predetermined
location 382, and a second end 384 of the brace 380 may be free to slide on
and/or over the
trailer chassis while raising the container portion 225. The second end 384
may be deployed
and locked into place at a location 386 of the frame 235 or 235b, for example
by forcing the
brace to arc over centre into a fixed pocket at the location 386 and then
slightly lowering the
container portion 225, and/or by pinning the second end 384 to the frame 235
or 235b at
location 386.
[0066] In some embodiments, after raising the container portion 225, the
hydraulic
actuators 350 may be de-powered such that temperature induced hydraulic drift
does not
induce unexpected box loading. The rigid bracing structure 380 may therefore
remove
dependence upon the hydraulic actuators 350 after said raising. At full
elevation the
container portion 225 functions at a storage silo. As illustrated, the
container portion 225
need not be fully vertical, but may be configured at an angle such as about 40
degrees. The
system may provide for a set of mobile self-deploying silos forming a storage
accumulator of
variable capacity. in some embodiments, the mobile support unit module may be
disconnected after de-powering of the hydraulic actuator, and used for other
purposes.
[0067] In some embodiments of the present invention, the front end of the
container
portion includes an input port through which the container portion may be
loaded with
granular material, for example input port 320 as illustrated in Figures 3A and
3B. In some
embodiments, the front end of the container portion may further include an
opening through
which the loading system, for example elevator 310 illustrated in Figures 3A
and 3B may be
loaded for storage and transportation when in the transportation
configuration. The stored
elevator 310 is illustrated in Figures 2A and 2B.
[0068] As further illustrated in Figures 2A, 2B, 4A and 4B, a discharge
chute 250 may be
provided at the rear of the container portion 225. The discharge chute 250 is
configured in-
line and in fluid communication with the output port and is oriented and
located to position
discharged granular material toward the delivery module for reception thereby.
For example,
16
CA 02777284 2012-05-17
the discharge chute 250 may be positioned to discharge the granular material
onto a
discharge conveyor of the delivery module. In some embodiments, the discharge
chute 250
may be positioned low and close to the discharge conveyor to reduce unused
volume in the
lowermost rear corner of the box.
[0069] In some embodiments, as illustrated in Figure 5A, the frame 235 may
be
constructed from standard structural members, such as steel beams, to form a
ladder frame
chassis. At one end of the chassis, a set of one or more axles may be fitted
at location 510.
At the other end of the chassis, a kingpin and coupler structure, or other
structure suitable for
coupling to a standard or non-standard truck fifth wheel may be provided at
location 520.
[0070] Figure 5A further illustrates the frame or trailer chassis 235
comprising a series of
longitudinal beams 530 and transverse cross-members 540 oriented to form a
rock-over
chassis, in accordance with embodiments of the present invention. The chassis
may
incorporate, toward the front end 520 a coupler structure with a standard SAE
kingpin and
toward the rear end 510 a suspension assembly and one or more axles and wheels
operatively
coupled thereto. In some embodiments, the suspension assembly may be located
and
oriented such that by deflating air springs thereof, the frame 235 can be
lowered into contact
with the ground to form a full length bearing structure.
[0071] Figure 5B illustrates in more detail the frame or trailer chassis
235b as it appears in
the configurations of Figures 1B, 2B, 3B and 4B.
[0072] In some embodiments, the rock-over chassis front end and/or rear end
may be
lowered to ground by an external crane. In some embodiments, the present
invention may
comprise hydraulic landing legs operatively coupled to the frame or rock-over
chassis. The
hydraulic landing legs may extend to contact ground to support the frame 235
or 235b while
the road tractor drives away, the legs then fully retracted for lowering of
the chassis to
ground. The frame or rock-over chassis may be configured to present adequate
ground
contact area so that the ground footprint pressure remains below a
predetermined maximum
level.
17
CA 02777284 2012-05-17
[0073] In
some embodiments, the in-feed elevator 310, for example as illustrated in
Figures 3 and 4, may be dimensioned such that the elevator 310 reaches from
the input port
320 to substantially ground level, when the elevator 310 is fully deployed and
the container
portion 225 is elevated to its full height in an operational configuration.
Thus, the elevator
310 can transport material from approximately ground level to the height of
the input port
320. In some embodiments, the container portion 225 may be raised while empty,
and
subsequently loaded via the elevator 310 at full elevation, thereby decreasing
lifting capacity
requirements of the hydraulic actuators 350. In some embodiments, the elevator
310 may be
tilted upward and inserted into the container portion 225 for stowage in the
transportation
configuration, for example as illustrated in Figures 2A and 2B.
[0074] In
some embodiments, the in-feed elevator 310 comprises a continuous belt
equipped with cleats, buckets or other features for conveying material upward
to the input
port. The conveyor belt may be contained within a rigid frame extending
approximately the
full length of the conveyor belt such that the frame allows the conveyor
system to be non-
continuously supported along its length. The frame may be hingedly coupled at
the upper
end to a fixed location on the container portion 225. The frame may be
supported by
deployable legs or wheels at its lower end to ground. The frame may be
connected to a self-
propelled vehicle such as a vehicle as described herein. The frame is
configured with a
predetermined structural rigidity to resist bending due to payload and system
weight, and
buckling due to belt tension.
[0075] In
some embodiments, the in-feed elevator 310 may be deployable from a stored
position within the container portion 225, for example stowed and deployed via
the container
portion input port 320 or another port. Such a port may be located at the
upper front corner
of the front face of the container portion. The in-feed elevator 310 may, in
deployment, be
tilted, for example by a hinge, to an approximately vertical orientation such
that the
lowermost end of the belt is proximate to ground. In some embodiments, the
deployed in-
feed elevator 310 may be supplied with granular material by a standard low-
elevation belly
unloading conveyor directly from a series of bulk tankers or other bulk
material transporters.
