TECHNICAL FIELD

The present disclosure relates generally to transferring materials from a transport unit or vehicle to a destination at a site, and more particularly, to a configuration of a flexible auger for transferring materials from a transport unit or vehicle to a destination at a site.

BACKGROUND

During the drilling and completion of hydrocarbon wells such as oil and gas wells, various wellbore treating fluids are used for any number of purposes. For example, high viscosity gels are used to create fractures in oil and gas bearing formations to increase production. High viscosity and high density gels are also used to maintain positive hydrostatic pressure in the well while limiting flow of well fluids into earth formations during installation of completion equipment. High viscosity fluids are used to flow sand into wells during gravel packing and stimulation operations. The high viscosity fluids are normally produced by mixing dry powder and/or granular materials and agents with water at the well site as they are needed for a particular treatment. Systems for metering and mixing the various materials are normally portable, for example, skid- or truck-mounted, since they are needed for only short periods of time at a well site.

Materials required at a site are normally or generally transported to a site in or on a transport unit or vehicle including but not limited to a commercial or common carrier tank truck, train, container on a trailer, a railcar or any other type of transport unit. Once the transport unit or vehicle and mixing system are at the site, the material (for example, bulk material) must be transferred or conveyed from the transport unit or vehicle into a blender or a supply tank for metering into a blender as needed. The material is usually transferred from the transport unit or vehicle pneumatically. For example, the material may be blown pneumatically from the transport unit or vehicle into an on-location storage/delivery system (for example, a silo, or any other container, storage system or material handling system). The storage/delivery system may then deliver the material onto a conveyor or into a hopper, which meters the bulk through a chute into a blender tub or any other destination at the site.

Currently, material, for example, sand or proppant, required at a hydrocarbon recovery site is handled using a multi-bin delivery truck/trailer (for example, a Fruehauf multi-bin delivery truck) or by containers delivered to the site. These delivery trucks transfer the material using a pneumatic system that blows the material into a material handling system or storage system at the site. However, this type of transfer takes an extended period of time and requires equipment and personnel to control or handle environmental conditions due to the transfer of the material. Further, the materials may not be able to be replenished in the time required to complete a job or to maintain a rate of transfer due to the delay in transferring the material. As the required amount of material per minute increases, the delays of transferring materials using delivery trucks become a drain on productivity of the operation and increases costs. Recently, to resolve this delay issue, the use of containers to continuously deliver the materials to blenders has been used. However, the continued increase in sand delivery rates as process efficiencies are pushed to the limit requires improved systems and methods that eliminate certain safety issues, for example, the need for faster movement of containers using forklifts. Providing a more robust and efficient material transfer configuration is required to address the safety, productivity, environmental and cost issues associated with the present systems.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a block diagram of a flexible auger material handling system for transferring material to a blender system, in accordance with one or more aspects of the present disclosure;

FIG. 2A is a block diagram of a flexible auger material handling system for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure;

FIG. 2B is a block diagram of a flexible auger material handling system for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure;

FIG. 3 is a block diagram of a trough-based flexible auger material handling system for transferring material to a blender system, in accordance with an embodiment of the present disclosure;

FIG. 4 is a block diagram of a trough-based flexible auger material handling system for transferring material to a blender system, in accordance with an embodiment of the present disclosure;

FIG. 5 is a block diagram of a flexible auger material handling system for transferring material to a blender system, in accordance with one or more aspects of the present disclosure;

FIG. 6 is a block diagram of a flexible auger material handling system for transferring material to a blender system, in accordance with one or more aspects of the present disclosure;

FIG. 7 is a block diagram of a flexible auger material handling system for transferring material to a blender system, in accordance with one or more aspects of the present disclosure;

FIG. 8A is a block diagram of a trough-based flexible auger material handling system for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure;

FIG. 8B is a block diagram of a trough-based flexible auger material handling system for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure;

FIG. 8C is a block diagram of a trough-based flexible auger material handling system for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure; and FIG. 9 is a block diagram of a trough-based flexible auger material handling system for transferring material at a site, in accordance with one or more aspects of the present disclosure.

DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve developers’ specific goals, such as compliance with system related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure. Furthermore, in no way should the following examples be read to limit, or define, the scope of the disclosure.

Throughout this disclosure, a reference numeral followed by an alphabetical character refers to a specific instance of an element and the reference numeral alone refers to the element generically or collectively. Thus, as an example (not shown in the drawings), widget“1 A” refers to an instance of a widget class, which may be referred to collectively as widgets“1” and any one of which may be referred to generically as a widget“1”. In the figures and the description, like numerals are intended to represent like elements.

Certain embodiments according to the present disclosure may be directed to systems and methods for efficiently managing transfer of material or bulk material (for example, solid or mostly solid with liquid material). Material handling systems are used in a wide variety of contexts including, but not limited to, drilling and completion of hydrocarbon wells (for example, oil and gas wells), concrete mixing applications, agriculture and others. The disclosed embodiments are directed to systems and methods for safe, efficient and cost-effective transfer of material from a job site or a hydrocarbon, well services or operation site to a desired destination at, for example, to a blender, storage system or material handling system.

In currently existing on-site bulk material handling applications, dry material (for example, sand, proppant, plugging agents, gel particulate, or dry-gel particulate) may be used during the formation of treatment fluids, for example, for a stimulation operation, perforation operation or a plug operation. In such applications, the bulk material is often transferred between transportation units, storage tanks, blenders, and other on-site components via pneumatic transfer, sand screws, chutes, conveyor belts, and other components. In certain applications, the material is stored in containers and these containers are brought in on trucks, unloaded, stored on location, and manipulated about the site as the material is needed.

