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Patent 2944980 Summary

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Claims and Abstract availability

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(12) Patent: (11) CA 2944980
(54) English Title: MONITORING AND CONTROL OF PROPPANT STORAGE FROM A DATAVAN
(54) French Title: SURVEILLANCE ET CONTROLE DU STOCKAGE D'AGENT DE SOUTENEMENT A PARTIR D'UN CAMION DE DONNEES
Status: Granted
Bibliographic Data
(51) International Patent Classification (IPC):
  • E21B 43/267 (2006.01)
  • E21B 43/26 (2006.01)
(72) Inventors :
  • OEHRING, JARED (United States of America)
  • HINDERLITER, BRANDON (United States of America)
  • BROWN, ARTHUR (United States of America)
(73) Owners :
  • US WELL SERVICES LLC (United States of America)
(71) Applicants :
  • US WELL SERVICES LLC (United States of America)
(74) Agent: BERESKIN & PARR LLP/S.E.N.C.R.L.,S.R.L.
(74) Associate agent:
(45) Issued: 2022-07-12
(22) Filed Date: 2016-08-12
(41) Open to Public Inspection: 2017-02-12
Examination requested: 2019-07-26
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data:
Application No. Country/Territory Date
62/204,331 United States of America 2015-08-12

Abstracts

English Abstract

A system and method that remotely monitors and controls proppant usage in a fracturing operation. The system and method allow operators to wirelessly monitor and control proppant storage units from inside a datavan through sensors and control mechanisms that interface with fracturing software to schedule the flow of the proppant. A sensor monitors the weight, container level, or volume of the proppant being used to keep the induced hydraulic fracture open. A serial to Ethernet converter converts this information and sends it wirelessly to a datavan. A user at the datavan controls the proppant usage through a display in the datavan of the storage units with the appropriate weight. The container monitoring software links with the fracturing software, providing real-time information about proppant usage so that the user can properly schedule proppant flow to the well through valves, conveyor belts, and other control mechanisms.


French Abstract

Il sagit dun système et dun procédé qui surveillent et contrôlent, à distance, lutilisation dagent de soutènement dans une opération de fracturation. Le système et le procédé permettent aux opérateurs de surveiller et de contrôler, par voie sans fil, les mémoires dagent de soutènement depuis lintérieur dun camion de données au moyen de capteurs et de mécanismes de contrôle qui sinterfacent avec le logiciel de fracturation pour prévoir lécoulement de lagent de soutènement. Un capteur surveille le poids, le niveau de conteneur, ou le volume de lagent de soutènement utilisé pour garder la fracturation hydraulique induite ouverte. Un convertisseur série-Ethernet convertit ces informations et les envoie, par voie sans fil, à un camion de données. Un utilisateur du camion de données contrôle lutilisation de lagent de soutènement à laide dun affichage, dans le camion de données, des mémoires avec le poids approprié. Le logiciel de surveillance du conteneur se lie au logiciel de fracturation, fournissant des informations en temps réel sur lutilisation de lagent de soutènement afin de permettre à lutilisateur de prévoir correctement lécoulement de lagent de soutènement vers le puits par les soupapes, les bandes transporteuses et dautres mécanismes de contrôle.

Claims

Note: Claims are shown in the official language in which they were submitted.


CLAIMS
1. A system for use with a fracturing operation comprising:
a plurality of electric-powered pumps fluidly connected to a well and powered
by
at least one electric motor, and configured to pump fluid into the well at
high pressure so
that the fluid passes from the well into the formation, and fractures the
formation;
a variable frequency drive connected to the electric motor to control the
speed of
the motor, wherein the variable frequency drive frequently performs electric
motor
diagnostics to prevent damage to the at least one electric motor;
a weight monitoring system in selective cooperation with a proppant container
that selectively contains proppant used in fracturing;
an information handling system in communication with the weight monitoring
system; and
a proppant dispensing system coupled with the proppant container and that is
in
communication with and selectively activated by the information handling
system.
2. The system of claim 1, further including a serial to Ethernet converter
for sending
and receiving Ethernet data to and from the information handling system, and
for
sending and receiving serial data to and from the proppant container.
3. The system of claim 1, wherein the information handling system
selectively
sends commands to actuate a valve coupled with the proppant container to
provide a
designated amount of proppant for use by a fracturing operation.
4. The system of claim 1, wherein the information handling system alerts a
user if
an amount of proppant in the proppant container is below a threshold level,
and where
the information handling system estimates the amount of proppant in the
proppant
container based on a signal received from the weight monitoring system.
5. The system of claim 1, wherein the weight monitoring system comprises a
sensor
for measuring one or more of a weight of the proppant container, a level of
proppant in
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Date Recue/Date Received 2021-08-03