In some embodiments, the in-feed elevator may be coupled, at an end proximate
to the input
port, to a set of one or more outboard rollers. The outboard rollers may be
located on both
18
CA 02777284 2012-05-17
sides of the frame. A pair of channels, configured to accommodate the rollers
therein, may
also be provided inside of the container portion for stowage of the in-feed
elevator in the
transportation configuration. In some embodiments, a fixed roller, for example
at location
312 as illustrated in Figures 4A and 4B, may be located at the lowermost edge
of the port
receiving the in-feed elevator, the fixed roller bearing against the underside
of the in-feed
elevator frame, thereby providing support during storage and deployment.
[0076] Figure 6 illustrates a flexible chute 600 provided in accordance
with some
embodiments of the invention. The flexible chute 600 may be fitted to a
discharge chute or
output port of a mobile storage module for directing granular material to the
delivery module.
The flexible chute 900 comprises a set of interlocking conical members 610,
such as
approximately concentric diminishing cones, which are movable relative to each
other so that
the chute 600 output may be configurably located as needed for granular
material discharge.
[0077] The rear end of the container portion of a mobile storage module
comprises an
output port, for example formed in a flat structural wall. In some
embodiments, the output
port may comprise a hydraulically or manually operated variable aperture or
other metering
device. In some embodiments, the output port may comprise a slide gate. In
some
embodiments, a discharge chute may be coupled to the output port.
[0078] Figure 7 illustrates a variable aperture device 700 operatively
coupled to the output
port, in accordance with some embodiments. The aperture 710 may be varied in
size by
pivoting of a plurality of plates 720, pivotably coupled to a main body of the
variable
aperture device 700. The variable aperture device 700 may comprise a series of
overlapping
plates 720, arranged such that they form a roughly circular aperture 710 of
variable radius.
[0079] Figures I3A and 13B illustrate a slide gate variable aperture
device 1300 for
operatively coupling to the output port, in accordance with some embodiments.
An aperture
1310 can be fully closed, partially opened, or fully opened, by moving a gate
1320 to block
all, part, or none of the aperture 1310, respectively. An actuating arm 1325
is illustrated to
assist with movement of the gate 1320.
19
CA 02777284 2012-05-17
[0080] In some embodiments, rapid isolation of proppant flow is effected
by a gate
comprising a reinforced flat plate sliding in channels perpendicular to the
proppant flow and
arranged such that full withdrawal of the plate allows substantially maximum
flow and full
insertion of the plate allows substantially no flow. This gate valve may be
manually operated
with a local mechanically-advantaged lever or remotely by way of a quick-
acting hydraulic
cylinder. Alternatively a butterfly valve may be used for this application.
[0081] Figure 8 illustrates a frame 810 of a mobile storage module, in
accordance with
embodiments of the present invention, which extends partway underneath the
container
portion 820 to an intermediate location 815. The coupler structure for
coupling to the road
tractor 830 may then be incorporated into the container portion 820 rather
than the frame
810. This arrangement reduces weight of the mobile storage module and
potentially
increases allowable payload weight and/or available payload volume. In this
configuration,
the ground bearing envelope is reduced compared with a full-length frame, and
thus
additional frame surface area may be required to maintain adequately low
bearing pressure.
In some embodiments, the partial-length frame 810 may be configured to allow
for frame
adaptation to increase ground bearing area. For example, skids, deployable
footings,
sheeting, external supports, or the like, may be provided for this purpose.
[0082] In some embodiments, the mobile storage modules may be configured
for
accepting granular material from delivery vehicles other than dedicated dry-
bulk proppant
transporters and blowers. For example, a mobile storage module and/or in-feed
elevator of or
operatively coupled to the mobile storage module may be adaptable or
configured for use
with simple belly unloading vehicles such as grain trailers, or other locally
available
equipment. This may allow for substantially local infrastructure and
equipment, such as
associated with a local agricultural industry, to service and supply proppant,
or other granular
material, rather than specialized, expensive equipment sourced from a central
location. This
may be particularly advantageous in remote locations for operational reasons
such as cost
and scheduling. In some embodiments, such an in-feed elevator may be provided
as part of a
mobile in-feed conveyor module as described elsewhere herein.
Delivery Module
CA 02777284 2012-05-17
[0083] The present invention comprises one or more delivery modules,
configured to
receive granular material from the mobile storage modules and to convey the
granular
material to a predetermined delivery location. One or more powered conveyor
systems may
be provided on the delivery module for conveying the granular material.
Conveyance of
granular material may be, at various locations, at least partially assisted by
gravity, unassisted
by gravity, and/or conveyed against gravity.
[0084] In embodiments of the present invention, the delivery module may
be
reconfigurable between a transportation configuration and an operational or
site
configuration. In the transportation configuration, the delivery module may be
configured as
a standard or over-length trailer, for example subject to one or more
predetermined sets of
legal and/or regulatory requirements, and/or other height, length, width
and/or weight
restrictions. In the operational configuration, the delivery module may be
configured having
a granular material reception area with surface area and capacity adequate for
receiving
granular material from up to a predetermined number of mobile storage modules.
The
delivery module may be configured, in the operational configuration, to have a
lower bearing
surface with a predetermined portion contacting ground, adequate for
supporting the weight
of the delivery module and granular material thereon against ground. Conveyors
may be
stowed in the transportation configuration and deployed to cover or span a
greater surface
area in the operational configuration.
[0085] Figure 9 illustrates a top view of a delivery module 900 in
accordance with
embodiments of the present invention. As illustrated, the delivery module 900
comprises a
pair of main conveyors 910, 912 for receiving granular material from the
mobile storage
modules and conveying same to a discharge end 915. The delivery module 900 may
further
comprise or be operatively coupled to one or more discharge conveyors, for
example
conveyors 130 as illustrated in Figure IA and conveyors 132 as illustrated in
Figure 1B.
