Note: Descriptions are shown in the official language in which they were submitted.
CA 03155139 2022-03-21
TURBINE FRACTURING SEMI-TRAILER
TECHNICAL FIELD
The present invention relates to the field of oil and gas field operations,
and specifically to a
turbine fracturing semi-trailer.
BACKGROUND
In the working sites of fracturing in oil and gas fields all over the world,
the driving modes
for fracturing equipment mainly include the following two ways:
One driving mode is diesel engine driven, specifically a diesel engine is
connected to a
transmission through a transmission shaft to drive the fracturing plunger pump
to work. In other
words, a diesel engine is used as the power source, a transmission and a
transmission shaft are
used as the transmission devices, and a fracturing plunger pump is used as the
actuating element.
This configuration mode has the following disadvantages:
1 5 (1)
Large volume and heavy weight: When a diesel engine drives a transmission to
drive a
fracturing plunger pump through a transmission shaft, a large volume is
occupied, a heavy weight
is involved, the transportation is restricted, and the power density is low;
(2) Environmental problems: During operations on a well site, the fracturing
equipment
driven by the diesel engine would generate engine waste gas pollution and
noise pollution. The
noise exceeding 105 dBA will severely affect the normal life of nearby
residents;
(3) Cost inefficiency: The fracturing equipment driven by the diesel engine
requires relatively
high initial purchase costs and incurs high fuel consumption costs for unit
power during operation,
and the engine and the transmission also require very high routine maintenance
costs.
The other driving mode is electric drive fracturing, specifically an electric
motor is connected
to a transmission shaft or a coupling to drive the fracturing plunger pump to
work. In other words,
an electric motor is used as the power source, a transmission shaft or a
coupling is used as the
transmission device, and a fracturing plunger pump is used as the actuating
element.
Although the electric drive fracturing has many advantages itself, the power
supply on
fracturing well sites is the prerequisite for implementation of the electric
drive fracturing.
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Generally, it is difficult to supply power for the fracturing well sites in
that the power capacity on
the well sites is too small to drive the whole fracturing unit, or there are
not any power networks
at all on the well sites. Therefore, in common electric drive fracturing
sites, generators are
generally used to generate electricity. The most economical generation fuel is
natural gas, but the
users employing natural gas need to rent or purchase gas generators. For a
fracturing well site
without power networks, the power of the gas generator sets need up to at
least 30 MW. Purchasing
such high-power gas generator sets is a great investment for customers. More
importantly, in actual
work progress, the accidental shutdown of the gas generator sets would cause
the breakdown of
the whole electrical fracturing unit, thus seriously affecting the working
quality, even causing work
accidents possibly.
Therefore, it is an urgent need for a new fracturing equipment to solve the
disadvantages of
the above exsiting diesel engine-driven fracturing and electric drive
fracturing, thus better
satisfying the demands on the oil and gas field fracturing market globally.
SUMMARY
To overcome the deficiencies in the prior art, an objective of the present
invention is to
provide a turbine fracturing semi-trailer, wherein a turbine engine, a
reduction gearbox, a
transmission mechanism and a plunger pump are connected in a straight line
along the transmission
direction of power to avoid excessive transmission loss, thus ensuring
efficient transmission
performance. The turbine engine itself has the advantages of small size, light
weight and high
power density. For the same outline dimensions and weights, the unit power of
the turbine
fracturing equipment is more than two times of that of conventional diesel
engine fracturing
equipment. The turbine engine can use 100% natural gas as the fuel directly,
greatly reducing the
use-cost compared to the diesel consumption in diesel engine drive and the
investment on gas
generator sets in electric drive fracturing equipment. Meanwhile, the turbine
fracturing equipment
are usually operated with the plunger pumps drived one-to-one, unlike in
electric drive fracturing
equipment, a single high-power gas generator set is used to drive multiple
plunger pumps. That is
to say, a turbine fracturing equipment is employed to distribute the failure
risks of single high-
power gas generator onto each turbine fracturing equipment, avoiding that the
failure of single gas
generating equipment causes the risk of breakdown of the whole set of
fracturing equipment.
