A five-cylinder plunger pump with multi-point support

Abstract

The present invention discloses a five-cylinder plunger pump with multi-point support, comprising a power end assembly, a hydraulic end assembly and a reduction gearbox assembly, wherein the power end assembly comprises a crankcase, a crosshead housing and a spacer, wherein the crankcase, the crosshead housing and the spacer are connected in sequence, wherein the hydraulic end assembly is fixed on the spacer, wherein the reduction gearbox assembly is fixed on the crankcase, wherein a crankshaft support body is provided at the bottom of the crankcase, wherein the crankshaft support body is used to support the crankcase, wherein a crosshead support body is provided at the bottom of the crosshead housing, wherein the crosshead support body is used to support the crosshead housing, wherein a hydraulic support body is provided at the bottom of the spacer, wherein the hydraulic support body is used to support the hydraulic end assembly. Beneficial effect: by designing the crankcase, the crosshead housing and the hydraulic end assembly with multi-point support, the support strength of the plunger pump can be improved, vibration can be reduced, high-load operation can be better guaranteed and operation can be more stable.

Description

Technical Field

[0001] The present invention relates to the technical field of plunger pumps, and in particular to a five-cylinder plunger pump with multi-point support. Background Art

[0002] With the further development of unconventional oil and gas, shale oil and gas, the requirements for pressure and displacement of fracturing operations are constantly increasing. Not only does the operating pressure increase with the increase in the depth of horizontal wells, but the displacement required for single-stage wells is also getting higher and higher. This makes the scale of fracturing operations larger and larger. The harsh operating conditions also put higher requirements on fracturing equipment, especially plunger pumps. At present, in the process of shale oil and gas development, the operating pressure generally reaches 80-90MPa or even higher, and the displacement of a single stage operation is generally 1800m 3 -2000m 3 Even more, the plunger pump must not only be able to meet the needs of continuous operation with high pressure and large displacement, but also ensure the quality stability under continuous high-load operation, and reduce the pump downtime and maintenance time. Currently, the most widely used fracturing truck on the market is the 2500 type fracturing truck, which is equipped with a 2800hp plunger pump. Other commonly used fracturing pump types include 2500hp pumps, 3300hp pumps, 4000hp pumps, etc. Taking the 2800hp pump as an example, due to power limitations, the single pump displacement is low during high-pressure operation, and the displacement requirement for a single stage is 14-16m 3 At a shale gas well site with a flow rate of 100 / min, nearly 20 fracturing trucks are required to operate simultaneously to meet the total displacement requirements of the fracturing operation. This occupies a large area of the well site, making it difficult to arrange equipment in the confined oil and gas field. Furthermore, conventional plunger pumps face increasingly harsh operating conditions and long periods of high load operation, resulting in an increasing frequency of problems and increased maintenance and repair costs. In recent years, electric-driven fracturing operations have become increasingly popular. The use of electric motors has overcome the power limitations of diesel engines and is more suitable for driving high-power plunger pumps.

[0003] As the power of the plunger pump increases, higher requirements are placed on the operating stability and support strength of the plunger pump itself. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a five-cylinder plunger pump with multi-point support. By designing the crankcase, crosshead housing and hydraulic end assembly with multi-point support, the support strength of the plunger pump can be improved, vibration can be reduced, high-load operation can be better guaranteed, and the operation can be smoother. The crankcase and crosshead housing in the power end assembly of the five-cylinder plunger pump adopt an integral welded structure, which makes the structural strength of the power end assembly higher, the support stability better, and the vibration of the entire pump can be reduced. The cylinder spacing of the five-cylinder plunger pump is designed to be 13-14 inches, which increases the bearing area of the connecting rod, crosshead and bearing, and provides a guarantee for the high-power output of the five-cylinder plunger pump. The specific power of the five-cylinder plunger pump can reach 7000hp. The high-power five-cylinder plunger pump can effectively solve the problems of the small area of shale gas fracturing well site and the large amount of fracturing equipment required, which can reduce the use of equipment and facilitate well site layout.