[0086] As illustrated in Figure 9, the delivery module 900 comprises a
trailer chassis 905
upon which two main conveyors 910. 912 are mounted. Plural main conveyors may
be
provided for redundancy, to facilitate continued operation or failover in case
of failure of one
conveyor. Alternatively, a single conveyor may be provided, which may simplify
design and
21
CA 02777284 2012-05-17
in some cases provide increased conveyor surface area, or more conveyors may
be provided.
The trailer chassis 905 may be a rock-over chassis, or other suitable frame or
chassis. The
delivery module may be reconfigurable between a transportation configuration
and an
operational or site configuration. In the operational configuration, the
conveyors 910, 912
may be deployed outward relative to the transportation configuration. This
configuration, in
conjunction with a rock-over chassis, may facilitate deployment of the
conveyors 910, 912
close to ground and outboard of the trailer chassis 905 in the operational
configuration. In
some embodiments, the conveyors 910, 912 may be connected to the chassis 905
via a series
of laterally arranged sliding tubes spaced substantially evenly along the
length of each
conveyor. The sliding tubes may be deployed outward using one or more
hydraulic
actuators, for example. Figure 9 also illustrates location of semi-trailer
axles 925 and
hydraulics 930 operatively coupled to the sliding tubes for movement thereof,
thereby
facilitating deployment and stowage of the conveyors 910, 912.
[0087] In some embodiments, a main conveyor of the delivery module and an
associated
discharge conveyor may be associated via a common conveyor belt. The common
conveyor
belt may extend substantially horizontally over a first predetermined area
associated with the
main conveyor, to be situated substantially below the output ports of one or
more mobile
storage modules stationed around the delivery module. The common conveyor belt
may
further extend at an angle over a second predetermined area associated with
the discharge
conveyor, to raise the granular material to a predetermined height for
discharge. In this
manner, granular material, such as proppant, may be conveyed from output ports
of the
mobile storage modules and elevated to a height suitable for discharge into
vehicular, or
otherwise, mounted receptacles, such as blender modules.
[0088] In some embodiments, such as illustrated in Figure 9, the delivery
module
conveyors 910, 912 may be carried upon a dedicated, custom configured semi-
trailer chassis
905. The chassis 905 may comprise a frill-length rigid frame having, at a
first end 920, a
standard trailer kingpin and coupler structure, or other trailer coupling
components, and at a
second, discharge end 915 a set of one or more axles and/or suspension
assembly of the
semi-trailer. As mentioned previously, the chassis 905 may be a rock-over
chassis. When
disconnected from the road tractor, the first end 920 of the rock-over chassis
may be lowered
22
CA 02777284 2012-05-17
to ground, and the chassis lower surface may contact the ground, thereby
evenly distributing
load of the delivery module into the ground along the length of the rock-over
chassis. In
some embodiments, a suspension assembly may be located and oriented such that
by
deflating air springs thereof, the chassis 905 can be lowered into contact
with the ground to
form a full length bearing structure.
[0089] Figure 10 illustrates an end view of a discharge end of a delivery
module, in
accordance with embodiments of the present invention. As illustrated, the
discharge ends of
a pair of conveyors 910, 912 of the delivery module may be connected by a
discharge
manifold 1020 extending downwards and equipped with two discharge ports 1022,
1024.
The discharge manifold receives granular material from both left and right
conveyors 910,
912 and selectably provides the granular material to one or both of the two
discharge ports
1022, 1024. The manifold 1020 may comprise a configurable multiple orientation
gate or
other means for directing granular material from a selected one, or both of
the conveyors
910, 912 to a selected one, or both of the two discharge ports 1022, 1024. The
manifold
may thereby be configured to provide flow from one or more selected conveyors
to one or
more selected discharge ports, and/or to blend flow from each conveyor to a
selected
discharge port or both discharge ports. In some embodiments, the proportions
and amounts
of material provided to each discharge port and/or from each conveyor may be
adjusted,
thereby facilitating finer control of mixing. Figure 10 further illustrates
chassis 925 and
wheels 1040 of the delivery module.
[0090] Figure 11 illustrates a rear/discharge end of a delivery module in
both a
transportation configuration 1100 and an operational configuration 1110, in
accordance with
embodiments of the present invention. The chassis 1120 may be pivotably
coupled with a
wheeled portion 1130 containing the rear axles and wheels of the delivery
module semi-
trailer, for example via a pin joint or other pivotable coupling. In the
transportation
configuration, the wheeled portion 1130 may be lowered to engage ground, for
example by
actuation of one or more hydraulic cylinders 1140, the chassis 1120 lifted off
of ground
during transport. A removable brace 1135 may be installed in a substantially
triangular gap
between the chassis 1120 and the wheeled portion 1130 for improved support
during
transport. In the operational configuration, the brace 1125 may be removed and
the wheeled
23
CA 02777284 2012-05-17
portion 1130 raised, for example by actuation of the one or more hydraulic
cylinders 1140,
and the chassis lowered to engage ground. This configuration facilitates
tilting retraction of
the axles for the operational configuration, thereby facilitating engagement
of the chassis
1120 with the ground for load distribution. Tilting and retraction of axles
may also be
provided for in one or more mobile storage modules, for facilitating
engagement of the frame
thereof with ground to facilitate load distribution.
[0091] In some embodiments, the present invention may be configured to
facilitate
prevention of proppant loss, for example due to loss of proppant from
conveyors or due to
overflow in event of conveyor failure. For example, embodiments of the present
invention
comprise one or more covers, such as non-rigid covers or tarps, which may be
deployed to
enclose regions through which granular material is conveyed. For example, each
main
conveyor and/or discharge conveyor of the delivery module may be fully or
partially
enclosed by a cover over its length. The conveyor cover may comprise apertures
at
predetermined locations for receiving material from the output ports and/or
discharge chutes
of the mobile storage modules. One or more covers, such as fitted non-rigid
cowls may be
provided between the apertures of the conveyor cover and the output ports,
with approximate
seal at cover interfaces. In this manner, environmental contamination, such as
rain or snow,
may be restricted from entering the granular material as it is delivered from
the mobile
storage modules.