Unfortunately, release of material from these containers can generate, produce or release a relatively large amount of dust or particulates into the surrounding environment if not configured properly and result in unintended material spillage. In addition, the mechanical conveying system of these containers is generally run on auxiliary power and, therefore, requires an external power source to feed the bulk material from the material storage units to the blender. Also, the weight of the containers combined with the speed and elevation at which the containers must be manipulated around a site pose risks to personnel and equipment at a site. Further, such systems must operate with precision movement and timing to meet the parameters or criteria of an operation.

The flexible auger material transfer systems having one or more configurations disclosed herein are designed to address and eliminate the shortcomings associated with existing bulk material handling systems. Particles or dust emissions are prevented or minimized. Personnel, costs, operation time and machinery or equipment requirements may be reduced as the flexible auger configuration removes the need for site-based transport units such as forklifts. For example, one or more systems may include a multi-stage, flexible or bendable or both flexible and bendable auger system that conveys, transfers or transports material to a destination at a job site using a flexible coreless auger in a conduit that is flexible, bendable or both. For example, a stimulation operation at a site may require that a material such as sand or other proppant be available in a quantity and at a rate to support the required parameters or criteria of the stimulation operation. A flexible auger configuration provides transfer or transport of the required material at a rate that not only meets the required job parameters or criteria but also provides a configurable, safe, efficient and cost-effective system. The material during transfer is contained within a conduit and thus unwanted or undesirable particulates or emissions are controlled. The present disclosure provides a flexible auger material transfer system to efficiently and cost-effectively handle transfer or conveyance of any desirable material having a solid, solid with a liquid constituency, any other material or substance conveyable or transferable via a flexible coreless auger, or any combination thereof including, but not limited to, any one or more of water, cement, cement powder, sand, proppant, gel particulate, diverting agent, stimulation fluid, slurry, mud, mortar, concrete, dry-gel particulate, liquid additives, any other material or combination thereof from one location to any desired destination or location at a site without the need for or at a reduced need for additional personnel, equipment or environmental control systems.

Turning now to the drawings, FIG. 1 is a block diagram of a flexible auger material handling system 100 at, for example, a hydrocarbon, such as oil, well services or operations site for transferring material from a material handling system to a blender system 104, in accordance with one or more aspects of the present disclosure. The system 100 comprises a storage vessel or tank 102 on or about a transport unit or vehicle 118 for holding material 114, transporting material 1 14, transferring material 114 or any combination thereof, one or more auger conduits 1 10 comprising one or more augers 124, a conduit 107, one or more auger couplings 126, a blender system 104 and a transport unit or vehicle 120. In one or more embodiments, storage vessel or tank 102 may comprise any type of material handling system or a storage system including, but not limited to, a tank, a container, a cement container or any other type of material handling or storage system or combination thereof. Storage vessel or tank 102 and transport unit or vehicle 118 may be a single unit or vehicle such that the storage vessel or tank 102 is integrated with the transport unit or vehicle 118. Transport unit or vehicle 118 may comprise a trailer, a tractor trailer, a truck, a train, a rail car, any other vehicle or transportation mechanism or any combination thereof. In one or more embodiments, transport unit or vehicle 118 may comprise one or more wheels. In one or more embodiments, transport unit or vehicle 118 may comprise a hopper 116 or hopper 116 may be coupled to transport unit or vehicle 118, storage vessel or tank 102 or both. In one or more embodiments, hopper 116 may be stationary at a surface 103 at any location at a site, for example, a hydrocarbon exploration operation, recovery operation, production operation or any combination thereof at a site. Storage vessel or tank 102 may comprise a material 114 for use in a hydrocarbon exploration, recovery or production operation, such as a stimulation operation or any other operation, at a site. Material 1 14 may comprise a solid, a solid and a liquid that forms a substantially solid material, any other material or substance conveyable or transferable via an auger 124, or any combination thereof. In one or more embodiments, material 114 comprises any one or more of water, cement, cement powder, mud, sand, slurry, stimulation fluid, concrete, mortar, proppant, gel particulate, for example, a dry-gel particulate, diverting agent, liquid additive, any composition, mixture or additive require for a particular operation or any other solid, solid and liquid or combination thereof.

In one or more embodiments hopper 116 may comprise an auger connector 108, such as a rapid auger connect or quick connect. Auger connector 108 prevents any one or more environmental conditions from affecting the material 114 and provides an efficient or quick connection to any one or more auger conduits 110 at a site, such as auger conduit 110. In one or more embodiments, an auger conduit l lOa is disposed or positioned proximate to the storage vessel or tank 102. For example, the auger connector 108 couples to the hopper 116 and conduit

107 to allow material 114 dispensed into the hopper 116 to be conveyed through a conduit 107 to one or more auger conduits 110 (for example, an auger conduit l lOa). In one or more embodiments, auger connector 108 provides a quick connection or hookup between the hopper 116 and conduit 107. In one or more embodiments, auger connector 108 may automatically couple to conduit 107 or may be manually coupled to conduit 107. In one or more embodiments, conduit 107 comprises a casing, pipe, tube or hose that may be flexible or stiff. In one or more embodiments, conduit 107 gravity feeds material 114 to auger conduit l lOa. In one or more embodiments, an auger 124 may be actuated to transfer or convey material 114 to some other auger 124. In one or more embodiments, a conduit 107 may comprise an auger conduit 1 10 such that conduit 107 auger feeds material 114 to auger conduit 110a. In one or more embodiments, conduit 107, auger conduit 1 10 or both may comprise acrylic or polycarbonate pipes, carbon fiber or other fiber conduits, a casing, a casing coated with a hard surfacing materials including, but not limited to, carbide, polypropylene or any other suitable substance of material.