the proppant container, and a volume of proppant in the proppant container,
and
wherein the sensor comprises a measuring device selected from the group
consisting of
gamma ray gauges, radar gauges, laser gauges, weight measuring load cells,
pressure
sensors, ultrasonic gauges, and combinations thereof.
6. The system of claim 1, wherein control by the variable frequency drive
is either
wired or wireless.
7. The system of claim 1, wherein the proppant storage containers include
one of
silos or trailer mounted containers.
8. A method for conducting a fracturing operation comprising:
pumping fluid with a plurality of electric-powered pumps into a wellbore at
high
pressure so that the fluid passes from the wellbore into the formation, and
fractures the
formation;
controlling the speed of an electric motor powered the electric-powered pumps
with a variable frequency drive, wherein the variable frequency drive
frequently
performs electric motor diagnostics to prevent damage to the electric motor;
sensing an amount of proppant contained in at least one proppant storage
container;
comparing the amount of proppant sensed in the proppant storage container with

a designated amount of proppant; and
regulating a flow of proppant from the proppant storage container based on the

step of comparing the amount of proppant sensed and the designated amount of
proppant.
9. The method of claim 8, further comprising a scheduling step that
includes
interfacing with a fracturing system that can actuate valves and other control

mechanisms to provide proppant to fracturing operations on conveyor belts.
17
Date Recue/Date Received 2021-08-03

10. The method of claim 8, further comprising directing an amount of
proppant
toward a well through the use of conveyor belts that are controlled by a user
at a
datavan.
11. The method of claim 8, further comprising generating an alert if
proppant in the
proppant storage container goes below a threshold level.
12. The method of claim 8, wherein the sensing the amount of proppant in
the
proppant storage container comprises using a device that is selected from the
group
consisting of gamma ray gauges, radar gauges, laser gauges, weight measuring
load
cells, pressure sensors, ultrasonic gauges, and combinations thereof.
13. The method of claim 8, wherein the proppant storage containers include
one of
silos or trailer mounted containers.
18
Date Recue/Date Received 2021-08-03

Description

Note: Descriptions are shown in the official language in which they were submitted.


MONITORING AND CONTROL OF PROPPANT STORAGE FROM A DATAVAN
BACKGROUND OF THE INVENTION
1. Technical Field
[001] Embodiments of the present disclosure relate to systems and
methods for
wirelessly monitoring and controlling proppant usage in real time in a
hydraulic
fracturing operation.
2. Description of Related Art
[002] Horizontal drilling and hydraulic fracturing are two ways in which
unconventional sources of hydrocarbons can be tapped to provide energy
resources.
Hydraulic fracturing (fracking) operations typically require powering numerous

components in order to recover oil and gas resources from the ground. For
example,
pumps that inject fracking fluid down the wellbore, blenders that mix proppant
into the
fluid, cranes, wireline units, and many other components all must perform
different
functions in concert to carry out fracturing operations.
[003] Fracturing operations are highly complex and involve pumping
fracturing
fluid at a high pressure to hydraulically fracture the reservoir rock in the
well in order to
form fractures and stimulate production of hydrocarbons. The formed fractures
can then
be used to access hydrocarbons that could not have been accessed with
traditional oil
& gas well techniques. The fracturing fluid that is pumped down into the well
usually
includes a proppant that is a solid particulate such as sand or ceramic beads.
In many
known fracking systems, proppant, such as sand, glass beads, ceramic material,

bauxite, dry powders, rock salt, benzoic acid, fiber material, or cement
plastics, is mixed
with other materials and enhances the flow capacity of the fractures. The
proppant
props open the fractures and remains in the fractures after the end of the
hydraulic
fracturing operation.
1
Date Recue/Date Received 2020-12-30