[0092] In embodiments, the delivery module may be powered via an on-board
hydraulic
power pack, a hydraulic power pack of a mobile support unit module operatively
coupled
thereto, or a combination thereof.
Mobile Support Unit Module
[0093] The present invention further comprises one or more mobile support
unit modules.
A mobile support unit module may be configured as a remotely-controlled, self-
propelled
vehicle which is capable of connecting to and providing power to other modules
of the
system. In some embodiments, substantially all components of the system, such
as the
delivery modules and mobile storage modules, are powered by the one or more
mobile
24
CA 02777284 2012-05-17
support unit modules. In some embodiments, at least some components of the
system are
powered by the one or more mobile support unit modules.
[0094] In embodiments, the mobile support unit module comprises a
hydraulic power
pack which is configured for coupling to one or more other modules as needed
to provide a
source of hydraulic power. In some embodiments, the mobile support unit module
may
comprise plural hydraulic power packs. The hydraulic power pack may be used
for
deployment and operation of the modules in receipt of same. For example, the
hydraulic
power pack may be used for operating the system conveyors, raising and
lowering the mobile
storage modules, operating the discharge aperture, opening and closing input
ports or filling
hatches, and the like. The hydraulic power pack may be operatively coupled to
a system of
transmission lines, such as hydraulic hoses, carried aboard the mobile support
unit module.
Mating hydraulic connectors may be provided on the mobile support unit module
as well as
on other modules configured to receive hydraulic power.
[0095] In embodiments, the mobile support unit module may be configured
to operate as a
towing vehicle. The mobile support unit module may, for example, be configured
to tow
delivery modules and mobile storage modules, or other mobile equipment, into
place during
deployment, re-orientation, and teardown. The mobile support unit module may
be
configured as a four-wheel drive vehicle, track drive, or other vehicle having
sufficient
towing capacity and traction for a given environment. In some embodiments,
plural mobile
support unit modules may be coupled in series or in parallel for additional
towing capacity.
[0096] In embodiments, the mobile support unit module is configured to
provide heating.
Heating may be used to warm engines of various equipment, such as pumping
equipment.
Heating may be provided, for example, via a fluid (for example water, air or
oil) which is
heated in the mobile support unit module and circulated to equipment requiring
heating.
Heating may be provided via other means, such as electricity, conduction, or
the like.
[0097] In some embodiments, the hydraulic power may be used to provide
heating. For
example, the hydraulic power pack may be operatively coupled to a
hydraulically powered
fluid heater, such as a water heater, water shear, or other fluid heater. The
fluid heater may
be located aboard the mobile support unit module. Alternatively, the fluid
heater may be
CA 02777284 2012-05-17
located aboard the equipment to be heated, thereby mitigating potential heat
loss during hot
fluid transfer. The fluid heater may be fitted to equipment such as oilfield
equipment. In
some embodiments, the fluid heater may act as an engine block heater, for
example by
circulating warmed glycol or other fluid around an engine in a closed loop.
For example, the
hydraulic power pack may drive a water heater, the hot water in turn heating
the warmed
glycol circulating around the engine and/or other equipment to be heated.
[0098] In some embodiments, the mobile support unit module may, by
providing
hydraulic power, heating, and the like, facilitate operation of a frac pumper
or similar oilfield
equipment operating in cold environmental conditions, independent of the
oilfield
equipment's towing vehicle long-haul towing vehicle.
[0099] In embodiments, the mobile support unit module is configured to
provide starting
power. For example, for mobile pumpers or other combustion engine driven
equipment.
Starting power may be provided as electrical power, mechanical power,
hydraulic power, or
the like, or a combination thereof.
[00100] In some embodiments, more mobile support unit modules are provided
than are
required for system operation. Thus, at least some excess power capability or
redundancy is
present within the system.
[00101] The mobile support unit modules may be configured to fit in a
container such as a
box-type or vehicle carrier semi-trailer for transportation. Plural mobile
support unit
modules may be configured to fit within the same container. In some
embodiments, the
mobile power units may be partially disassembled or components may be folded
down, or the
like, to facilitate stowage into the container.
[00102] In some embodiments, each mobile support unit module comprises a
chassis, an
engine, a transmission system, a control system, and a hydraulic power pack.
The chassis,
engine and transmission system are configured to provide a vehicle with
adequate towing
capacity in off-road conditions, as would be readily understood by a worker
skilled in the art.
The control system comprises steering, acceleration and braking, and hydraulic
power pack
control. The control system is operatively coupled to a radiofrequency (RF)
interface by
26
CA 02777284 2012-05-17
which the mobile support unit module may be controlled by a remote operator,
and by which
telemetry information such as visual information and system status may be
provided to the
remote operator, as would be readily understood by a worker skilled in the
art. The RF
interface may comprise a remote operator interface, a remote RF transceiver,
an on-board RF
transceiver, and a mobile support unit module interface.
[00103] The remote operator interface may be implemented in hardware,
software, or both.
The remote operator interface may, for example, comprise input devices such as
joysticks,
touchscreens, touchpads, keyboards, buttons, mice, physical gestures, or the
like, by which
an operator can input commands in a predetermined manner. The remote operator
interface
is configured to encode the commands for transmission by the remote RF
transceiver, which
is operatively coupled to the remote operator interface. The remote RF
transceiver may be
further configured to receive telemetry information from the on-board RF
transceiver, which
is then provided to the remote operator interface for presentation to the
operator, for example
via annunciators, video screens, audio speakers, tactile output means, or the
like, or a
combination thereof.