In one or more embodiments, any one or more auger conduits 1 10 may comprise an auger 124 such that auger 124 is enclosed completely, substantially completely or partially by an outer surface of the auger conduit 110. FIG. 1 depicts auger conduit 110 with a portion or section exposed for illustration purposes such that the auger 124 is viewable. In one or more embodiments, auger conduit 110 comprises an auger opening or coupling 126 at one or both ends such that a material can be received at one end of the auger conduit 110 and conveyed through an opposite end of the auger conduit 110. For example, an auger 124 of an auger conduit 110 may be actuated, for example, by an auger motor 106, such that auger 124 rotates to transfer the material from a first end of the auger conduit 1 10 to a second end of the auger conduit 110. In one or more embodiments, auger conduit 110 is a flexible auger conduit and auger 124 is a flexible coreless auger. A flexible coreless auger allows for the auger conduit 110 to be flexible or bendable. For example, a flexible coreless auger, such as auger 124, may be used that traverses short distances at generally no more than forty-five degree bends without affecting or substantially affecting efficiency of the transfer of the material 1 14. A flexible coreless auger, such as auger 124, allows for use of flexible or bendable auger conduit 110, provides less friction to rotating parts, allows mulling of dry chemical (for example, to coat a material 114 that comprises a proppant) and allows for efficiency boosting by starting the transfer of material 114 at horizontal or downward slopes. Auger conduit 110 may be any length or width as is suitable for a given auger 123, operation, configuration or site. In one or more embodiments, large bend radii coreless augers 110 may be used to improve fatigue life of the augers 110. In one or more embodiments, auger opening or coupling 126 couples to an auger motor 106, such as l06a or 106h. In one or more embodiments, an auger motor 106 couples directly or indirectly to an auger conduit 110. In one or more embodiments, an auger motor 126 is in line with, disposed about or adjacent to an auger conduit 110. Auger motor 106 may be any type of motor suitable for actuating, powering, turning or rotating an auger, such as, auger 124. Auger motor 106 may comprise an electric motor. Auger motor 106 may be powered using any suitable power source.

In one or more embodiments, an additive material handling system 112 may couple via an auger conduit 110b to auger conduit l lOa. Additive material handling system 112 may comprise an additive 122. Additive 122 may comprise any one or more of dry additives such as dry gel, acids, MicroScout®, or small amounts of liquid additives such as proppant coating materials, SandWedge®, and the like. Auger conduit 110b may be disposed at an angle, horizontal or otherwise to auger conduit 110a to convey or transfer additive 122. Auger conduit 110b conveys or transports additive 122 via auger 124b to auger conduit 126. In one or more embodiments, additive material handling system 112 may comprise an auger motor 106, such as auger motor l06a, and may actuate, rotate or turn auger l24b when actuated. As the motor 106 rotates or turns auger 124b, the additive 122 is mixed or combined with the material 1 14 from conduit 107. Auger conduit 124b may be coupled to auger motor 106a, any other auger motor (not shown), or any other power source suitable to actuate, rotate or turn auger 124b.

In one or more embodiments, the material 114, additive 122, or any combination thereof is conveyed or transferred to blender system 104 via auger l24a of auger conduit 1 lOa. In one or more embodiments, motor l06a or any other motor may actuate auger l24a to transfer material 114, additive 122 or both to another location. Auger conduit 1 lOa may be disposed or positioned below or within surface 103. Surface 103 may comprise a subsurface 105. Subsurface 105 may comprise a terrain, a sub-terrain or a formation or any combination thereof. In one or more embodiments, surface 103 may be a raised surface such that the subsurface 105 is above ground level but within surface 103 such that any equipment or components are protected from wear and tear. While auger conduit 110a is shown disposed or positioned below surface 103 in subsurface 105, the present disclosure contemplates that any one or more portions of auger conduit l lOa may be disposed above the surface 103, for example, horizontally disposed along surface 103.

An auger motor 106n may couple to auger conduit 11 On via an auger coupling 126 or may couple directly to auger conduit 110h. Auger coupling 126 may couple auger conduit 110h to auger conduit 110a. Auger conduit 11 On may comprise an auger 124n. When auger motor 106h is actuated, auger 124h is actuated, rotated or turned and the material 114, the additive 122 or both are conveyed or transferred from auger conduit l lOa through auger conduit 11 On to or into the blender system 104 via blender input 128. Blender input 128 may be an opening, a metering gate or any other input that allows for any mixture, composition, material or substance to be conveyed or transferred into the blender system 104. Blender system 104 may be disposed or positioned on or about a transport unit or vehicle 120. Blender system 104 and transport unit or vehicle 120 may be a single unit or vehicle such that the blender system 104 is integrated with the transport unit or vehicle 120. Transport unit or vehicle 120 may comprise a trailer, a tractor trailer, a truck, a rail car, any other vehicle or transportation mechanism or any combination thereof. In one or more embodiments, transport unit or vehicle 120 may comprise one or more wheels.

In one or more embodiments, any one or more storage vessels or tanks 102, transport units or vehicles 118, blender systems 104, transport units or vehicles 120 or any combination thereof may be positioned or disposed at any location at a site. In one or more embodiments, any one or more auger conduits 1 lOa may couple any one or more storage vessels or tanks 102 to any one or more blender systems 104. In one or more embodiments, any one or more auger conduits 1 10 may comprise any one or more augers 124. In one or more embodiments, any one or more auger conduits 110 may couple to any one or more motors 106. In one or more embodiments, any one or more additive material handling systems 112 may be disposed or positioned on or about any one or more transport units or vehicles 118, one or more transport units or vehicles 120 or any other location at a site. In one or more embodiments, any one or more auger conduits 110b may couple any one or more auger additive material handling systems 112 to any one or more auger conduits 1 10a.