[004] The proppant is supplied to the blenders and mixers and then to the
well
through a proppant delivery system located at the wellsite. The proppant is
usually
stored in large containers that are heavy and are connected to conveyor belts
which
lead to other mixing equipment and finally into the wellbore, where the
mixture is
pumped into the reservoir. The containers usually are refilled at the site by
trucks that
come in and empty the proppant into them. Gates are controlled by the user to
open
and close the proppant containers. However, in this operational scenario
operators of
the hydraulic fracturing system need to be stationed outside at the containers
using
hydraulic valves, or a short range wireless remote control that is hand held
for controls.
[005] The operators report in to the datavan using a radio headset to
communicate the container weights or fill levels. This is inconvenient and
there are not
always extra personnel available for the task. Also, having a worker walk over
to the
container to adjust the flow takes minutes, which is a long time to have to
manually
check the proppant level. Further there is airborne silica around the
container, which
can cause silicosis. Silicosis is lung fibrosis caused by inhalation of dust
containing
silica. Silica is usually found in the sand used as a proppant. Operators are
also
exposed to dangerous weather in extremely cold, hot, or hazardous
environments. Also,
operators would normally have to determine what container and how much to use
manually, which can lead to operator error. The incorrect aggregate of
proppant could
be used by selecting the wrong container.
[006] Another issue with the manual control of the containers is that when
the
gates controlling proppant flow from the containers are left open spilling
product, this
causes profit loss. It also causes environmental harm and there is a major
safety
concern. When a wrong container is open and the incorrect aggregate or
proppant is
sent out to be mixed with the fracturing slurry, it is hard to figure out what
tank the
proppant came from and can result in a violation of customer contract. There
is also
confusion that occurs at the pre-stage planning because operators are unsure
what
container is being used and how the containers are being scheduled for later
use.
2
Date Recue/Date Received 2020-12-30

[007] These and other problems with manually monitoring and controlling the

proppant usage have been observed in the field.
SUMMARY OF THE INVENTION
[008] The method and system of the present invention provide real-time
remote
monitoring of proppant, such as sand and glass beads, as it is being fed from
proppant
containers and mixed into the fracturing fluid. Operators inside a datavan are
able to
wirelessly monitor the weight, container level or volume of the proppant and
control the
proppants in the proppant containers through remote monitoring software in a
datavan.
[0009] Embodiments of systems and methods of the present disclosure
include a
proppant container with control box connected to a sensor for monitoring the
amount of
proppant, an RS232 or RS435 serial data protocol on the control box, a
wireless
Ethernet converter to send the signal from the control box located at the
proppant
container, a wireless receiver with signal out ports for serial or Ethernet
ports to receive
the data from the sensor to the datavan and a piece of software on an
information
handling system in the datavan that computes the total and allows the user to
interface
with the fracturing control software to schedule proppant usage and flow.
[0010] Embodiments of the invention include software that acquires and
displays
the proppant data to a user in a datavan, and power supplies that supply power
to the
serial to Ethernet converter, measuring sensor, and transmitter.
[0011] Embodiments of the invention also include wireless control of the
storage
containers and conveyor belts.
[0012] Embodiments of the invention include a serial to Ethernet
converter that
takes the serial data output from a sensor at a proppant container and
converts it to the
Ethernet protocol to be sent to a datavan with an Ethernet receiver where it
is
processed and displayed to a user who is monitoring and controlling the
proppant flow.
The software also allows for scheduling and remote monitoring of the weight,
volume
and amount of proppant in each proppant container. The monitoring software,
which
3
Date Recue/Date Received 2020-12-30

receives the signal from the proppant equipment can also communicate with
fracturing
software in the datavan to allow for more automation of the fracturing process
as a
whole.
[0013] Embodiments of the invention can schedule and automate which
containers to run the proppant from, allowing for the proper mixture of
proppants from
different containers to make up the fracturing fluid.
[0014] Embodiments of the invention can relay the container weight to a
datavan
information handling system, a personal laptop or a separate Human Machine
Interface
(HMI) mounted in the datavan.
[0015] Embodiments of the present invention measure the containers weight
by
gamma ray gauges, radar gauges, laser gauges, and ultrasonic gauges. Also
weight
measuring load cells and pressure sensors along the vertical height of the
vessel can
be used.
[0016] Embodiments of the invention include that the communications can
be
wired or wireless.
[0017] Embodiments of the invention can convert the serial data to
wireless, but it
is possible to transmit the signal without converting it first.
[0018] Embodiments of the invention can include only the monitoring of
the
proppant flow and not control.
[0019] Embodiments of the invention can be used on several type of
proppant
storage containers including silos, capable of holding 200,000 lbs to 300,000
lbs, kings,
or sand hogs, large trailer mounted containers similar to a fracturing tank on
wheels that
holds from 300,000 lbs to 400,000 lbs, or smaller individual proppant boxes,
which hold
from 40,000 lbs to 60,000 lbs and can be set directly on a conveyor belt.
4
Date Recue/Date Received 2020-12-30

