Patent · US12134961B2 · B2 · US

Method and system for metering proppant

(11) Publication number

US12134961B2

(21) Application number

17/862,204

(22) Filing date

2022-07-11

(30) Priority date

2020-06-30

(43) Publication date

2024-11-05

(45) Date of grant

2024-11-05

(51) IPC

B65G 43/00; B65G 65/42; E21B 21/06; E21B 43/16; E21B 43/26; E21B 43/267

(52) CPC

E21B Earth or rock drilling; obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells: 43/16, 21/06, 43/2607, 43/267
B65G Transport or storage devices, e.g. conveyors for loading or tipping, shop conveyor systems or pneumatic tube conveyors: 43/00, 65/34, 65/42
G01G Weighing: 11/08

(73) Assignee

NexStage LLC

(72) Inventors

Jared Hindman; Roy Richmond

(54) Title

Method and system for metering proppant

(57) Abstract

A method and system for metering proppant discharged from a storage container is disclosed. In certain embodiments, a method may comprise loading a known amount of a first proppant type into a storage container, detecting proppant at or adjacent to a discharge outlet of the storage container via one or more sensors coupled to the storage container, operating a metering device at a predetermined speed, wherein the metering device may be coupled to the discharge outlet of the storage container, and wherein the metering device may comprise one or more pockets for receiving the first proppant type. In certain embodiments, the method may further comprise dispensing a known amount of the first proppant type from the storage container via the metering device, wherein an encoder coupled to the metering device may emit pulses during the dispensing. In certain embodiments, the method may further comprise determining an amount of the first proppant type dispensed by at least one pocket of the one or more pockets of the metering device based at least in part on the pulses and determining a relationship between the known amount of the first proppant type dispensed by each pocket and a speed of the metering device.

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Claims (20)

A method comprising: coupling a metering device to a storage container, wherein the metering device comprises one or more pockets; loading the storage container with a first amount of a first proppant; calibrating the metering device for the first proppant by dispensing a second amount of the first proppant via the metering device at two or more speeds, wherein the calibrating is based at least in part on a number of pulses emitted by an encoder coupled to the metering device; and operating the metering device for the first proppant based on the calibrating step.
The method of claim 1, wherein the calibrating step comprises dispensing the second amount of the first proppant via the metering device at three or more speeds of the metering device.
The method of claim 1, wherein the calibrating step further comprises calculating an amount of the first proppant dispensed by at least one of the one or more pockets based at least in part on the second amount of the first proppant dispensed by the metering device and the number of pulses emitted by the encoder.
The method of claim 3, wherein the calibrating step further comprises determining a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the two or more speeds of the metering device.
The method of claim 4, further comprising: loading the storage container with a third amount of a second proppant; and calibrating the metering device for the second proppant based on the relationship between the calculated amount of the first proppant dispensed per pocket and the two or more speeds of the metering device.
The method of claim 1, further comprising determining a weight of the first proppant dispensed by at least one of the one or more pockets.
The method of claim 6, further comprising calculating a total amount dispensed of the first proppant based at least in part on the determined weight of the first proppant dispensed by at least one of the one or more pockets.
The method of claim 7, wherein calculating the total dispensed amount of the first proppant further comprises adding a residual amount of the first proppant associated with a time period when the metering device is slowing to a stop.
A system comprising: a storage container; a metering device coupled to the storage container, wherein the metering device comprises one or more pockets for receiving proppant; an encoder coupled to the metering device, wherein the encoder emits one or more pulses; and a control unit coupled to the metering device, wherein the control unit is configured to calibrate the metering device for a first proppant based at least in part on a dispensed first amount of the first proppant at two or more speeds and on the one or more pulses.
The system of claim 9, wherein the control unit is further configured to calibrate the metering device for a first proppant based at least in part on a dispensed first amount of the first proppant at three or more speeds and on the one or more pulses.
The system of claim 9, wherein the control unit is further configured to calculate an amount of the first proppant dispensed per pocket based at least in part on the dispensed first amount of the first proppant at the two or more speeds and on the one or more pulses.
The system of claim 11, wherein the control unit is further configured to determine a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the speed of the metering device.
The system of claim 9, wherein the control unit is further configured to determine a weight of the first proppant dispensed by at least one of the one or more pockets.
The system of claim 13, wherein the control unit is further configured to calculate a total amount dispensed of the first proppant based, at least in part, on the determined weight of the first proppant dispensed by at least one of the one or more pockets.
The system of claim 14, wherein the control unit is further configured to calculate the total dispensed amount of the first proppant further comprises adding a residual amount of the first proppant associated with a time period when the metering device is slowing to a stop.
A method comprising: coupling a metering device to a storage container, wherein the metering device comprises one or more pockets; loading the storage container with a first amount of a first proppant; calibrating the metering device for the first proppant by dispensing a second amount of the first proppant via the metering device at two or more speeds, wherein the calibrating is based at least in part on a number of pulses emitted by an encoder coupled to the metering device; calculating an amount of the first proppant dispensed by at least one of the one or more pockets based at least in part on the second amount of the first proppant dispensed by the metering device and the number of pulses emitted by the encoder; loading the storage container with a third amount of a second proppant; calibrating the metering device for the second proppant based on a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the two or more speeds of the metering device; and operating the metering device for one or more of the first proppant and the second proppant based on one or more of the calibrating of the metering device for the first proppant and the calibrating of the metering device for the second proppant.
The method of claim 16, further comprising calculating a total amount dispensed of one or more of the first proppant and the second proppant based, at least in part, on the calibrating of the metering device for the first proppant and the calibrating of the metering device for the second proppant.
The method of claim 17, wherein calculating the total amount dispensed of one or more of the first proppant and the second proppant further comprises adding a residual amount of one or more of the first proppant and the second proppant associated with a time period when the metering device is slowing to a stop.
The method of claim 16, wherein the calibrating step for the first proppant comprises dispensing the second amount of the first proppant via the metering device at three or more speeds of the metering device.
The method of claim 16, wherein the calibrating step for the first proppant comprises determining a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the two or more speeds of the metering device.