[0005] The objective of the present invention is achieved through the following technical measures: a multi-point supported five-cylinder plunger pump, comprising a power end assembly, a hydraulic end assembly and a reduction gear assembly, the power end assembly comprising a crankcase, a crosshead case and a spacer, the crankcase, the crosshead case and the spacer are connected in sequence, the hydraulic end assembly is fixed on the spacer, the reduction gear assembly is fixed on the crankcase, a crankshaft support body is provided at the bottom of the crankcase, the crankshaft support body is used to support the crankcase, a crosshead support body is provided at the bottom of the crosshead case, the crosshead support body is used to support the crosshead case, a hydraulic support body is provided at the bottom of the spacer, the hydraulic support body is used to support the hydraulic end assembly.

[0006] Furthermore, the crankcase and the crosshead case are integrally welded to form a power end housing, which is connected to a spacer. The power end housing includes a vertical plate, a bearing seat, a front end plate, a rear cover plate, a bottom plate, a support plate and an upper cover plate. The number of the vertical plates is 6, and the number of the bearing seats is 6. One vertical plate is connected to one bearing seat. The 6 vertical plates are arranged in parallel to form a power end cavity. The bottom plate is installed at the bottom of the power end cavity, the upper cover plate is installed at the top of the power end cavity, the front end plate is installed at the front end of the power end cavity, and the rear cover plate is installed at the rear end of the power end cavity. A support plate is provided between two adjacent parallel vertical plates.

[0007] Furthermore, a crosshead assembly is arranged in the crosshead housing, a connecting rod assembly is arranged between the crankcase and the crosshead housing, a crankshaft is arranged in the crankcase, one end of the connecting rod assembly is connected to the crankshaft through a connecting rod bearing, and the other end of the connecting rod assembly is connected to the crosshead assembly through a crosshead bearing. Both the connecting rod bearing and the crosshead bearing are steel back bearings with alloy plating.

[0008] Furthermore, the cylinder spacing of the five-cylinder plunger pump is 13-14 inches.

[0009] Compared with the prior art, the beneficial effects of the present invention are: through the multi-point support design of the crankcase, crosshead case and hydraulic end assembly, the support strength of the five-cylinder plunger pump can be improved, vibration can be reduced, high-load operation can be better guaranteed, and operation can be smoother. The crankcase and crosshead case in the power end assembly of the five-cylinder plunger pump adopt an integral welded structure, which makes the structural strength of the power end assembly higher, the support stability is better, and the vibration of the entire pump can be reduced. The cylinder spacing of the five-cylinder plunger pump is designed to be 13-14 inches, which increases the bearing area of the connecting rod, crosshead and bearing, and provides a guarantee for the high-power output of the five-cylinder plunger pump. The specific power of the five-cylinder plunger pump can reach 7000hp. The high-power five-cylinder plunger pump can effectively solve the problems of the small area of ​​shale gas fracturing well site and the large amount of fracturing equipment required, which can reduce the use of equipment and facilitate well site layout.

[0010] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 It is a structural diagram of this five-cylinder plunger pump.

[0012] Figure 2 It is a structural diagram of the power end assembly.

[0013] Figure 3 It is a structural diagram of the power end housing.

[0014] Figure 4 It is a structural diagram of the reduction gearbox assembly.

[0015] Figure 5 It is a cross-sectional view of a planetary gearbox.

[0016] Figure 6 It is a cross-sectional view of the parallel stage reduction gearbox.

[0017] Figure 7 It is a structural diagram of the crankshaft.

[0018] Figure 8 It is a structural diagram of the connection between the connecting rod assembly and the crosshead assembly.