BRIEF DESCRIPTION OF DRAWINGS
[0020] The foregoing aspects, features, and advantages of embodiments of
the
present disclosure will further be appreciated when considered with reference
to the
following description of embodiments and accompanying drawings. In describing
embodiments of the disclosure illustrated in the appended drawings, specific
terminology will be used for the sake of clarity. However, the disclosure is
not intended
to be limited to the specific terms used, and it is to be understood that each
specific
term includes equivalents that operate in a similar manner to accomplish a
similar
purpose.
[0021] FIG. 1 is a block diagram of an embodiment of the present
invention.
[0022] FIG. 2 is a block diagram of a second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] The foregoing aspects, features, and advantages of the present
disclosure
will be further appreciated when considered with reference to the following
description
of embodiments and accompanying drawings. In describing the embodiments of the

disclosure illustrated in the appended drawings, specific terminology will be
used for the
sake of clarity. However, the disclosure is not intended to be limited to the
specific terms
used, and it is to be understood that each specific term includes equivalents
that
operate in a similar manner to accomplish a similar purpose.
[0024] The present invention provides a system and method for wirelessly
monitoring and controlling proppant flow from proppant storage containers in a
hydraulic
fracturing operation. The proppant can include sand, glass beads and other
known
materials that is mixed into a fracturing fluid and that is pumped through a
wellbore into
a well in order to create fractures and extract hydrocarbons. The proppant
storage
containers can be stationary or attached to a trailer and can be of various
sizes
depending on the application.
Date Recue/Date Received 2020-12-30

[0025] Components of a system for monitoring proppant usage and flow can
include a control box at the proppant container with sensors which are coupled
to the
proppant storage container and have serial connections, such as RS232 or RS485

serial connectors, a wireless Ethernet converter to send data signals
indicating the
readings of the sensors that monitor the weight of the container in real time,
and a
wireless receiver with signal out ports for serial or Ethernet that receives
the signals
sent from the control box and formulates them for viewing to a user in a
datavan. A
variety of power supplies can be used to power the converters. In addition,
the software
to acquire and display the data, as well as to communicate with the fracturing
control
software can be included as well. For the control of the storage, there can be
a control
box outside or inside the proppant storage containers that can contain wiring
and a
display for operations that is wirelessly connected to the datavan.
[0026] FIG. 1 shows in schematic form an embodiment of a system 100 for
remote and real-time monitoring of proppant storage in a container. In one
example of
the system 100, there is a datavan 102 where a user operates an information
handling
system 107 with a processor and memory for storing computer readable media
accessible by the processor with instructions and with a display 106.. The
information
handling system 107 may also include nonvolatile storage area accessible by
the
processor, and logics for performing each of the steps described herein. In
the
illustrated example, the information handling system 107 interfaces with a
wireless
receiver 108 that can be connected to a LAN or other type of wireless network
through
normal wireless connections or serial to Ethernet devices. Serial to Ethernet
devices
can be provided by Moxa (640 Herman Road, Suite 5, Jackson, NJ 08527,
http://www.moxastore.com), which manufactures serial to Ethernet devices and
servers.
Other wireless receivers can also be customized for this particular
application. Due to
the distances between equipment being up to 400 feet, and other
electromagnetic
inference, Ethernet may not be reliable and therefore another suitable long
range
protocol may be used such as Radio Frequency (AM or FM).
6
Date Recue/Date Received 2020-12-30

[0027] In the exhibit shown in FIG. 1, the datavan 102 communicates with
a
proppant container 114 through a control box 104 at a well site 112. The
proppant
monitoring system 100 includes a control box 104 shown connected to a proppant