[00104] The remote RF transceiver, which is typically located with or near the
remote
operator interface, and the on-board RF transceiver, which is typically
located on board the
mobile support unit module, are configured for radio communication with each
other. Radio
communication may comprise conveying digital and/or analog data via RF signal
modulation
in accordance with one of a variety of protocols as would be readily
understood by a worker
skilled in the art. For example, data may be conveyed via one or more of:
amplitude
modulation, frequency modulation, frequency shift keying, phase shift keying,
direct
sequence spread spectrum protocols, frequency hopping protocols, multiple
access
communication, WiFiTM signals, or the like. Radio frequencies used for
communication
may fall within unlicensed spectrum (such as ISM bands) or licensed spectrum.
Commands
and data may be encoded in accordance with a predetermined protocol. For
example, binary
codewords associated with a predetermined dictionary of commands may be
exchanged
between transceivers.
27
CA 02777284 2012-05-17
[00105] The on-board RF transceiver is configured to interface with a mobile
support unit
module interface, for example by forwarding commands to the mobile support
unit module
interface and receiving data from the mobile support unit module interface for
transmission
to the remote RF transceiver. The mobile support unit module interface may
comprise a
microprocessor or microcontroller, operatively coupled to various electrical
and/or
mechanical components of the mobile support unit module and/or control system.
Operative
coupling may be via solenoids, optical couplings, electronic circuits,
electromechanical
interfaces, and the like.
[00106] The mobile support unit module and other modules of the system may
further be
configured to communicate with each other, for example via a wired or wireless
link. The
various modules may comprise inter-module communication systems, comprising
communication and processing electronics configured for this purpose. Thus,
for example,
the mobile support unit module may be configured to query and determine the
location and
operational status of other modules of the system. Operational status may
include, for
example, whether another module is currently in a transportation or
operational
configuration, whether the module requires starting power, heat, or hydraulic
power, or the
like. Location may be determined at a distance by providing various modules
with electronic
beacons, such as radio or infra-red beacons, or by using machine vision
systems. The mobile
support unit module may search for and discover beacons or predetermined
visual patterns,
and home in on them in order to reach a desired module and service same. The
inter-module
communication system may be configured to facilitate wireless communication,
similarly to
wireless communication between the remote RF transceiver and on-board RF
transceiver.
[00107] In some embodiments, the control system may provide for autonomous or
semi-
autonomous control of the mobile support unit module. The remote operator may
issue a
command to the mobile support unit module, which then autonomously executes a
sequence
of operations in order to execute one or more predetermined tasks associated
with the
command. Such tasks may include tasks associated with setting up,
reconfiguring or tearing
down one or more modules of the system, operating the system, connecting with
and
providing hydraulic power to a predetermined module of the system, connecting
to a
predetermined module, towing a predetermined module, or the like, or a
combination thereof
28
CA 02777284 2012-05-17
[00108] For example, a mobile support unit module may be configured to
autonomously
move toward a mobile storage module arranged in a transportation
configuration, wherein the
movement is assisted by a beacon or machine vision. The mobile support unit
module may
then autonomously connect its hydraulic power pack to a hydraulic port of the
mobile storage
module. The mobile storage module, upon detecting that hydraulic power is
available, may
self-deploy. Various other autonomous operations may also be performed. Semi-
autonomous operations may comprise a series of autonomous sub-operations,
separated by
intervals at which an operator inspects the situation, adjusts operation if
necessary, and
initiates the next autonomous sub-operation in the series.
[00109] In some embodiments, the mobile support unit module may be operable
via
manual remote control. A remote operator receives telemetry data such as on-
board camera
feeds, speed and location information, and the like, and inputs appropriate
commands to
operate the mobile support unit module.
[00110] In embodiments of the present invention, the mobile support unit
module and/or a
remote control module is configured to facilitate automatic control of one
more
functionalities of one or more other modules, such as delivery modules, mobile
storage
modules, in-feed conveyor modules, and possibly even other mobile support unit
modules.
The mobile support unit module and/or the remote control module may comprise a
computer,
programmable logic controller, or the like, configured to generate and provide
control signals
for facilitating such automatic control. The computer, programmable logic
controller, or the
like, may further be configured to receive telemetry signals from said modules
for facilitating
status monitoring, feedback control loops, or the like.
[00111] The control signals and telemetry signals may be exchanged between the
mobile
support unit modules and/or remote control module and the other modules via
the inter-
module communication system. Thus, for example, the mobile support unit module
may
generate control signals which are wirelessly transmitted to another selected
module,
received by a corresponding wireless transceiver of the selected module, and
converted to
signals useful for remote control of the selected module.
29
CA 02777284 2012-05-17
[00112] In some embodiments, the control signals are generated automatically
by the
mobile support unit module and/or the remote control module, thereby
facilitating automatic
(autonomous) or semi-automatic (semi-autonomous) control. In some embodiments,
the
control signals are generated in response to local or remote operator input,
thereby
facilitating manual remote control and some aspects of semi-autonomous
control.
[00113] In embodiments, one or more of the following functionalities may be
controlled by
the mobile support unit module and/or the remote control module via the above-
described
configuration: the rate at which granular material fills a mobile storage
module; opening and
closing the input port or filling hatch of a mobile storage unit; the rate at
which granular
material is discharged from a mobile storage module; and the rate at which
material is
provided by the delivery module. Other functionalities may also be controlled.
For example,
various motors, actuators, fans, blowers, engines, solenoids, relays, sensors,
annunciators,
lock-outs, and the like, may be controlled individually or in a coordinated
manner by the
mobile support unit module. The mobile support unit module may further control
functionalities of plural modules in a coordinated manner.