FIG. 2A is a block diagram of a flexible auger material handling system 200 at, for example, a hydrocarbon, such as oil, well services and operation site, for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure. One or more components in FIG. 2A operate in a similar manner to like components discussed above with respect to FIG. 1. The flexible auger material handling system 200 comprises a storage vessel or tank 102 on or about a transport unit or vehicle 1 18 positioned or disposed on a bridge or ramp 202 proximate to a trough 212, a hopper 116, a material handling system, for example, silo or storage bin 204, a blender system 104 as illustrated in FIG. 1, any other material handling or storage system or combination thereof, one or more auger conduits 1 lOc, 1 lOd and

1 lOm, and one or more auger motors l06c, 106d and l06m coupled to one or more auger augers l06c, l06d and l06m, respectively. Hopper 116 receives material 114 and dispenses or conveys material 1 14 to or into the trough 212. For example, hopper 116 may gravity feed the material 1 14 to or into the trough 212.

In one or more embodiments, the transport unit or vehicle 1 18 may be positioned on the bridge 202 such that the transport unit or vehicle 1 18 traverses the bridge 202 to position the storage vessel or tank 102 above a hopper 1 16 that has been positioned or disposed within, inside, about or above a trough 212. In one or more embodiments, the hopper 1 16 is integral to any one or more of the storage vessel or tank 102 and the transport unit or vehicle 1 18. In one or more embodiments, the hopper 1 16 may be positioned or disposed within, inside, about or above trough 212 before, after or during positioning of the storage vessel or tank 102 on the bridge 202. In one or more embodiments, bridge 202 may be any suitable height or width for a given operation, configuration or site. In one or more embodiments, bridge 202 may form the sides of trough 212 or may traverse at least a portion of trough 212.

An auger conduit 1 lOc may be coupled to a motor l06c. A portion of the auger conduit 1 lOc may be disposed below the trough 212 while another portion of the auger conduit 1 lOc may exit the trough 212 and may extend upward towards a silo or storage bin 204. The angle of auger conduit 1 lOc may be any suitable angle, for example, an angle such that a sufficient length of the conduit is either in a downward slope or horizontal prior to the angle. In one or more embodiments, a suitable angle for a portion of the auger conduit l lOc to provide efficient transfer of material 1 14 may be at or less than forty-five degrees. Auger conduit l lOc may comprise an auger 124c. Material 114 may be released or dispensed from storage vessel or tank 102 through hopper 116 to trough 212 at any rate. For example, hopper 116 may comprise a metering gate or valve to meter material 114, material 1 14 may be dispensed or released from storage vessel or tank 102 until the material 1 14 in trough 212 prevents any additional material 1 14 from being released or dispensed, any other method or process may be used to control the rate of release of material 1 14, or any combination thereof. In one or more embodiments, hopper 1 16 may comprise a dump mechanism that is automatically metered by any stagnant material 1 14 that builds up when trough 212 is at capacity.

In one or more embodiments, a strip 206 may cover or substantially cover a top outer surface of the auger conduit 1 10c to protect the auger conduit 110c from wear and tear and to provide a safe environment. Strip 206 may be beveled or rounded or may fit the curvature of the auger conduit 1 lOc. Strip 206 may have a width such that conduit 1 lOc is protected from being crushed by any heavy equipment traffic. In one or more embodiments, auger conduit 1 lOc may be disposed below a surface as discussed with respect to FIG. 1.

Auger conduit 110c may be coupled to an auger conduit 11 Od. Auger motor 106d may couple to the auger conduit l lOd and may be actuated to actuate, rotate or turn auger l24d. Auger motor l06c may be actuated to actuate, turn or rotate auger l24c of auger conduit l lOc which conveys or transfers material 114 to auger conduit l lOd. Auger motor l06d may be actuated to actuate, turn or rotate auger l24d to convey or transfer material 114 into silo or storage bin 204. Auger conduit l lOd may comprise one or more openings 214. As the auger l24d conveys or transfers the material 114, the material 114 is dispensed or exits from the auger conduit 1 lOd via the one or more openings 214 which may be spaced at any interval along auger conduit l lOd. For example, when the material 114 reaches a first opening 214, actuation, rotation or turning of the auger 124d causes the material 114 to dispense into the silo or storage bin 204 until the material covers or prevents any additional material 114 from dispensing in which case the auger l24d conveys or transfers remaining material 114 through the auger conduit l lOd to a second opening 214 where the material 1 14 is dispensed or exits from the auger conduit l lOd into the silo or storage bin 204. This process may continue until all or a determined amount of material 114 has been transferred into the silo or storage bin 204 or the silo or storage bin 204 has reached a capacity for holding material 114. Auger conduit 1 lOd may extend to any height within silo or storage bin 204 to convey or transfer material 114 into the silo or storage bin 204 as material 210.

Silo or storage bin 204 may hold or store a material 210. In one or more embodiments, silo or storage bin 204 may be portable or mobile such that it is trucked or transported to a location or site on a trailer or support structure 220 in a horizontal configuration and then is erected to a vertical configuration as illustrated in FIG. 2A. In current configurations, a silo may be filled with material, for example, sand, by blowing the material into the silo using a pneumatic system, for example, a Fruehauf pneumatic trailer. Such a process is slow and may take days to fill the silo with the required material. The flexible auger material handling system 200 of FIG. 2A and other embodiments discussed herein provide more efficient and expedient systems for transferring material to a destination, such as a silo or storage bin 204 or any other destination at a site.