Description

This invention relates to a method and system for metering proppant discharged from a storage container.

Large quantities of particulate material commonly referred to as “proppant” are often needed to support fracturing operations. The ability to meter the amount of proppant used to sufficiently support well operations is therefore beneficial. Currently, present methods often involve measuring the amount of proppant in a storage container, for example, a silo, based on the weight of the filled storage container using a load cell. However, load cells may be susceptible to inaccuracies due to environmental factors, such as an uneven ground or changes in ambient temperature and may also need to be recalibrated on a frequent basis. Other methods of measuring the amount of proppant in a silo include using a level sensor, which are also unreliable. Level sensors only measure a level of proppant at a single point at a given time, and therefore, may be susceptible to inaccuracies due to uneven levels of proppant. For example, as proppant is filled into a silo, a vertical cone may form about the center of the silo, and as proppant is drained from a silo, an inverted vertical cone may form about the center of the silo. Thus, a level sensor may be susceptible a high variance based on the shape of the proppant in the silo and may not provide accurate measurements.

Another issue with present systems is the need to both load proppant into storage containers while simultaneously unloading proppant for transport to blenders, mixers, or other equipment.

Citations (25)

US3981417A
US4520677A
US4528848A
US5394747A
US5253535A
US5697488A
US5725160A
US20090142147A1
US9545616B2
US20180141012A1
US11512989B2
US20210156719A1
US10975677B2
US20200187547A1
US20190144216A1
US11643287B2
US20190277129A1
US11560780B2
US10989018B2
US20200262641A1
US11286116B2
US11880804B1
US20220081231A1
US20230348177A1
US11821298B1