container 114. The control box 104 can contain circuitry and wiring along with
computer
readable media for storing instructions and a processor and input means for
the user to
manually operate the container 114. In most embodiments the control box 104
will be
attached to and be a part of the proppant container 114. Included in the
control box 104
is a serial receiver 128 that can connect to a serial to Ethernet converter
110, also
potentially produced by Moxa. The control box 104 can further contain a
wireless
transmitter 130 for transmitting information to the datavan 102.
[0028] Further, the control box 104 has a serial receiver 128 that is
connected via
a serial cable to a serial transmitter 126 in a proppant container 114. The
proppant
container has a sensor 118 which monitors the weight of the proppant container
114
and its contents. The sensor 118 gathers information about the weight of the
proppant
in the container and sends it via serial or analog connection to the serial
transmitter 126
to the control box 104 through its own serial receiver 128. That information
is then
converted by a serial to Ethernet converter 110 and sent via wireless
transmitter 130 to
the datavan 102. Proppant can be selectively dispensed from proppant container
114 by
opening and closing gate 120, such as with an actuator 122. Sensor readings
from
sensor 118 are constantly sent back to the datavan 102 through the serial to
Ethernet
converter 110. There is also a conveyor 124 that can be selectively activated
in this
embodiment.
[0029] The weight of the proppant container 114 and its contents can be
relayed
to one or more of the datavan information handling system 107, a personal
laptop,
and/or a separate human machine interface (HMI) mounted in the datavan 102
through
the control box 104. In the datavan a wireless receiver 108 receives the data
(wireless
transmission is indicated by a dashed line in FIG. 1) and then the information
is sent to
the information handling system 107 and displayed to the user via a display
106 in
multiple formats. The connections between the wireless receiver 108 and the
7
Date Recue/Date Received 2020-12-30

information handling system 107 can be Ethernet or the wireless receiver can
be
directly installed in the information handling system 107. Further the
connection
between the information handling system 107 and the display 106 can be
Ethernet or
serial connection types.
[0030] In addition, the amount of proppant in the proppant container 114
can be
gauged by measuring its total weight and subtracting the weight of the
proppant
container 114 itself, such as with a load cell. In one example a load cell
includes a strain
gauge that mounts to the proppant container 114 and emits a signal that is
representative of the weight of proppant in the proppant container 114. This
embodiment is not limited to any one sensor and there are several different
ways an
accurate weight measurement can be obtained. Optionally, volume of the
proppant can
be measured. Gamma ray (radioactive) gauges, radar gauges, laser gauges, and
ultrasonic gauges can optionally be used in place of weight measuring load
cells or as a
redundancy to load cells. Even pressure sensors along the vertical height of
the
proppant container 114 can be used. Furthermore, the communications can be
either
wired or wireless. Although the above-discussed embodiments seek to convert
the
serial communications to Ethernet, it is possible to transmit serial data
wirelessly without
converting it. Proppant is tracked based on weight using load cells, and if a
level sensor
is used such as a gamma, radar, laser or sonic sensor, then the geometry of
the
container is taken into consideration when the weight is calculated. An
algorithm is used
that takes into account the current proppant level, the proppant weight per
volume, the
density of the proppant and the geometry of the container.
[0031] According to one embodiment of the invention shown in FIG. 1, the
signal
and electrical characteristics of communications associated with the control
box 104
and weight sensor 118 can be in accordance with Serial R5232 or R5485 protocol

standards. Serial R5232 or R5485 protocols are standard communications
protocols
within the industry and other embodiments of the invention can include
different
standards. Optionally the operation of the control box 104 and weight sensor
118 can
be in accordance with Ethernet standards, and the data from these devices
transmitted
8
Date Recue/Date Received 2020-12-30

wirelessly to the datavan 102. The datavan 102 can then receive the wireless
signal and
output it to display 106. The display 106 shows a representation of each
container and a
number with the appropriate scale weight. To keep each container unconfused
and
receiving properly, an output signal and an input signal can be separated on
respectively numbered corn ports. For example, container one can be received
through
com port one, container two can be routed to com port two, etc. Another option
is to
order the data sent in the serial stream so that the first value in the data
packet can
pertain to the weight of the first container, the second value can pertain to
the second
container, and so on.
[0032]
In an example of operation, the weight or volume of the proppant (or sand)
in the proppant container 114 is monitored, either instantaneously or over
time, and
compared to a designated weight (or volume) or change in weight (or volume)
over
time. To ensure a sufficient amount of proppant is on hand in the containers)
114 for
use in the fracturing process, a threshold low point of proppant in the
container 114 is
established, and operations protocol is to keep the amount of proppant in the
container
114 to be at least or greater than the threshold low point. Thus an advantage
of
employing the monitoring system 100 described herein is that by monitoring the