[00114] In some embodiments, functionalities as described above as well as
other
functionalities may be controlled by controlling the operation of one module
or a
combination of modules. For example, controlling the rate at which granular
material fills a
mobile storage module may comprise controlling the conveyor speed of a mobile
in-feed
conveyor module operatively coupled to the mobile storage module, and possibly
controlling
the mobile storage module to ensure its input port is open. Controlling the
rate at which
granular material is discharged from a mobile storage module may comprise
controlling the
variable aperture size at the mobile storage module output port, and possibly
controlling the
conveyor speed of the delivery module receiving the granular material.
Controlling the rate
at which material is provided by the delivery module may comprise controlling
both the
conveyor speed of the delivery module and the rate at which granular material
is discharged
from each of the mobile storage modules providing material to the delivery
module.
[00115] In some embodiments, the system may be controlled, for example via the
mobile
support unit module and/or via the remote control module, so as to provide a
desired blend of
CA 02777284 2012-05-17
various types of granular materials, such as various proppant types, as output
of one or more
delivery modules. For example, two or more different mobile storage modules
may be
provided with two or more different granular materials or two or more
different blends of
granular materials. By controlling the variable aperture size of the different
mobile storage
modules, a desired blend of different granular materials may be provided to
the delivery
module and conveyed thereby. In some embodiments, the blend of different
granular
materials may be subsequently mixed to provide for a substantial uniform
consistency of the
blend.
[00116] In some embodiments, the output ports of plural mobile storage modules
may be
controlled, for example via the mobile support unit module and/or the remote
control
module, in a coordinated manner. For example, the variable discharge apertures
or gates at
the output ports of different mobile storage modules feeding a common delivery
module may
be opened and closed in sequence, such that granular material is substantially
continuously
provided to the delivery module as each of the mobile storage modules are
emptied. For
example, the aperture of a first mobile storage module may be opened to feed
the delivery
module then closed as the mobile storage module is emptied, while concurrently
the aperture
of a second mobile storage module may be opened to take over providing of the
granular
material.
[00117] In some embodiments, one or more mobile in-feed conveyor modules may
be
controlled, for example via the mobile support unit module and/or the remote
control
module, so as to sequentially fill different mobile storage modules. The
overall storage
capacity of the mobile storage modules may thereby be managed as they are
emptied of
granular material. In some embodiments, controlling a mobile in-feed conveyor
module may
generally comprise causing the mobile in-feed conveyor module to move, under
its own
power, to a desired mobile storage module, deploy to its operational
configuration, and begin
feeding the mobile storage module with a supply of granular material.
[00118] In some embodiments, sequential filling of the mobile storage modules
may be
controlled, for example via the mobile support unit module and/or the remote
control
module, in coordination with sequential discharge of the mobile storage
modules. For
31
CA 02777284 2012-05-17
example, the mobile storage module may be controlled such that the mobile
storage modules
are emptied of granular material at different times, and the different times
are spaced apart
sufficiently that the emptied mobile storage modules may be re-filled by the
set of available
in-feed conveyors, such that the waiting times for re-filling of mobile
storage modules is
minimized or eliminated, or at least such that a continuous supply of granular
material may
be delivered via the delivery modules.
[00119] In some embodiments, control signals provided to the various system
modules, for
example via the mobile support unit module and/or the remote control module,
may be
derived from manual input command or from pre-set parameter control.
[00120] In some embodiments, the various modules may provide feedback signals
useful
for adjusting subsequent control signals. Such feedback signals may include
one or more of:
feedback indicative of storage module container portion contents by weight
(for example
provided by a load cell contained within the storage module rear hinge pin),
feedback
indicative of delivery module and/or in-feed conveyor module conveyor speed,
feedback
indicative of open/closed status and/or aperture size of output ports,
discharge apertures,
input ports, and the like.
[00121] As described above, in some embodiments the mobile support unit module
and/or
the remote control module, or a set of mobile support unit modules and/or
remote control
modules, may operate to control the system as a whole, either autonomously,
semi-
autonomously, or by relaying remote operator commands. Various operations,
such as
deployment operations, teardown operations, granular material delivery
operations,
adjustment of granular material mix, and the like, may be executed via such
control.
[00122] Figure 14 illustrates a block diagram of a mobile support unit module
1400 and
associated systems, in accordance with an embodiment of the present invention.
The mobile
support unit module 1400 comprises a control system 1410, a starting power
system 1415, a
power port 1417 for conveying the starting power to another module when
operatively
coupled thereto, a heating system 1420, a heating power 1422 for conveying the
heat to
another module when operatively coupled thereto, an engine 1425 for providing
power and
mobility, a hydraulic power pack 1430, and a hydraulic power port 1432 for
conveying the
32
CA 02777284 2012-05-17
hydraulic power to another module when operatively coupled thereto. The mobile
support
unit module 1400 further comprises an inter-module communication system 1435
for
detecting, communicating with and/or controlling other modules of the system.
The mobile
support unit module 1400 further comprises a telemetry system 1437, for
gathering telemetry
data such as camera images, module and system status information, and the
like. The mobile
support unit module 1400 further comprises the following components of an RF
interface
1460: a mobile support unit module interface 1445 and an on-board RF
transceiver 1440.
The RF interface 1460 further comprises a remote RF transceiver 1450 in radio
communication with the on-board RF transceiver 1440, and a remote operator
interface 1455.
The various illustrated components are operatively interconnected and function
substantially
as described above.
Remote Control Module
[00123] As described above, the mobile support unit module may provide control
signals to
one or more other modules and/or components of the system. The mobile support
unit
module may in turn be controlled via an RF interface, comprising a remote RF
transceiver
and a remote operator interface. The RF interface (including a remote operator
interface) and
the mobile support unit may thus function as an embodiment of a remote control
module,
configured for remote control (for example manual, automatic or semi-automatic
control) of
the system.