[0019] Among them, 1. Power end assembly, 2. Reducer assembly, 3. Fluid end assembly, 4. Drive flange, 5. Power end housing, 6. Crankshaft, 7. Bearing, 8. Connecting rod bearing, 9. Connecting rod body, 10. Slide rail, 11. Crosshead, 12. Crosshead bearing, 13. Tie rod, 14. Spacer, 15. Long screw, 16. Nut, 17. Clamp, 18. Plunger, 19. Valve box, 20. Crankshaft support, 21. Crosshead support, 22. Fluid Support body, 23. Rear cover, 24. Vertical plate, 25. Bearing seat, 26. Bottom plate, 27. Support plate, 28. Front end plate, 29. Upper cover, 30. Parallel stage reducer, 31. Planetary stage reducer, 32. Inner ring gear, 33. Planet gear, 34. Sun gear, 35. Planet carrier, 36. Big gear, 37. Small gear, 38. Spline, 39. Connecting rod cover, 40. Connecting rod bolt, 41. Crosshead gland, 42. Guide plate, 43. Screw. DETAILED DESCRIPTION

[0020] Examples, such as Figures 1 to 8 As shown, a five-cylinder plunger pump with an integral power end structure includes a power end assembly 1, a fluid end assembly 3 and a reduction gearbox assembly 2. One end of the power end assembly 1 is connected to the fluid end assembly 3, and the other end of the power end assembly 1 is connected to the reduction gearbox assembly 2. The power end assembly 1 includes a crankcase, a crosshead housing and a spacer 14. The crankcase and the crosshead housing are integrally welded to form a power end housing 5. The power end housing 5 is connected to the spacer 14. The power end housing 5 includes a vertical plate 24, a bearing seat 25, a front end plate 28, and a rear end plate 29. The cover plate 23, the bottom plate 26, the support plate 27 and the upper cover plate 29, the number of the vertical plates 24 is 6, the number of the bearing seats 25 is 6, one vertical plate 24 is connected to one bearing seat 25, and the 6 vertical plates 24 are arranged in parallel to form a power end cavity. The bottom plate 26 is installed at the bottom of the power end cavity, the upper cover plate 29 is installed at the top of the power end cavity, the front end plate 28 is installed at the front end of the power end cavity, and the rear cover plate 23 is installed at the rear end of the power end cavity. A support plate 27 is provided between two adjacent parallel vertical plates 24. The crankcase and crosshead case in the five-cylinder plunger pump power end assembly 1 adopt an integral welded structure, which makes the structural strength of the power end assembly 1 higher and the support stability better. It can effectively reduce the load-bearing deformation of the power end housing 5, reduce the vibration of the entire pump, and improve the operating stability of the five-cylinder plunger pump.

[0021] A crankshaft support 20 is located at the bottom of the crankcase, supporting the crankcase. A crosshead support 21 is located at the bottom of the crosshead housing, supporting the crosshead housing. A hydraulic support 22 is located at the bottom of the spacer 14, supporting the hydraulic end assembly 3. The five-cylinder plunger pump utilizes a multi-point support design, which improves its support strength, reduces vibration, and ensures smoother operation under high loads.

[0022] The crankcase is provided with a crankshaft 6 and a bearing 7. The crankshaft 6 is integrally forged from alloy steel and includes six journals and five cranks. A crank is provided between two adjacent journals. The cylinder spacing of the five-cylinder plunger pump is 13-14 inches. The design of increasing the cylinder spacing is conducive to increasing the contact area between the crankshaft 6 and the connecting rod bearing 8, and between the crosshead 11 and the slide rail 10, thereby improving the support strength. This provides a guarantee for the high-power output of the five-cylinder plunger pump. The high-power five-cylinder plunger pump can effectively solve the problems of the small area of shale gas fracturing well sites and the large number of required fracturing equipment, reduce the use of equipment, and facilitate well site layout. There are six bearings 7, and the six bearings 7 are mounted on the six journals. At the same time, the outer rings of the bearings 7 are assembled on the six bearing seats 25 of the power end housing 5, and can realize rotational motion in the bearing seats 25.