In one or more embodiments, material 210 is the same as material 114. In one or more embodiments, material 210 may comprise material 114 combined with another material, solid, fluid, any other substance or combination thereof. For example, material 114 may be combined with another material as discussed with respect to FIG. 1. In one or more embodiments, material 210 may be dispensed from silo or storage bin 204 via auger conduit l lOm. Auger conduit 110m may comprise an auger l24m. Auger conduit l24m may be coupled to a motor l06m. As motor l06m actuates, turns or rotates auger l24m, material 210 may be dispensed or transferred through a pipe or tubing 208 to a blender system 104. In one or more embodiments, any one or more auger conduits 110 may be coupled to any one or more motors 106 and any one or more auger conduits 110 may comprise any one or more augers 124. In one or more embodiments, any one or more of auger conduits 1 lOd and 1 lOm may be permanently or removably coupled to or installed in silo or storage bin 204. In one or more embodiments, auger conduit l lOd may traverse an interior of the silo or storage bin 204 at any angle or vertically.

FIG. 2B illustrates a block diagram of a flexible auger material handling system 250 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material to a material handling system, in accordance with one or more aspects of the present disclosure. FIG. 2B is similar to FIG. 2A except that auger conduit l lOd may be coupled to or installed vertically or substantially vertically on an exterior surface of silo or storage bin 204 with auger conduit l lOd having one or more openings 214 so that material 114 may be transferred or conveyed into a port 216 of silo or storage bin 204. For example, silo or storage bin 204 may be disposed, positioned, transported or any combination hereof on a trailer or support structure 220 and once erected in a vertical or substantially vertical position auger conduit 11 Od is installed such that one or more openings 14 align with one or more ports 216.

In one or more embodiments, silo or storage bin 204 comprises one or more sensors 218. The one or more sensors 218 may be positioned or disposed vertically along an inner surface of silo or storage bin 204 at any one or more intervals. The one or more sensors 218 may detect the level of material 210 and may convey this level to an information handling system or gauge, activate an indicator, for example, a light emitting diode, trigger an alarm, or communicate with any other device or system so as to indicate or provide notification of the level of material 210. In one or more embodiments, silo or storage bin 204 may comprise a visual indicator of the level of material 210. In one or more embodiments, silo or storage bin 204 may be portable such that the silo or storage bin 204 may be positioned or disposed at any location at a site.

FIG. 3 illustrates a block diagram of a trough-based flexible auger material handling system 300 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material 322 to a blender system 104, in accordance with an embodiment of the present disclosure. One or more components in FIG. 3 operate in a similar manner to like components discussed above with respect to FIG. 1. FIG. 3 illustrates a flexible auger material handling system similar to that illustrated in FIG. 1 except that material 114 is dispensed, transferred or conveyed from storage vessel or tank 102 of a transport unit or vehicle 118 to a hopper 116 from within an enclosure 302. The transport unit or vehicle 118 with the storage tank or vessel 102 may traverse a bridge 318 to enter an enclosure 302. Bridge 318 may be similar to bridge 202 of FIGS. 2A and 2B except that bridge 318 may be an elevation sufficient to elevate transport unit or vehicle 118, hopper 116 or both above a conduit 107. Bridge 318 may extend the entire length or any portion of a length of enclosure 302. Enclosure 302 may be any length and any quantity of transport units or vehicles 118 may traverse the bridge 318 and enclosure 302 at any given time, for example, as illustrated in FIG. 9. Enclosure 302 may completely cover or partially cover any portion of transport unit or vehicle 118, storage vessel or tank 102, or both. In one or more embodiments, hopper 1 16 may be integral with the transport unit or vehicle 118 or may be coupled to transport unit or vehicle 118 or may be disposed or positioned about trough 314 within enclosure 302.

Enclosure 302 may comprise a top 304, a bottom 308 and two sides 306. In one or more embodiments, enclosure 302 may be a permanent structure. In one or more embodiments, enclosure 302 may be a temporary structure and may be constructed on site. Enclosure 302 may protect the material 114 from any one or more environmental conditions such as rain, wind or any other conditions. Enclosure 302 may have openings at either or both ends to allow transport unit 118 and storage vessel or tank 102 to traverse the enclosure 302. One or more guides 310 may be positioned or disposed on the bottom 308 to guide a transport unit or vehicle 118 through the enclosure 302 or to align the transport unit or vehicle 1 18, the hopper 1 16 or both with the bin 312. Bottom 308 may comprise an opening 320 that aligns with hopper 116 so that material 114 from storage vessel or tank 102 may be dispensed or transferred to a bin 312. Bin 312 may be disposed or positioned under hopper 116 in a trough 314. Trough 314 may extend an entire length or any portion of a length of enclosure 302 and may be formed by bridge 318. Trough 314 may be at any depth or width and bridge 318 may be at any height or elevation or depth. The depth or width or both of trough 314 may be based, at least in part, on the required amount of material 322, the length of the enclosure 302, the rate of dispensing of material 114 and additive 122, capacity of blender system 104, one or more parameters associated with an operation, any other factor or criteria or any combination thereof. The height, elevation or depth of bridge 318 may be based, at least in part, on one or more properties of transport unit or vehicle

118, trough 314, enclosure 302 or any combination thereof. Bin 312 may be disposed or positioned on a platform 316 that is disposed or positioned on a surface 303. In one or more embodiments, bin 312 is disposed on positioned on surface 303. Surface 303 and subsurface 305 are similar to surface 103 and subsurface 105 of FIG. 1 such that the description of surface 103 and subsurface 105 is applicable to surface 303 and subsurface 305.