[00124] Additionally or alternatively, remote control of modules and/or
components of the
system may be provided for via a different remote control module
configuration. For
example, the above-described control functionality provided by the mobile
support unit
module may be located aboard a different module or co-located with the remote
operator
interface and remote RF transceiver. Thus, the remote control module may
comprise an
operator-held unit which transmits radiofrequency control signals to various
other RF
transceivers in the system. The operator-held unit may thus comprise a
computer,
programmable logic controller, inter-module communication system, and the like
as
described above, to thereby facilitate remote control of the system without
necessarily
routing control signals through a mobile support unit module.
33
CA 02777284 2012-05-17
[00125] In some embodiments, various modules of the system may be fitted with
RF signal
relays, such that control signals may be forwarded by the signal relays. In
some
embodiments, one or more modules such as mobile storage modules or a delivery
module
may comprise the components related to control functionality of the mobile
support module
as described above. Thus, for example, a delivery module or mobile storage
module may
comprise the computer or programmable logic controller, inter-module
communication
system, and on-board RF transceiver previously described as being housed
aboard the mobile
support module. The control functionality may thus be unchanged, although the
control
signals originate from or are routed through a different location.
In-Feed Conveyor Module
[00126] Embodiments of the present invention comprise one or more mobile in-
feed
conveyor modules, configured for conveying granular material from a material
source to a
selected mobile storage module.
[00127] In some embodiments, a mobile in-feed conveyor module is configured as
a
remotely-controlled, self-propelled vehicle which is optionally capable of
connecting to and
providing power to other modules of the system. In some embodiments,
substantially all
components of the system, such as the delivery modules and mobile storage
modules, are
powered by the one or more mobile in-feed conveyor modules. In some
embodiments, at
least some components of the system are powered by the one or more mobile in-
feed
conveyor modules. In some embodiments, modules of the system are powered at
least in part
by a combination of in-feed conveyor modules and mobile support unit modules.
[00128] In some embodiments, at least one mobile in-feed conveyor module is
configured
to also operate as a mobile support unit module as described elsewhere herein.
Thus, an in-
feed conveyor module may also be capable of providing control signals,
hydraulic power,
heating, towing capacity, and the like.
[00129] In some embodiments, regardless of whether or not other functionality
is provided,
the primary purpose of an in-feed conveyor module is to provide a mobile
platform for an in-
feed conveyor or elevator operatively coupled thereto. The mobile in-feed
conveyor module
34
CA 02777284 2012-05-17
may be remotely or locally, and manually or automatically operated to position
the conveyor
or elevator appropriately. Positioning of the conveyor or elevator may be such
that granular
material such as proppant is conveyed directly or indirectly from some source
at
approximately ground height to the height of a selected mobile storage unit
input port when
the mobile storage unit is in the raised operational configuration. The source
of granular
material may be some method of road transport vehicle, a container thereof, a
silo, an
uncontained source of granular material, or the like.
[00130] Figure 15 illustrates an in-feed conveyor module 1500 arranged in a
transportation
configuration, in accordance with embodiments of the present invention. The in-
feed
conveyor module 1500 comprises a chassis 1510, wheels 1515, which may be motor-
driven
at one axle or multiple axles, and an in-feed conveyor 1520, which is
deployable in the
operational configuration to convey granular material from substantially
ground level to the
input port of a mobile storage module. The in-feed conveyor 1520 further
comprises
foldable sections 1522 and 1524, which are foldable and deployable via
mechanical actuators
(not shown). Folding of the sections 1522 and 1524 may facilitate stowage of
the module
1500 and may also improve maneuverability when the module 1500 is controllably
maneuvered around the work site under its own power. The in-feed conveyor
module 1500
further comprises an engine, a transmission system, a control system, and a
radio transceiver
system, similarly to those of the mobile support unit module described herein.
The in-feed
conveyor module may further comprise components such as an inter-module
communication
system, hydraulic power pack, heating system, starting power system, and the
like.
[00131] The in-feed conveyor module 1500 further comprises a pivot mount 1530
and a
hydraulic actuator 1535, which are together configured to pivot the in-feed
conveyor 1520
between its transportation configuration as shown in Figure 15 and its
operational
configuration as shown in Figure 16.
[00132] Figure 16 illustrates the in-feed conveyor module 1500 of Figure 15,
arranged in
an operational configuration, in accordance with embodiments of the present
invention. The
module is illustrated in both a side view and an end view.
Set-up, Operation and Tear-down
CA 02777284 2012-05-17
[00133] Embodiments of the present invention are reconfigurable between
transportation
and operational configurations, thereby facilitating mobility, and relatively
quick set-up and
tear-down when compared with at least some prior art solutions. Each mobile
storage
module and delivery module may be hauled to a work site by a separate truck,
for example.
Embodiments of the present invention provide for a self-erecting, and
substantially self-
sufficient, system for storage and handling of proppant or other granular
material. In some
embodiments, the system may be set up on site within hours.
[00134] In some embodiments, the present invention may provide for storage and
delivery
capacity of suitable for projects requiring about 50,000 cubic feet of
granular material such
as proppant. For example, the system may comprise plural mobile storage
modules, each
configured for holding up to 5,000 cubic feet of granular material, which may
be discharged
by gravity to a delivery module. Ten mobile storage modules so configured may
thus
provide about 50,000 cubic feet of granular material. The rate at which
granular material
may be supplied may also scale with the number of mobile storage modules used,
subject to
capacity of the distribution module arrangement in use. More or fewer mobile
storage
modules may also be provided, thereby making the system scalable as required
by an
operation. Each delivery module may be capable of servicing up to a
predetermined number
of mobile storage modules. Thus, in some embodiments, plural delivery modules
may be
provided, end-to-end or in parallel, to satisfy operational requirements. One,
two or more
mobile support unit modules may be provided, depending on operating
requirements.