The objective of the present invention is achieved by the following technical
measures: a
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turbine fracturing semi-trailer, including a semi-trailer body, a turbine
engine, a reduction gearbox,
a transmission mechanism and a plunger pump, wherein the turbine engine, the
reduction gearbox,
the transmission mechanism and the plunger pump are disposed on the semi-
trailer body, an output
end of the turbine engine is connected to the reduction gearbox, the reduction
gearbox and the
plunger pump are connected through a transmission mechanism in a transmission
way.
Further, the turbine engine is provided with an exhaust system disposed on an
opposite side
of the reduction gearbox, the exhaust system includes an exhaust silencer and
an exhaust piping,
the exhaust silencer is communicated with an exhaust port of the turbine
engine through the
exhaust piping.
Further, the exhaust system, the turbine engine, the reduction gearbox, the
transmission
mechanism and the plunger pump are disposed in a straight line along the
transmission direction
of power.
Further, an air intake system is disposed on the semi-trailer body, the air
intake system
includes an air intake filter, an air intake silencer and an air intake
piping, one end of the air intake
.. silencer is connected to the air intake filter, the other end of the air
intake silencer is connected to
the air intake piping, and the other end of the air intake piping is
communicated with an air intake
port of the turbine engine.
Further, the power of the plunger pump is 5000 hp or above.
Further, the transmission mechanism is a transmission shaft or a coupling.
Further, the number of axles of the semi-trailer is 3 or above.
Further, a hydraulic power unit is disposed on a gooseneck of the semi-trailer
body, the
hydraulic power unit is used to drive the hydraulic system on the turbine
fracturing semi-trailer.
Further, the hydraulic power unit is driven by a diesel engine or driven by an
electric motor.
Further, a cooling system is disposed on a gooseneck of the semi-trailer body,
the cooling
system cools oils used on the turbine fracturing semi-trailer.
Compared with the prior art, the beneficial effects of the present invention
are as follows: the
turbine engine, the reduction gearbox, the transmission mechanism and the
plunger pump are
connected in a straight line along the transmission direction of power to
avoid excessive
transmission loss, thus ensuring efficient transmission performance. The
turbine engine itself has
the advantages of small size, light weight and high power density. For the
same outline dimensions
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and weights, the unit power of the turbine fracturing equipment is more than
two times of that of
conventional diesel engine fracturing equipment. The turbine engine can use
100% natural gas as
the fuel directly, greatly reducing the use-cost compared to the diesel
consumption in diesel engine
drive and the investment on gas generator sets in electric drive fracturing
equipment. Meanwhile,
the turbine fracturing equipment is usually operated with the plunger pumps
drived one-to-one,
unlike in electric drive fracturing equipment, a single high-power gas
generator set is used to drive
multiple plunger pumps. That is to say, a turbine fracturing equipment is
employed to distribute
the failure risks of single high-power gas generator onto each turbine
fracturing equipment,
avoiding that the failure of single gas generating equipment causes the risk
of breakdown of the
whole set of fracturing equipment.
The present invention will be described in detail below with reference to the
accompanying
drawings and specific implementations.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic structural diagram of the present invention.
Wherein, 1. cooling system; 2. hydraulic power unit; 3. semi-trailer body; 4.
exhaust silencer;
5. exhaust piping; 6. air intake system; 7. turbine engine; 8. reduction
gearbox; 9. transmission
shaft; and 10. plunger pump.
DESCRIPTION OF THE EMBODIMENTS
As shown in FIG. 1, a turbine fracturing semi-trailer, including a semi-
trailer body 3, a turbine
engine 7, a reduction gearbox 8, a transmission mechanism and a plunger pump
10, wherein the
turbine engine 7 is the power source of the power transmission system of the
entire semi-trailer;
the turbine engine 7, the reduction gearbox 8, the transmission mechanism and
the plunger pump
10 are disposed on the semi-trailer body 3; the semi-trailer body 3 is also
provided with
components such as battery wires, a fuel tank, a lubricating oil tank, and a
hydraulic oil tank, thus
providing oil and support for the mounted components such as the turbine
engine 7, the reduction
gearbox 8, and the plunger pump 10; an output end of the turbine engine 7 is
connected to the
reduction gearbox 8, the reduction gearbox 8 and the plunger pump 10 are
connected through a
transmission mechanism in a transmission way. The reduction gearbox 8 is used
to slow down and
increase the torque of the power output of the turbine engine 7, and then
drive the plunger pump
10 to work through a transmission mechanism.