proppant amount in the container 114 with the controls described herein, if
the threshold
low point is approached, or soon to be approached, proppant can be added to
that
particular container 114. In another example of operation, if a rate change of
weight of a
proppant container 114 deviates from a designated value, the gate 120 on the
particular
proppant container 114 can be adjusted so that the rate change of weight is at
or close
to the designated value. Excursions of the rate change of weight from the
designated
value, which can be less than or greater than the designated rate change of
weight of
the proppant container, can indicate that the amount of proppant being
dispensed from
the container 114 exceeds a capacity of proppant handling hardware, such as a
conveyor, thereby resulting in spillage of proppant, or generating proppant
dust. This
can be corrected (via monitoring software in the information handling system)
that
identifies the rate of weight change excursion and contains instructions to
send
controlling commands to the actuator 122 that in turn adjust a position of the
gate 120 to
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Date Recue/Date Received 2020-12-30

affect a flow of proppant from the container 114. Additionally, monitoring a
rate of weight
change of a proppant container 114 can provide an indication of how much, if
any,
proppant is being dispensed from the container 114. Thus if it is desired that
proppant
be dispensed from a one of the containers 114, but not from another one of the

containers 114, logics in the information handling system 107 can compare
monitored
rate weight changes of proppants in the containers 114 to determine if
proppant is being
dispensed from designated proppant containers 114, and if not, command signals
can
be transmitted from the information handling system 107 to the actuator 122 to
open a
gate 120 on a container 114 from which proppant is to be dispensed, and close
a gate
120 on a container 114 from which proppant is not to be dispensed.
[0033] FIG. 2 shows in schematic form an alternate embodiment of a system
200
for monitoring and controlling proppant flow. The wireless proppant monitoring
and
controlling system 200 of FIG. 2 includes a datavan 202 with a wireless
connection
inside via a wireless transceiver 208. The datavan 202 can contain a human
machine
interface (HMI) 206 such as a display and an information handling system (IHS)
207
with a processor, memory and storage for storing the data gathered through the

wireless connection. A control box 204 contains a serial transceiver 228 that
selectively
communicates with a sensor 218 for monitoring the weight of the proppant
container
214 and its contents via a serial transceiver 226.
[0034] In the example of FIG. 2, the information is transmitted after it
is sent from
the sensor 218 via analog connection from a serial transceiver 226 to another
serial
transceiver 228 in the control box 204. The information is then sent through a
serial
connection to another information handling system (IHS) 234 in the control box
204.
This IHS 234 may have another human machine interface (HMI) 232 connected to
it for
access by a user. 'The IHS 234 then selectively converts the data through a
serial to
Ethernet converter 210 and sends it back to the datavan 202 through a wireless

transceiver 230 on the control box 204 where it is processed by the wireless
transceiver
208. The datavan 202 can control an actuator 222 on the proppant container 214
by
sending a control command through the HMI 206 connected to the IHS 207 at the
Date Recue/Date Received 2020-12-30

datavan 202 through the wireless transceiver 208 to the control box 204. The
wireless
transceiver 230 in the control box 204 receives the command, converts it to
serial
through the serial to Ethernet converter 210, sends it to the IHS 234, which
then sends
it to the proppant container 214 through the serial transceiver 228. A serial
transceiver
226 at the proppant container receives the command and actuates the actuator
222
connected to the gate 220. The serial transceiver 226 can also actuate the
conveyor
224 as shown in FIG.2.
[0035] The information related to the weight of the container from the
sensor 218
can also be catalogued and displayed to a user in the datavan 202. The
information can
be updated in real time through the wireless connection in the datavan 202 and
the user
can also control the operations of the conveyor belts 224 and actuator 222
that release
the proppant through an actuator 222, which in some embodiments is an
proportional
hydraulic valve, into the mixing system by interfacing with fracturing
software that is also
stored in the datavan 202. In one embodiment there are multiple computers in
the
datavan, one that is in charge of proppant delivery and another for the
fracturing
operation. These different computers run programs that can share data between
themselves. In another embodiment the proppant monitoring and control system
will be
integrated into fracturing software which monitors the entire fracturing
operation.
[0036] To control proppant flow from the containers, the same software
can be
modified to send commands through the same wireless transceiver 208 on the
datavan
202 to the wireless transceiver 230 at the control box 204 at the well site
212 where it
can then be converted back to serial for use by the control box's own IHS 234
to
open/close sand gates, speed up/slow down the conveyor belt 224, etc. The
monitoring
and control system that receives the signal from the control box 204 and
proppant
container 214 can also communicate with a portion of the fracturing system in
the
datavan 202 to allow for a higher level of automation if desired (as described
below).
Proppant in the container 214 may be released through the wireless control of
the valve
gate 220 located at the container 214. This can release proppant onto a
conveyor 224
11
Date Recue/Date Received 2020-12-30