[00135] In embodiments of the present invention, one or more modules, such as
mobile
storage modules and delivery modules, may be powered by self-contained
hydraulic power
packs, or other appropriate sources of fluid or mechanical power. Each module
may be
powered by its own power pack, with power packs being interchangeable between
modules
in case of failure events. Plural modules may be powered by a single power
pack of
adequate capacity. Each power pack may comprise a prime mover, such as a
combustion
engine, a hydraulic pump, a hydraulic reservoir and associated filtering,
plumbing and
control valves, and possibly other components configured together for
supplying hydraulic
power. In some configurations, plural modules can operate independently, but
the hydraulic
power packs may be configured to allow cross connection between modules or to
auxiliary
36
CA 02777284 2012-05-17
equipment as may be required. In some embodiments, each module having its own
power
pack may be operable independently. This reduces requirements for external
lifting
equipment or power sources, which may not be readily available on site. As
described
above, power packs may additionally or alternatively be provided aboard mobile
support unit
modules. In some embodiments, mobile support unit modules may be used for
substantially
all power needs, thereby eliminating the need for on-board power packs,
although on-board
power packs or spare power packs not mounted on a mobile support unit module
vehicle may
be provided, for example for backup purposes.
[00136] Figure 12 illustrates a partial top view of a system for handling
granular material in
accordance with the present invention. The system comprises a plurality of
mobile storage
modules 200a, 200b, 200c, 200d arranged around a delivery module 900. Each
mobile
storage module 200a, 200b, 200c, 200d comprises a discharge chute 250a, 250b,
250c, 250d,
respectively. A first pair of discharge chutes 250a, 250b are positioned
overtop of a first
conveyor 912 of the delivery module, and a second pair of discharge chutes
250c, 250d are
positioned overtop of a second conveyor 910 of the delivery module. During
normal
operation, the first pair of discharge chutes 250a, 250b discharge granular
material onto the
first conveyor 912, and the second pair of discharge chutes 250c, 250d
discharge granular
material onto the second conveyor 910. Granular material is then conveyed to a
discharge
end of the delivery module. A crossover conveyor 1240 may be provided as shown
should
the first conveyor 912 fail. The crossover conveyor 1240 may have a first end
which may be
oriented under the discharge chute 250a or another chute, and a second end
overtop of the
second conveyor. The crossover conveyor 1240 may thus be configured to convey
material
from the discharge chute 250a to the second conveyor 910, thereby bypassing
the first
conveyor 912 in the event of failure thereof. One or more crossover conveyors
may be
provided which may be oriented and/or re-oriented as needed between a selected
discharge
chute and a selected conveyor.
Uses
[00137] Embodiments of the present invention may be used for storing and
delivering
proppant for drilling by hydraulic fracturing, for example for oil and gas
drilling, shale
37
CA 02777284 2012-05-17
drilling, and the like. In accordance with some embodiments, the present
invention may be
configured to convey the proppant material, via the delivery module, to one or
more blender
modules. The blender modules may receive and combine the proppant with water
and
possibly other chemicals to create slurry which is then provided to one or
more hydraulic
fracturing pumps for pumping into a well borehole for drilling.
[00138] In some embodiments, the present invention may be employed as a
material
storage and metering device for granular or flow-able materials other than
proppant, and/or in
applications other than well stimulation. For example, embodiments of the
present invention
may be employed to receive, store and convey a predetermined granular material
in
applications such as agriculture, in construction, road sanding and salting,
and the like. In
some embodiments, the present invention may be configured for water recovery
storage for
slick water fracking operations.
Additional Embodiments
[00139] Embodiments of the present technology provide a delivery module for
handling
granular material, the delivery module configured, in a delivery module
operational
configuration, to receive said granular material from one or more mobile
storage modules
and to convey said granular material to a predetermined delivery location, the
one or more
mobile storage modules adjacent to the delivery module, each of the one or
more mobile
storage modules configured, in a mobile storage module operational
configuration, to hold
and dispense said granular material downward to the delivery module.
[00140] Embodiments of the present technology provide a mobile storage module
for
handling granular material, the mobile storage module configured, in a mobile
storage
module operational configuration, to hold and dispense said granular material
downward to
an adjacent delivery module, the delivery module configured, in a delivery
module
operational configuration, to receive said granular material from the mobile
storage module
and to convey said granular material to a predetermined delivery location.
[00141] In some embodiments, the mobile storage module is reconfigurable
between said
mobile storage module operational configuration and a mobile storage module
transportation
38
CA 02777284 2014-12-03
configuration, the mobile storage module towable as a trailer in the mobile
storage module
transportation configuration.
[00142] In some embodiments, the mobile storage module comprises: a frame; a
container
portion supported by the frame and pivotably coupled thereto, the container
portion
configured to store said granular material and comprising an input port for
receiving said
granular material and an output port for dispensing said granular material;
and an actuating
system configured to pivot the container between a lowered position and a
raised position,
wherein, in the raised position, the input is located above the output. In
some embodiments,
the mobile storage module comprises or is operatively coupled to a loading
system
configured to convey said granular material thereto.
[00143] In some embodiments, the mobile storage module comprises a chassis,
the chassis
reconfigurable between a semi-trailer chassis for transportation and a bearing
surface for
support against ground during operation. In some embodiments, the chassis is a
rock-over
chassis. In some embodiments, the chassis comprises a wheeled portion movable
relative to
a bearing surface portion between a first position and a second position, the
wheeled portion
configured to engage ground in the first position for transportation, the
wheeled portion
configured to retract from ground in the second position to facilitate
engagement of ground
by the bearing surface portion.
[00144] It is obvious that the foregoing embodiments of the invention are
examples and can
be varied in many ways. As such, the scope of the following claims should not
be limited by
the particular embodiments set forth herein, but should be given the broadest
interpretation
consistent with the description as a whole, accounting for modifications as
would be obvious
to one skilled in the art.
39
