Note: Descriptions are shown in the official language in which they were submitted.
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SINGLE-MOTOR, SINGLE-PUMP ELECTRIC DRIVE FRACTURING SEMI-TRAILER
TECHNICAL FIELD
[0001] The present invention relates to the technical field of electric drive
fracturing equipment, and
specifically to a single-motor single-pump electric drive fracturing semi-
trailer.
BACKGROUND
[0002] In the working sites of fracturing in oil and gas fields all over the
world, the power driving modes
for plunger pumps mainly include the following two ways:
[0003] One driving mode is that a diesel engine is connected to a transmission
to drive the fracturing
plunger pump through a transmission shaft 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 plunger
pump is used as the actuating element.
[0004] This configuration mode has the following disadvantages:
[0005] (1) Large volume and heavy weight: When a diesel engine drives a
transmission to drive a
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;
[0006] (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;
[0007] (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.
[0008] The other driving mode is that an electric motor is connected to a
transmission shaft or a
coupling to drive the 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 plunger pump is used
as the actuating element, i.e, electric drive fracturing.
[0009] Electric drive fracturing equipment is relatively widely used in some
places with complete power
facilities. The existing electric drive fracturing equipment is usually
provided with special power supply
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equipment to provide the driving power. The power supply equipment and the
electric drive fracturing
equipment are usually arranged one-to-one, or one high-power power supply
equipment is used to
drive several electric drive fracturing equipment (hereinafter referred to as
one-to-many). However, no
matter one-to-one or one-to-many, in the practical use of a well site, it
takes too much time to arrange
the electric drive fracturing equipment and the power supply equipment (i.e,
electric drive fracturing
equipment and power supply equipment should be used in complete sets);
furthermore, each electric
drive fracturing equipment should be connected to the power supply equipment,
so that the electric
drive fracturing equipment could enter working state; the above processes are
all time and labor
consuming, and there are also too many connection wires between equipment, and
it seems relatively
cumbersome.
[0010] Therefore, there is an urgent need for an economical and
environmentally friendly electric drive
fracturing equipment with small volume and simple connection.
SUMMARY
[0011] To overcome the deficiencies in the prior art, an objective of the
present invention is to provide
a single-motor single-pump electric drive fracturing semi-trailer, which
optimally merge a traditional
power supply semi-trailer and a fracturing semi-trailer together to realize
the function of a semi-trailer
for supplying power and fracturing simultaneously, without the need of using a
power supply semi-
trailer and a fracturing semi-trailer as a complete set, making it more
flexible in practical uses, greatly
optimizing the wellsite arrangement in oil and gas fields and facilitating the
transportation; only one set
of high voltage cable is need to connect to a high voltage power supply to
reach working state, the
wiring installation is more faster; compared with diesel-driven fracturing,
electric drive fracturing
generates low noise and no waste emission pollution; driven by electricity, it
is cheaper to use than
diesel. A five cylinder plunger pump of 5000 hp or above, especially 7000 hp,
is employed to greatly
enhance the output power of the single-motor single-pump electric drive
fracturing semi-trailer of the
invention, and in the context of high output power of single-semi-trailer, the
wellsite power density per
unit area is also greatly enhanced. The power end housing of the five cylinder
plunger pump adopts an
integral welding structure, so that the power end assembly has a higher
structural strength and a better
support stability to reduce vibration of the whole pump. The cylinder spacing
of the five cylinder plunger
pump is 13-14 inches, ensuring the high-power output of the five cylinder
plunger pump. The high-
power five cylinder plunger pump can effectively solve the problems of narrow
area and many fracturing
equipment being required in shale gas fracturing wellsite, thus reducing the
use of equipment and
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facilitating the arrangement of the wellsite. The multi-point support design
of the crankcase, the
crosshead case and the hydraulic end assembly can enhance the support strength
of the five cylinder
plunger pump and reduce the vibration, thus better ensuring high load
operation and more smoothly
running.
[0012] The objective of the present invention is achieved by the following
technical measures: A single-
motor single-pump electric drive fracturing semi-trailer, including a semi-
trailer body, a plunger pump, a
radiator, a power supply unit and an electric motor, wherein the power supply
unit, the electric motor,
the radiator and the plunger pump are integrated on the semi-trailer body,
there are one electric motor,
one radiator, and one plunger pump, the power supply unit provides power for
the electric motor, the
electric motor is connected to the plunger pump, the radiator cools the
lubricating oil of the plunger
pump.