for mixing into the fracturing slurry. This data can be used with the data
that is gathered
from the weight sensor 218 to more accurately control the proppant flow.
[0037] In some alternate embodiments, the system 200 allows for two way
communications to allow for monitoring and control of the container 214 and
conveyor
belt (also referred to as a dual belt) 224. In addition, system 200 can be
used on several
different types of proppant storage containers including silos (tall
containers similar to
farm silos capable of holding 200,000 lbs to 300,000 lbs), sand kings
(sometimes called
sand hogs, large trailer mounted containers similar in idea to a frac tank on
wheels,
capable of holding 300,000 lbs to 400,000 lbs), or sand boxes (which are
smaller
containers which are set on top of the conveyor belt and unloaded which can
contain
40,000 lbs to 60,000 lbs). The sand equipment units can be electric powered,
diesel
powered, gravity fed, and/or solar powered. In addition, the system 200 is not
limited to
use with vertical sand silos, but the can be applied to other sand storage
equipment as
well. Various sensors can be added to the system to control the flow of
proppant and
weight and the embodiment described above should not be limited to a single
configuration.
[0038] One advantage of the system 200 is the ability to keep personnel
away
from air born silica that exists around proppant storage units, and which can
cause
silicosis or other health problems. Silicosis is lung fibrosis caused by the
inhalation of
dust containing silica. Operators can also be kept out of the weather in
extremely cold,
hot, or hazardous environments. Another advantage is the removal of human
error of
dispensing proppant from the wrong storage container. In some embodiments of
the
invention, there are multiple gates on the container or containers and
different levels of
open and close for the multiple gates that can be set by the user at the
datavan. Some
gates can only open fully or close fully as well depending on the application.
[0039] In some embodiments, a live video feed can be directed from the
container 214 to the datavan 202 through a camera 236 that sends a Radio-
Frequency
(RI7) signal back to the IHS 234 at the control box 204, thereby making it
possible to
12
Date Recue/Date Received 2020-12-30

know instantly if a gate 220 was left open, spilling product on the ground and
costing
profit loss or causing an environmental or safety hazard, or conversely, if a
gate
commanded to open was stuck shut due to a mechanism failure. An improperly
operating gate can cause the failure of a fracturing operation. This
information is
converted to wireless and transmitted to the datavan 202. Datavan operators
can also
use the video feed to determine if the wrong container was opened, causing an
incorrect aggregate to be mixed into the fracturing slurry. The same weight
monitoring
can also allow datavan operators to see if a certain container is being
unloaded into
which will help prevent confusion regarding logistics and pre-stage planning.
[0040] Set points for proppant delivery and conveyor speed can be a
simple P1D
closed feedback loop. A sensor can monitor the speed of the conveyor and that
sensor
sends a signal to the datavan via the system to indicate if the desired speed
has been
reached. If the sensor indicates it has reached the proper speed, then the
conveyor will
hold the speed. If it indicates the speed value has been overshot, the system
will send
out a command signal to slow down the belt. This process is repeated multiple
times
until the correct weight goal has been achieved by the system The P, I, and D
values
will determine the stability and response time of the control system, and
these values
are dependent upon the user's desired response times, and the determined
amount of
overshoot and undershoot that is tolerable in the positioning of the gate.
User entered
set points for the desired weight of sand remaining in the containers) will
signal the end
of the job once that weight is reached and will trigger the gate(s) to close,
thus ending
the feedback control loop. Further, other components in the fracturing system,
such as
the blender can alter these values as part of the overall fracturing software
depending
on the uses of the system.
[0041] According to certain embodiments, which include multiple
containers, it is
possible to schedule and automate which of these containers to access. For
example,
the fracturing system can issue a command to close a 40/70 aggregate sand
container,
while simultaneously issuing a command to open a 20/40 aggregate container. In
an
embodiment, closing a particular sand (or proppant) container involves closing
the gate
13
Date Recue/Date Received 2020-12-30