Record as JSON

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  "publication_number": "US12134961B2",
  "country": "US",
  "kind": "B2",
  "title": "Method and system for metering proppant",
  "abstract": "A method and system for metering proppant discharged from a storage container is disclosed. In certain embodiments, a method may comprise loading a known amount of a first proppant type into a storage container, detecting proppant at or adjacent to a discharge outlet of the storage container via one or more sensors coupled to the storage container, operating a metering device at a predetermined speed, wherein the metering device may be coupled to the discharge outlet of the storage container, and wherein the metering device may comprise one or more pockets for receiving the first proppant type. In certain embodiments, the method may further comprise dispensing a known amount of the first proppant type from the storage container via the metering device, wherein an encoder coupled to the metering device may emit pulses during the dispensing. In certain embodiments, the method may further comprise determining an amount of the first proppant type dispensed by at least one pocket of the one or more pockets of the metering device based at least in part on the pulses and determining a relationship between the known amount of the first proppant type dispensed by each pocket and a speed of the metering device.",
  "claims": [
    "1. A method comprising: coupling a metering device to a storage container, wherein the metering device comprises one or more pockets; loading the storage container with a first amount of a first proppant; calibrating the metering device for the first proppant by dispensing a second amount of the first proppant via the metering device at two or more speeds, wherein the calibrating is based at least in part on a number of pulses emitted by an encoder coupled to the metering device; and operating the metering device for the first proppant based on the calibrating step.",
    "2. The method of claim 1, wherein the calibrating step comprises dispensing the second amount of the first proppant via the metering device at three or more speeds of the metering device.",
    "3. The method of claim 1, wherein the calibrating step further comprises calculating an amount of the first proppant dispensed by at least one of the one or more pockets based at least in part on the second amount of the first proppant dispensed by the metering device and the number of pulses emitted by the encoder.",
    "4. The method of claim 3, wherein the calibrating step further comprises determining a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the two or more speeds of the metering device.",
    "5. The method of claim 4, further comprising: loading the storage container with a third amount of a second proppant; and calibrating the metering device for the second proppant based on the relationship between the calculated amount of the first proppant dispensed per pocket and the two or more speeds of the metering device.",
    "6. The method of claim 1, further comprising determining a weight of the first proppant dispensed by at least one of the one or more pockets.",
    "7. The method of claim 6, further comprising calculating a total amount dispensed of the first proppant based at least in part on the determined weight of the first proppant dispensed by at least one of the one or more pockets.",
    "8. The method of claim 7, wherein calculating the total dispensed amount of the first proppant further comprises adding a residual amount of the first proppant associated with a time period when the metering device is slowing to a stop.",
    "9. A system comprising: a storage container; a metering device coupled to the storage container, wherein the metering device comprises one or more pockets for receiving proppant; an encoder coupled to the metering device, wherein the encoder emits one or more pulses; and a control unit coupled to the metering device, wherein the control unit is configured to calibrate the metering device for a first proppant based at least in part on a dispensed first amount of the first proppant at two or more speeds and on the one or more pulses.",
    "10. The system of claim 9, wherein the control unit is further configured to calibrate the metering device for a first proppant based at least in part on a dispensed first amount of the first proppant at three or more speeds and on the one or more pulses.",
    "11. The system of claim 9, wherein the control unit is further configured to calculate an amount of the first proppant dispensed per pocket based at least in part on the dispensed first amount of the first proppant at the two or more speeds and on the one or more pulses.",
    "12. The system of claim 11, wherein the control unit is further configured to determine a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the speed of the metering device.",
    "13. The system of claim 9, wherein the control unit is further configured to determine a weight of the first proppant dispensed by at least one of the one or more pockets.",
    "14. The system of claim 13, wherein the control unit is further configured to calculate a total amount dispensed of the first proppant based, at least in part, on the determined weight of the first proppant dispensed by at least one of the one or more pockets.",