[0013] Further, the power supply unit includes a voltage conversion unit and a
frequency conversion
unit. The frequency conversion unit is connected to the voltage conversion
unit, the voltage conversion
unit is disposed at one end of the semi-trailer body near the electric motor,
and the frequency
conversion unit is disposed on a gooseneck of the semi-trailer body.
[0014] Further, the voltage conversion unit has a compartment structure
provided with a high voltage
switch and a transformer therein. The high voltage switch is connected to the
transformer.
[0015] Further, the frequency conversion unit has a compartment structure
provided with a frequency
converter therein. An input end of the frequency converter is connected to the
voltage conversion unit,
and an output end of the frequency converter is connected to the electric
motor.
[0016] Further, the plunger pump is a five cylinder plunger pump which
includes a power end assembly,
a hydraulic end assembly and a reduction gearbox assembly. One end of the
power end assembly is
connected to the hydraulic end assembly, and the other end of the power end
assembly is connected to
the reduction gearbox assembly. The power end assembly includes a crankcase, a
crosshead case and a
spacer frame which are connected in sequence.
[0017] Further, the stroke of the five cylinder plunger pump is 10" or above.
[0018] Further, the power of the five cylinder plunger pump is 5000 hp or
above.
[0019] Further, the power of the five cylinder plunger pump is 7000 hp.
[0020] Further, the cylinder spacing of the five cylinder plunger pump is 13-
14 inches.
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[0021] Further, the crankcase and the crosshead case are integrally welded to
constitute a power end
housing which is connected to the spacer frame, the power end housing includes
a vertical plate, a
bearing seat, a front end plate, a back cover plate, a base plate, a support
plate and an upper cover
plate; there are six vertical plates and six bearing seats, each vertical
plate is connected to a
corresponding bearing seat, and the six vertical plates are arranged in
parallel to constitute a power end
chamber; the base plate is mounted at the bottom of the power end chamber, and
the upper cover
plate is mounted on the top of the power end chamber, the front end plate is
mounted at the front end
of the power end chamber, the back cover plate is mounted at the back end of
the power end chamber,
and the support plate is disposed between two adjacent vertical plates
arranged in parallel.
[0022] Further, a crankshaft support is disposed at the bottom of the
crankcase, and the crankshaft
support is used to support the crankcase.
[0023] Further, a crosshead support is disposed at the bottom of the crosshead
case, and the crosshead
support is used to support the crosshead case.
[0024] Further, a hydraulic support is disposed at the bottom of the spacer
frame, and the hydraulic
support is used to support the hydraulic end assembly.
[0025] Compared with the prior art, the beneficial effects of the present
invention are as follows: a
traditional power supply semi-trailer and a fracturing semi-trailer are
optimally merged together to
realize the function of a semi-trailer for supplying power and fracturing
simultaneously, without the
need of using a power supply semi-trailer and a fracturing semi-trailer as a
complete set, making it more
flexible in practical uses, greatly optimizing the wellsite arrangement in oil
and gas fields and facilitating
the transportation; only one set of high voltage cable is need to connect to a
high voltage power supply
to reach working state, the wiring installation is more faster; compared with
diesel-driven fracturing,
electric drive fracturing generates low noise and no waste emission pollution;
driven by electricity, it is
cheaper to use than diesel. A five cylinder plunger pump of 5000 hp or above,
especially 7000 hp, is
employed to greatly enhance the output power of the single-motor single-pump
electric drive fracturing
semi-trailer of the invention, and in the context of high output power of
single-semi-trailer, the wellsite
power density per unit area is also greatly enhanced. The power end housing of
the five cylinder plunger
pump adopts an integral welding structure, so that the power end assembly has
a higher structural
strength and a better support stability to reduce vibration of the whole pump.
The cylinder spacing of
the five cylinder plunger pump is 13-14 inches, ensuring the high-power output
of the five cylinder
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plunger pump. The high-power five cylinder plunger pump can effectively solve
the problems of narrow
area and many fracturing equipment being required in shale gas fracturing
wellsite, thus reducing the
use of equipment and facilitating the arrangement of the wellsite. The multi-
point support design of the
crankcase, the crosshead case and the hydraulic end assembly can enhance the
support strength of the
five cylinder plunger pump and reduce the vibration, thus better ensuring high
load operation and more
smoothly running.
[0026] The present invention will be described in detail below with reference
to the accompanying
drawings and specific implementations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 is a schematic structural diagram of a single-motor single-pump
electric drive fracturing
semi-trailer.
[0028] FIG. 2 is a schematic structural diagram of a five cylinder plunger
pump.
[0029] FIG. 3 is a schematic structural diagram of a power end housing.