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The turbine engine 7 is provided with an exhaust system disposed on an
opposite side of the
reduction gearbox 8, the exhaust system includes an exhaust silencer 4 and an
exhaust piping 5,
the exhaust silencer 4 is communicated with an exhaust port of the turbine
engine 7 through the
exhaust piping 5. The exhaust piping 5 is used to direct the exhaust of the
turbine engine 7 into the
exhaust silencer 4, and the exhaust silencer 4 can reduce the exhaust noise.
The exhaust system, the turbine engine 7, the reduction gearbox 8, the
transmission
mechanism and the plunger pump 10 are disposed in a straight line along the
transmission direction
of power. The turbine engine 7, the reduction gearbox 8, the transmission
mechanism and the
plunger pump 10 are connected in a straight line along the transmission
direction of power to avoid
excessive transmission loss, thus ensuring efficient transmission performance.
Moreover, such a
configuration can lower the height of center of gravity of the equipment on
the semi-trailer body
for convenience of transportation. The turbine engine 7 itself has the
advantages of small size,
light weight and high power density. For the same outline dimensions and
weights, the unit power
of the turbine fracturing equipment is more than two times of that of
conventional diesel engine
fracturing equipment. The turbine engine 7 can use 100% natural gas as the
fuel directly, greatly
reducing the use-cost compared to the diesel consumption in diesel engine
drive and the investment
on gas generator sets in electric drive fracturing equipment. Of course, the
turbine engine 7 also
can use 100% fuel oil as the fuel, while natural gas is preferably used, which
can reduce the fuel
cost much more than fuel oil. Meanwhile, the turbine fracturing equipment is
usually operated
with the plunger pumps 10 drived one-to-one, unlike in electric drive
fracturing equipment, a
single high-power gas generator set is used to drive multiple plunger pumps
10. That is to say, a
turbine fracturing equipment is employed to distribute the failure risks of
single high-power gas
generator onto each turbine fracturing equipment, avoiding that the failure of
single gas generating
equipment causes the risk of breakdown of the whole set of fracturing
equipment.
An air intake system 6 is disposed on the semi-trailer body 3, the air intake
system 6 includes
an air intake filter, an air intake silencer and an air intake piping, one end
of the air intake silencer
is connected to the air intake filter, the other end of the air intake
silencer is connected to the air
intake piping, and the other end of the air intake piping is communicated with
an air intake port of
the turbine engine 7.
The power of the plunger pump 10 is 5000 hp or above; the greater the power of
the plunger
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pump 10 is, the more suitable for lone-time and high-load continuous operation
conditions.
The transmission mechanism is a transmission shaft 9 or a coupling.
The number of axles of the semi-trailer body 3 is 3 or above, to ensure an
adequate bearing
capacity.
A hydraulic power unit 2 is disposed on a gooseneck of the semi-trailer body
3, the hydraulic
power unit 2 is used to drive the hydraulic system on the turbine fracturing
semi-trailer. The
hydraulic system includes a hydraulic pump, a hydraulic motor, various valves,
a hydraulic oil
tank, a hydraulic oil radiator, etc. (The main role of the hydraulic system is
to drive the fuel pump
of the turbine engine 7, the starting motor of the turbine engine 7, the power
end lubrication system
1 0 of
the plunger pump 10, the lubrication system of the reduction gearbox 8,
various oil radiators and
the like).
The hydraulic power unit 2 is a diesel engine or an electric motor.
A cooling system 1 is disposed on a gooseneck of the semi-trailer body 3, the
cooling system
1 cools oils used on the turbine fracturing semi-trailer. The used oils
include engine oil and
1 5
hydraulic oil for the turbine engine 7, lubricating oil for the plunger pump
10, lubricating oil for
the reduction gearbox 8, and the like.
It will be appreciated to persons skilled in the art that the present
invention is not limited to
the foregoing embodiments, which together with the context described in the
specification are only
used to illustrate the principle of the present invention. Various changes and
improvements may
20 be
made to the present invention without departing from the spirit and scope of
the present
invention. All these changes and improvements shall fall within the protection
scope of the present
invention. The protection scope of the present invention is defined by the
appended claims and
equivalents thereof.
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