As material 114 is dispensed, transferred, conveyed or metered from hopper 116 into bin 312, auger conduit 1 lOb may transfer or convey additive 122 from additive material handling system 112 via auger l24b to bin 312 to mull additive 122 and material 114 to form or resulting in material 322. Material 322 comprises some amount of material 114 and some amount of additive 122. Material 322 is transferred via auger connector 108 and conduit 107 to auger conduit l lOa as motor l06a is actuated to actuate, turn or rotate auger l24a of auger conduit 110a. As motor 106n actuates, turns or rotates auger 124n of auger conduit 110h, material 322 is transferred or conveyed to blender system 104. In one or more embodiments, material 114, additive 122 or both may be released or dispensed from storage vessel or tank 102 through hopper 116 or additive material handling system 112, respectively, to bin 312 at any rate. For example, hopper 116 may comprise a metering gate or valve to meter material 114, material 114 may be dispensed or released from storage vessel or tank 102 until the material 114 in trough 314 prevents any additional material 114 from being released or dispensed, a sensor 324 may be disposed or positioned on or about bottom 308 or opening 320 to detect a level of material 114, any other method or process may be used to control the rate of release of material 114, or any combination thereof.

In one or more embodiments, enclosure 302, trough 314 and bin 312 may have a length or distal end such that any one or more of transport units or vehicles 118 may traverse the enclosure 302 at any given time. In one or more embodiments, enclosure 302, trough 314 and bin 312 may have a length or distal end such that any one or more transport units or vehicles 118 may traverse the enclosure 302 continuously at a rate such that a required quantity of material 114 is dispensed or transferred at a rate to the bin 312 as the transport units or vehicles 118 traverses the enclosure 302. For example, the rate of speed of any one or more transport units or vehicles 118 may be such that the required quantity of material 114 dispensed or transferred by the time the one or more transport units or vehicles 118 exit the enclosure 302.

FIG. 4 illustrates a block diagram of a trough-based flexible auger material handling system 400 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material 322 to a blender system 104, in accordance with an embodiment of the present disclosure. FIG. 4 is similar to FIG. 3 except that the storage vessel or tank comprises or is replaced by a container 410. Container 410 may be positioned or disposed on transport unit or vehicle 418. Transport unit or vehicle 418 may be similar to transport unit or vehicle 118. In one or more embodiments, container 410 may be completely separable and transportable from transport unit or vehicle 418, such that any container 410 may be selectively removed from the transport unit or vehicle 418 and replaced with another container 410.

Enclosure 402 is similar to enclosure 302 except that enclosure 402 has dimensions sufficient to allow container 410 and transport unit or vehicle 418 to traverse the enclosure 402. In one or more embodiments, enclosure 302 and enclosure 402 are the same enclosure. Enclosure 402 comprises a top 404, a bottom 408 and two sides 406. Bottom 408 comprises an opening 420 similar to opening 320.

FIG. 5 illustrates a block diagram of a flexible auger material handling system 500 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material, for example, material 114, material 322 or both to a blender system 104, in accordance with one or more aspects of the present disclosure. FIG. 5 is similar to FIG. 1 except that FIG. 5 includes a blender hopper 502 that comprises a material 504 that transfers or conveys material 504 to blender system 104 via a conduit 506. Material 504 is blended in blender system 104 with material 1 14, for example, conveyed or transferred from storage tank or vessel 102 via auger l24a. In one or more embodiments, hopper 502 may comprise additive material handling system 112 and material 504 may comprise additive 122.

FIG. 6 illustrates a block diagram of a flexible auger material handling system 600 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material, for example, material 114 of FIG. 1 or material 322 of FIG. 3, to a blender system 104, in accordance with one or more aspects of the present disclosure. FIG. 6 is similar to the configuration of FIG. 1 except that FIG. 6 comprises a container 410 disposed or positioned on or about a transport unit or vehicle 418 at a surface 103.

FIG. 7 illustrates a block diagram of a flexible auger material handling system 700 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material to a blender system 104, in accordance with one or more aspects of the present disclosure. FIG. 7 is similar to FIG. 1, except that the storage vessel or tank comprises a cement container 702 that holds or stores cement or any other fine powdered material 708 and is disposed or positioned on a transport unit or vehicle 718. Transport unit or vehicle 718 may be similar to transport unit or vehicle 118 of FIG. 1. In one or more embodiments, cement container 702 comprises a hopper 716. In one or more embodiments, hopper 716 couples to cement container 702, transport unit or vehicle 718 or both. In one or more embodiments, a free-standing auger 706 extends into the cement container 702 and may couple to an auger conduit 1 lOe that comprises an auger l24e. Free-standing auger 706 may whip around when actuated, turned or rotated to prevent cement 708 from clumping. Auger conduit 1 lOe may couple to an auger connector 108 to dispense, convey or transfer cement 708 to an auger conduit 124a when auger conduit 124a is actuated, rotated or turned by auger motor 106a.