[0030] In the figures, 1. semi-trailer body, 2. frequency conversion unit, 3.
voltage conversion unit, 4.
electric motor, 5. plunger pump, 6. radiator, 7. power end assembly, 8.
reduction gearbox assembly, 9.
hydraulic end assembly, 10. driving flange, 11. power end housing, 12.
crankshaft support, 13. crosshead
support, 14. hydraulic support, 15. back cover plate, 16. vertical plate, 17.
bearing seat, 18. base plate,
19. support plate, 20. front end plate, and 21. upper cover plate.
DESCRIPTION OF THE EMBODIMENTS
[0031] As shown in FIGS. 1 to 3, an embodiment provides a single-motor single-
pump electric drive
fracturing semi-trailer, including a semi-trailer body 1, a plunger pump 5, a
radiator 6, a power supply
unit and an electric motor 4, wherein the power supply unit, the electric
motor 4, the radiator 6 and the
plunger pump 5 are integrated on the semi-trailer body 1, there are one
electric motor 4, one radiator 6,
and one plunger pump 5, the power supply unit provides power for the electric
motor 4, the electric
motor 4 is connected to the plunger pump 5, and the radiator 6 cools the
lubricating oil of the plunger
pump 5. The power supply unit includes a voltage conversion unit 3 and a
frequency conversion unit 2,
the frequency conversion unit 2 is connected to the voltage conversion unit 3,
the voltage conversion
unit 3 is disposed at one end of the semi-trailer body 1 near the electric
motor 4, and the frequency
conversion unit 2 is disposed on a gooseneck of the semi-trailer body 1. The
number of axles of the
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semi-trailer body 1 is 4. The semi-trailer is further provided with an
electrical control cabinet to
implement local manipulation of the semi-trailer. A traditional power supply
semi-trailer and a
fracturing semi-trailer are optimally merged together to realize the function
of a semi-trailer for
supplying power and fracturing simultaneously. Compared to that the existing
power supply semi-trailer
and a fracturing semi-trailer are used as a complete set, (for example, when
one power supply semi-
trailer is used to drive multiple fracturing semi-trailers, wiring is
relatively tedious, there would be a lot
of wiring accumulation and intricate lines in the field, and it may take up a
lot of time on the
arrangements of every power supply semi-trailer and multiple fracturing semi-
trailers), in field uses, the
power supply semi-trailer and the fracturing semi-trailer are separately
transported, moved, and then
wired and installed. The single-motor single-pump electric drive fracturing
semi-trailer of the invention
only need to be moved once, and it can be connected to a high voltage power
supply only through a set
of high voltage cable to reach working state. Compared with diesel-driven
fracturing, electric drive
fracturing generates low noise and no waste emission pollution; driven by
electricity, it is cheaper to use
than diesel.
[0032] The voltage conversion unit 3 has a compartment structure provided with
a high voltage switch
and a transformer therein, the high voltage switch is connected to the
transformer. The frequency
conversion unit 2 has a compartment structure provided with a frequency
converter therein, an input
end of the frequency converter is connected to the voltage conversion unit 3,
specifically, the input end
of the frequency converter is connected to the transformer, and an output end
of the frequency
converter is connected to the electric motor 4.
[0033] The plunger pump 5 is a five cylinder plunger pump which includes a
power end assembly 7, a
hydraulic end assembly 9 and a reduction gearbox assembly 8, one end of the
power end assembly 7 is
connected to the hydraulic end assembly 9, the other end of the power end
assembly 7 is connected to
the reduction gearbox assembly 8, the power end assembly 7 includes a
crankcase, a crosshead case and
a spacer frame which are connected in sequence.
[0034] The stroke of the five cylinder plunger pump is 10" or above. The
design of long stroke is
beneficial to realize the operation requirement of large displacement and
enhance the operation
efficiency.
[0035] The power of the five cylinder plunger pump is 5000 hp or above. More
preferably, the power of
the five cylinder plunger pump is 7000 hp. The cylinder spacing of the five
cylinder plunger pump is 13-
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14 inches, ensuring the high-power output of the five cylinder plunger pump.
The high-power five
cylinder plunger pump can effectively solve the problems of narrow area and
many fracturing
equipment being required in shale gas fracturing wellsite, thus reducing the
use of equipment and
facilitating the arrangement of the wellsite.