220 on the container 214 through which proppant/sand is dispensed from the
container
214 to suspend the flow of proppant from the container 214. Similarly, in one
example,
opening a container 214 is done by opening the respective gate 220 on the
container
214 so that proppant can be dispensed to a designated conveyor 224. Opening
and
closing the gates 220 can be performed by activating the respective actuators
222
coupled with the gates 220. The speed of a belt on conveyor 224 can be
controlled
remotely, as well as the container outlet gate 220 which can be choked to
control the
amount of sand being fed to the belt. If wellhead pressure exceeds a set
point, or if an
emergency stop (E-Stop/E-Kill) button or emergency power off (EPO) button is
pressed,
the gates 220 on the containers can be automatically closed thereby preventing
lost
product (proppant). The conveyor belt 224 can also be linked to the E-Stop and
EPO in
case of an emergency.
[0042] The connections between the HMI 206 and the IHS 207 can be serial
or
Ethernet. The dashed line in FIG. 2 represents wireless communications between
the
wireless transceiver 230 in the control box 204 and the wireless transceiver
in the
datavan 202, but also wired communications can be used as well. The HMI 232 on
the
control box 204 can also be external or internal and the IHS 234 can be a
small
programmable logic control device. The actuator 222 can also be an electrical
or air
actuator instead of a proportional hydraulic valve. Additionally, the conveyor
can be a
part of the proppant container, or a separate piece of equipment.
[0043] A further embodiment of the invention includes a blender that is
connected
to the IHS 207 of the datavan 202. The blender can have an information
handling
system and a human machine interface that communicates with the datavan 202 in

order to further control the proppant flow. The blender is capable of making
changes to
the proppant flow in a similar manner as the datavan 202. The blender can send
control
signals to the datavan 202 through its own information handling system to the
IHS 207
of the datavan indicating a certain flow of proppant and these signals can be
sent to the
control box 204 and the proppant container 214. Therefore any changes
requested by a
14
Date Recue/Date Received 2020-12-30

user operating the blender are taken into consideration when delivering the
proppant.
The connections can be either serial or Ethernet, but are not limited in this
embodiment.
[0044]
Embodiments of the system 200 described herein allow for the wireless
monitoring and control of proppant and proppant storage containers 214 in a
remote
location. Proppant container 214 in the embodiment of Fig. 2 contains a single
type of
proppant, however, it is possible to have multiple proppants in multiple
containers with
multiple valves actuated remotely, or different compartments in the same
container
which contain different aggregates of proppant, so that the user in the
datavan 202 can
schedule a different mixture of proppants for the desired fracturing fluid and
application.
Persons of ordinary skill in the art will appreciate that the systems and
methods
described herein are not limited to the particular structures described but
that changes
to the invention can be made that are consistent with this disclosure.
Date Recue/Date Received 2020-12-30

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2022-07-12
(22) Filed 2016-08-12
(41) Open to Public Inspection 2017-02-12
Examination Requested 2019-07-26
(45) Issued 2022-07-12

Abandonment History

There is no abandonment history.

Maintenance Fee

Last Payment of $210.51 was received on 2023-06-21


 Upcoming maintenance fee amounts

Description Date Amount
Next Payment if small entity fee 2024-08-12 $100.00
Next Payment if standard fee 2024-08-12 $277.00

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Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $400.00 2016-08-12
Maintenance Fee - Application - New Act 2 2018-08-13 $100.00 2018-07-24
Maintenance Fee - Application - New Act 3 2019-08-12 $100.00 2019-07-22
Request for Examination $800.00 2019-07-26
Maintenance Fee - Application - New Act 4 2020-08-12 $100.00 2020-07-22
Maintenance Fee - Application - New Act 5 2021-08-12 $204.00 2021-07-23
Final Fee 2022-05-13 $305.39 2022-04-22
Maintenance Fee - Patent - New Act 6 2022-08-12 $203.59 2022-07-22
Maintenance Fee - Patent - New Act 7 2023-08-14 $210.51 2023-06-21
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
US WELL SERVICES LLC
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Examiner Requisition 2020-08-31 4 184
Amendment 2020-12-30 42 2,123
Description 2020-12-30 15 775
Claims 2020-12-30 3 99
Examiner Requisition 2021-04-01 4 224
Electronic Grant Certificate 2022-07-12 1 2,527
Amendment 2021-08-03 14 666
Claims 2021-08-03 3 105
Final Fee 2022-04-22 5 140
Representative Drawing 2022-06-15 1 8
Cover Page 2022-06-15 1 44
Cover Page 2017-01-31 1 46
Abstract 2016-08-12 1 22
Description 2016-08-12 18 724
Claims 2016-08-12 3 95
Drawings 2016-08-12 2 35
Representative Drawing 2017-01-17 1 10
Request for Examination 2019-07-26 1 46
Assignment 2016-08-12 3 118