FIG. 8A is a block diagram of a trough-based flexible auger material handling system 800 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring material 322 to a material handling system 804, in accordance with one or more aspects of the present disclosure. FIG. 8 is similar to FIG. 4 except that the material 322 is transferred to a material handling system 804. Material handling system 804 may comprise one or more containers 806, for example, containers 806a, 806b and 806c, one or more auger conduits 110, for example, auger conduits 110s, l lOt and l lOu and a frame 808. Containers 806 may be disposed or positioned on frame 808 at or about a site or surface 803. Frame 808 may be sized or have appropriate dimensions to receive and support a plurality of containers 806. Any one or more of containers 806 may be portable containers that are removable from frame 808. Frame 808 may be an elevation or height such that material 322 that has been transferred or conveyed to containers 806 may be gravity or gravity assisted fed, dispensed, conveyed or transferred from containers 806 to any other location, device or system at the site, for example, to hopper 814. In one or more embodiments containers 806 are similar to or the same as containers 410. Material 322 may be transferred or conveyed via auger conduit l lOa to auger conduit 11 Op as auger motors l06a and 106p are actuated to actuate, rotate or turn augers l24a and l24p respectively. In one or more embodiments, auger conduit 110a may be disposed or positioned at a surface 803 similar to FIGS. 2A and 2B or below or within a surface 805 similar to FIG. 1, for example.

Auger conduit 11 Op may couple to a valve or connector 812. In one or more embodiments, valve or connector 812 may be positioned or disposed on or about or otherwise coupled to material handling system 804. Valve or connector 812 may direct or guide material 322 to the desired or selected container 806 via a corresponding auger conduit 110. Valve or connector 812 may be manually or automatically controlled such that an auger conduit 110 may be actuated to transfer material 322 to a selected container 806. Each container 806 may comprise one or more ports or openings 810 for receiving material 322 from auger conduits 110. For example, container 806a may comprise a port or opening 8l0a, container 806b may comprise a port or opening 810b and container 806c may comprise a port or opening 810c. In one or more embodiments, at least a portion of auger conduits 1 lOs, 1 lOt and 1 lOu is positioned or disposed inside of containers 806a, 806b and 806c, respectively. In one or more embodiments, auger conduits 1 lOs, 1 lOt and 1 lOu comprise one or more openings 816, for example, openings 816a, 816b and 816c, respectively. Openings 816 may be the same or similar to openings 214 discussed above with respect to FIG. 2 A. For example, as the augers l24s, l24t and l24u of auger conduits 110s, l lOt and l lOu, respectively, conveys or transfers the material 322, the material 322 is dispensed or exits from the auger conduits 110s, l lOt and l lOu via the one or more openings 816a, 816b, 816c, respectively, which may be spaced at any interval along auger conduits 1 lOs, 1 lOt and 1 lOu, respectively.

In one or more embodiments, as illustrated in FIG. 8B, a trough-based flexible auger material handling system 850 may be similar to trough-based flexible auger material handling system 800 and material handling system 854 may be similar to material handling system 804 except that any one or more containers 806d, 806e and 806f are portable or replaceable such that any one or more containers 806d, 806e and 806f may be retrieved and replaced by one or more other containers. For example, a maneuvering device 820 including but not limited to a forklift, a crane or other device or vehicle for moving, lifting, transporting or maneuvering any one or more of container 806d, container 806e and 806f may engage any one or more of container 806 d, container 806e and container 806f to remove any one or more of container 806d, container 806e and container 806f from the frame 808 and deposit or transport any one or more of container 806d, 806e and 806f to another location. The maneuvering device 820 may also replace any removed container 806d, 806e, 806f or any combination thereof with a new container. For example, in one or more embodiments, an empty container 806d may be removed from the frame 808 by a maneuvering device 820 and replaced by another container 806d or any other type of container containing a desired or required material. In one or more embodiments, a material may be conveyed or transferred into a container 806d from a top opening 818d, a container 806e from a top opening 818e and a container 806f from a top opening 818f.

One or more auger conduits l lOv, l lOw and 11 Ox comprising augers l24v, l24w and l24x, respectively, may transfer, convey or feed material 322 to one or more openings 818d, 8l 8e and 8l8f of containers 806d, 806e and 806f, respectively. Any one or more of containers 806d, 806e and 806f may convey a material 322 or any other material into a hopper 814 via any one or more openings 8l0d, 8l0e and 81 Of, respectively. For example, a gate, valve or any other metering mechanism may be coupled to any one or more of the openings 8l0d, 8l0e and 81 Of to allow a material 322 to be transferred, conveyed or gravity-fed to hopper 814. In one or more embodiments, as illustrated in FIG. 8C, a trough-based flexible auger material handling system 860 may be similar to trough-based flexible auger material handling system 800, 850 or both and material handling system 864 may be similar to material handling system 804, 854 or both except that any one or more containers 806 disposed or positioned on frame 808 may comprise any type of container including, but not limited to, any one or more of container 806a, container 806e, and container 806g. An auger conduit 1 lOy comprising an auger l24y may couple to an opening 818g or a port of container 806 via a connector 816, such as a quick-connect. In one or more embodiments, auger conduit l24y may traverse a substantially vertical side of container 806g similar to auger conduit l lOd of FIG. 2B. Material may be transferred to container 806g via auger conduit l lOy. Material 322 or any other material be transferred, conveyed or gravity-fed from container 806g to hopper 814 via an opening 8l0g. In one or more embodiments, one or more additional material handling systems may be used to transfer, convey or deliver any other material via an auger conduit using a flexible coreless auger to a container as discussed above with respect to any one or more embodiments.

In any one or more embodiments, any one or more of material handling systems 804, 854 and 864 may be disposed or positioned at a site including, but not limited to, any one or more sites illustrated in FIGS. 1-8C. Further, the present disclosure contemplates that any number of containers 806 of FIGS. 8A-8C, blender systems 104 of FIGS. 1, 3-7, silos or storage bins 204 of FIGS. 2A and 2B, any other storage or handling system, or any combination thereof may be positioned or disposed at or about a site according to any one or more configurations as discussed with respect to FIGS. 1-8C.