[0036] The crankcase and the crosshead case are integrally welded to
constitute a power end housing
11 which is connected to the spacer frame, the power end housing 11 includes a
vertical plate 16, a
bearing seat 17, a front end plate 20, a back cover plate 15, a base plate 18,
a support plate 19 and an
upper cover plate 21; there are six vertical plates 16 and six bearing seats
17, each vertical plate 16 is
connected to a corresponding bearing seat 17, and the six vertical plates 16
are arranged in parallel to
constitute a power end chamber; the base plate 18 is mounted at the bottom of
the power end
chamber, the upper cover plate 21 is mounted on the top of the power end
chamber, the front end
plate 20 is mounted at the front end of the power end chamber, and the back
cover plate 15 is mounted
at the back end of the power end chamber; and the support plate 19 is disposed
between two adjacent
vertical plates 16 arranged in parallel. The crankcase and the crosshead case
in the power end assembly
7 of the five cylinder plunger pump are integrally welded so that the power
end assembly 7 has a higher
structural strength and a better support stability to reduce vibration of the
whole pump. A crankshaft is
disposed in the crankcase. A crosshead, a crosshead cap and a crosshead
bearing bush are disposed in
the crosshead case. A connecting rod, a connecting rod cap and a connecting
rod bearing bush are
disposed between the crankcase and the crosshead case. The crankshaft adopts a
setting of five-crank
and six-journal. One end of the crankshaft is connected to the reduction
gearbox assembly 8, the other
end of the crankshaft is connected to the connecting rod through a connecting
rod cap and a connecting
rod bearing bush, the other end of the connecting rod is connected to the
crosshead through a
crosshead cap and a crosshead bearing bush, the other end of the crosshead is
connected with a pull
rod, and the other end of the pull rod is connected to a hydraulic end valve
housing through a plunger
and a clamp. The crankshaft is mounted on the bearing seat 17 of the power end
housing 11 through six
cylindrical roller bearings to allow the crankshaft rotation. The support
plate 19 is fixedly installed with
two slide rails to form a semi-circular space. A crosshead is mounted within
the semi-circular space to
allow linear motion. The reduction gearbox assembly 8 includes a planetary
reduction gearbox and a
parallel reduction gearbox, the transmission gears of which are all bevel
gears. The planetary reduction
gearbox includes a sun gear, four planetary gears, a planetary carrier and an
inner gear ring, constituting
a planetary gear mechanism, with the sun gear at the center of the planetary
gear mechanism; the
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parallel reduction gearbox includes a pinion and a bull gear, the pinion is
connected to an input end, the
bull gear is connected to a sun gear of the planetary reduction gearbox. A
reduction gearbox is used to
slow down and increase the torque. A driving flange 10 is disposed outside the
planetary reduction
gearbox, through which an external power source is connected for power input.
The parallel reduction
gearbox is connected to the crankshaft for power output.
[0037] A crankshaft support 12 is disposed at the bottom of the crankcase,
which is used to support the
crankcase. A crosshead support 13 is disposed at the bottom of the crosshead
case, which is used to
support the crosshead case. A hydraulic support 14 is disposed at the bottom
of the spacer frame, which
is used to support the hydraulic end assembly 9. The multi-point support
design of the crankcase, the
crosshead case and the hydraulic end assembly 9 can enhance the support
strength of the five cylinder
plunger pump and reduce the vibration, thus better ensuring high load
operation and more smoothly
running.
[0038] The operating principle of the plunger pump 5: An external power or
rotating speed is
transferred through the driving flange 10 to drive the reduction gearbox
assembly 8 to rotate. Power
and torque are transferred to the crankshaft through the two-stage speed
shifting of the planetary
reduction gearbox and the parallel reduction gearbox. The crankshaft rotates
within the power end
housing 11, driving the motion of the connecting rod, the crosshead and the
pull rod, converting the
rotational motion of the crankshaft into the reciprocating linear motion of
the pull rod. The pull rod
drives the plunger through a clamp to move back and forth within the valve
housing, thus realizing the
low pressure liquid suction and high pressure liquid discharge, i.e, realizing
the pumping of liquid.
[0039] The operating principle of the single-motor single-pump electric drive
fracturing semi-trailer: an
input end of the high voltage switch is connected to the high voltage power
supply through a cable, an
output end of the high voltage switch is connected to the transformer. The
high voltage switch is
configured to control the power supply on and off of the whole single-motor
single-pump electric drive
fracturing semi-trailer. High voltage electricity is dropped by a transformer
to supply power to the
frequency converter, the frequency converter drives the electric motor 4 to
work, and the electric motor
4 drives the plunger pump 5 to work. The radiator 6 cools the lubricating oil
of the plunger pump 5.
[0040] 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 be made to the
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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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