    "15. The system of claim 14, wherein the control unit is further configured to calculate the total dispensed amount of the first proppant further comprises adding a residual amount of the first proppant associated with a time period when the metering device is slowing to a stop.",
    "16. A method comprising: coupling a metering device to a storage container, wherein the metering device comprises one or more pockets; loading the storage container with a first amount of a first proppant; calibrating the metering device for the first proppant by dispensing a second amount of the first proppant via the metering device at two or more speeds, wherein the calibrating is based at least in part on a number of pulses emitted by an encoder coupled to the metering device; calculating an amount of the first proppant dispensed by at least one of the one or more pockets based at least in part on the second amount of the first proppant dispensed by the metering device and the number of pulses emitted by the encoder; loading the storage container with a third amount of a second proppant; calibrating the metering device for the second proppant based on a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the two or more speeds of the metering device; and operating the metering device for one or more of the first proppant and the second proppant based on one or more of the calibrating of the metering device for the first proppant and the calibrating of the metering device for the second proppant.",
    "17. The method of claim 16, further comprising calculating a total amount dispensed of one or more of the first proppant and the second proppant based, at least in part, on the calibrating of the metering device for the first proppant and the calibrating of the metering device for the second proppant.",
    "18. The method of claim 17, wherein calculating the total amount dispensed of one or more of the first proppant and the second proppant further comprises adding a residual amount of one or more of the first proppant and the second proppant associated with a time period when the metering device is slowing to a stop.",
    "19. The method of claim 16, wherein the calibrating step for the first proppant comprises dispensing the second amount of the first proppant via the metering device at three or more speeds of the metering device.",
    "20. The method of claim 16, wherein the calibrating step for the first proppant comprises determining a relationship between the calculated amount of the first proppant dispensed by at least one of the one or more pockets and the two or more speeds of the metering device."
  ],
  "description_excerpt": "This invention relates to a method and system for metering proppant discharged from a storage container.\n\nLarge quantities of particulate material commonly referred to as “proppant” are often needed to support fracturing operations. The ability to meter the amount of proppant used to sufficiently support well operations is therefore beneficial. Currently, present methods often involve measuring the amount of proppant in a storage container, for example, a silo, based on the weight of the filled storage container using a load cell. However, load cells may be susceptible to inaccuracies due to environmental factors, such as an uneven ground or changes in ambient temperature and may also need to be recalibrated on a frequent basis. Other methods of measuring the amount of proppant in a silo include using a level sensor, which are also unreliable. Level sensors only measure a level of proppant at a single point at a given time, and therefore, may be susceptible to inaccuracies due to uneven levels of proppant. For example, as proppant is filled into a silo, a vertical cone may form about the center of the silo, and as proppant is drained from a silo, an inverted vertical cone may form about the center of the silo. Thus, a level sensor may be susceptible a high variance based on the shape of the proppant in the silo and may not provide accurate measurements.\n\nAnother issue with present systems is the need to both load proppant into storage containers while simultaneously unloading proppant for transport to blenders, mixers, or other equipment.",
  "cpc": [
    "E21B 43/16",
    "B65G 43/00",
    "B65G 65/34",
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    "E21B 21/06",
    "E21B 43/2607",
    "E21B 43/267",
    "G01G 11/08"
  ],
  "ipc": [
    "B65G 43/00",
    "B65G 65/42",
    "E21B 21/06",
    "E21B 43/16",
    "E21B 43/26",
    "E21B 43/267"
  ],
  "assignees": [
    "NexStage LLC"
  ],
  "inventors": [
    "Jared Hindman",
    "Roy Richmond"
  ],
  "filing_date": "2022-07-11",
  "publication_date": "2024-11-05",
  "grant_date": "2024-11-05",
  "priority_date": "2020-06-30",
  "application_number": "US-202217862204-A",
  "family_id": "78958387",
  "cited_by_count": 0,
  "citations": [
    "US3981417A",
    "US4520677A",
    "US4528848A",
    "US5394747A",
    "US5253535A",
    "US5697488A",
    "US5725160A",
    "US20090142147A1",
    "US9545616B2",
    "US20180141012A1",
    "US11512989B2",
    "US20210156719A1",
    "US10975677B2",
    "US20200187547A1",
    "US20190144216A1",
    "US11643287B2",
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}

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