FIG. 9 is a block diagram of a trough-based flexible auger system 900 at, for example, a hydrocarbon, such as oil, well services or operation site, for transferring a material at a site, in accordance with one or more aspects of the present disclosure. A trough 316 may traverse a portion of a site such that one or more transport units or vehicles 902, for example, transport units or vehicles 902a, 902b, 902c and 902n. One or more auger conduits 110, for example, auger conduits l lOg, 11 Oh, l lOi, l lOj and 110k may couple to auger conduit 1 1 Of to convey a material via augers l24f, 124g, l24h, 124i, 124j and l24k to a desired location, system or device at a site.

In one or more embodiments, a flexible auger material handling system at a hydrocarbon well services or operation site, comprising a storage vessel, wherein the storage vessel comprises a material, a first flexible coreless auger coupled to the storage vessel, a trough positioned below the storage vessel, wherein the first flexible coreless auger receives the material from the trough and a material handling system coupled to the first flexible coreless auger, wherein the first flexible coreless auger transfers the material to the material handling system. In one or more embodiments, the flexible auger material handling system further comprises a first auger conduit positioned proximate to the storage vessel, wherein the first auger conduit comprises the first flexible coreless auger, a first auger motor coupled to the first auger conduit, wherein the first auger motor rotates the first flexible coreless auger, a second auger conduit coupled to a material handling system and the first auger conduit, wherein the second auger conduit comprises a second flexible coreless auger, a second auger motor coupled to the second auger conduit, wherein the second auger motor rotates the second flexible coreless auger and wherein the first flexible coreless auger and second flexible coreless auger rotate to transfer the material from the trough to the material handling system. In one or more embodiments, the flexible auger material handling system further comprises a hopper coupled to the storage vessel, wherein the hopper receives the material from the storage vessel and an auger connector coupled to the hopper and the first auger conduit. In one or more embodiments, the flexible auger material handling system further comprises a bridge positioned proximate to the trough, wherein the storage vessel is positioned on the bridge. In one or more embodiments, the flexible auger material handling system further comprises an additive storage system, wherein the additive storage system comprises an additive and a third auger conduit coupled to the additive storage system, wherein the third auger conduit transfers the additive to the trough. In one or more embodiments, the flexible auger material handling system further comprises an enclosure that traverses the trough, wherein the storage vessel is within the enclosure and above the trough. In one or more embodiments, a third auger conduit coupled to a container of the material handling system and the second auger conduit. In one or more embodiments, the flexible auger material handling system wherein at least the first auger conduit is positioned below a surface. In one or more embodiments, the flexible auger material handling system further comprises a bin positioned in the trough and coupled to the first auger conduit, wherein the bin receives the material from the storage vessel, and wherein the first auger conduit receives the material from the bin.

In one or more embodiments, a method for transferring a material using a flexible coreless auger material handling system comprises actuating a first flexible coreless auger coupled to a storage vessel, wherein the storage vessel comprises a material used in at least one of a hydrocarbon exploration, recovery and production operation and transferring the material to a material handling system coupled to the first flexible coreless auger. In one or more embodiments, the method further comprises wherein some couples the material handling system to the first flexible coreless auger and actuating a second flexible coreless auger to transfer the material from the first flexible coreless auger to the material handling system. In one or more embodiments, the method comprises actuating a third flexible coreless auger to transfer the material from the material handling system to another location. In one or more embodiments, the method comprises actuating a fourth flexible coreless auger coupled between an additive material handling system and the first flexible coreless auger, wherein the additive material handling system comprises an additive and mixing the additive with the material. In one or more embodiments, the method further comprises wherein actuating the first flexible coreless auger comprises actuating a first auger motor that rotates the first flexible coreless auger. In one or more embodiments, the method further comprises traversing a bridge above a trough by a transport unit, wherein the transport unit comprises the storage vessel, and wherein at least a portion of the first flexible coreless auger is disposed within the trough. In one or more embodiments, the method further comprises blending the material in a blender system.

In one or more embodiments, a flexible auger material handling system at a hydrocarbon well services or operation site, comprises a storage vessel, wherein the storage vessel comprises a material, a first flexible coreless auger coupled to the storage vessel and a material handling system coupled to the first flexible coreless auger, wherein the first flexible coreless auger transfers the material to the material handling system. In one or more embodiments, the flexible auger material handling system further comprises a hopper coupled to the storage vessel, wherein the hopper receives the material from the storage vessel, a first auger conduit coupled to the hopper, wherein the first auger conduit comprises the first flexible coreless auger, a first auger motor coupled to the first auger conduit, wherein the first auger motor rotates the first flexible coreless auger, a second auger conduit coupled to a material handling system and the first auger conduit, wherein the second auger conduit comprises a second flexible coreless auger, a second auger motor coupled to the second auger conduit, wherein the second auger motor rotates the second flexible coreless auger and wherein the first flexible coreless auger and second flexible coreless auger rotate to transfer the material from the hopper to the material handling system. In one or more embodiments, the flexible auger material handling system further comprises wherein the material handling system is a silo, wherein the second auger conduit is positioned at an angle within the silo, wherein the second auger conduit comprises one or more openings, wherein the material is transferred from the second auger conduit into the silo via the one or more openings and a third auger conduit coupled to the silo, wherein the third auger conduit transfers the material from the silo to another location. In one or more embodiments, the flexible auger material handling system further comprises an additive material handling system, wherein the additive material handling system comprises an additive and a third auger conduit coupled to the additive storage system, wherein the third auger conduit transfers the additive to the trough.

Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the following claims.