[0023] A spline 38 is provided within the crankshaft 6. The reduction gearbox assembly 2 is bolted to the power end housing 5. The reduction gearbox assembly 2 is provided with an external spline that connects to the spline 38 for power output. The mounting angle of the reduction gearbox assembly 2 can be adjusted according to input requirements. A drive flange 4 is provided on the outside of the reduction gearbox assembly 2, which is connected to an external power source to achieve power input.

[0024] The crosshead housing houses a crosshead assembly, with a connecting rod assembly located between the crankcase and the crosshead housing. A crankshaft 6 is housed within the crankcase. One end of the connecting rod assembly is connected to the crankshaft 6 via a connecting rod bearing 8. The other end of the connecting rod assembly is connected to the crosshead assembly via a crosshead bearing 12, enabling reciprocating movement. The other end of the crosshead assembly is connected to a tie rod 13. The tie rod 13 is hollow. Both the connecting rod bearing 8 and the crosshead bearing 12 are steel-backed bearings with an alloy coating. They offer a large aspect ratio and high support strength.

[0025] A slide rail 10 is fixed on the support plate 27 in the power end housing 5. There are two slide rails 10, and the two slide rails 10 form a semicircular space. The crosshead 11 is installed in the semicircular space to achieve reciprocating linear motion.

[0026] The crosshead assembly is designed as a split structure, including a crosshead gland 41 and a crosshead 11. The crosshead gland 41 and the crosshead 11 are connected to facilitate assembly and disassembly with the connecting rod assembly.

[0027] The connecting rod assembly includes a connecting rod cap 39 and a connecting rod body 9. The connecting rod cap 39 and the connecting rod body 9 are forged as a single piece and then cut to provide high strength. The connecting rod cap 39 and the connecting rod body 9 are connected by bolts. Specifically, one end of the connecting rod body 9 is connected to the crankshaft via the connecting rod cap 39, connecting rod bolts 40, and connecting rod bearing shell 8. The other end of the connecting rod body 9 is connected to the crosshead 11 via a crosshead gland 41 and crosshead bearing shell 12. Guide plates 42, made of copper alloy, are fixed to the upper and lower ends of the crosshead 11 by screws 43. The guide plates 42 are in direct contact with the slide rail 10, allowing relative motion.

[0028] Lubricating oil passages are designed on the crankshaft 6 , the connecting rod body 9 , and the crosshead 11 for lubricating the bearings 7 , the connecting rod bearings 8 , and the crosshead bearings 12 .

[0029] The hydraulic end assembly 3 includes a valve box 19, a plunger 18, a clamp 17, etc. The hydraulic end assembly 3 connects the plunger 18 and the pull rod 13 together through the clamp 17, and uses a long screw 15 and a nut 16 to fix it on the spacer 14. The long screw 15 is connected to the power end housing 5 through a thread.

[0030] The five-cylinder plunger pump with an integral power end structure has a stroke of 11 inches. The long stroke design is well suited to the current shale gas fracturing zipper operation requirements, reducing the amount of equipment at the well site and improving operational efficiency and economy.

[0031] The reduction gearbox assembly 2 comprises a planetary-stage reduction gearbox 31 and a parallel-stage reduction gearbox 30. One end of the planetary-stage reduction gearbox 31 is connected to the power-end assembly 1, and the other end is connected to the parallel-stage reduction gearbox 30. The planetary-stage reduction gearbox 31 and the parallel-stage reduction gearbox 30 achieve a two-stage reduction in the reduction gearbox assembly 2, with a reduction ratio of 8:1-15:1. The parallel-stage reduction gearbox 30 includes a large gear 36 and a small gear 37 for primary reduction. The planetary-stage reduction gearbox 31 comprises a planetary gear mechanism consisting of an internal ring gear 32, four planetary gears 33, a sun gear 34, and a planet carrier 35, for secondary reduction. The sun gear 34 is located at the center of the planetary gear mechanism, meshing with the planetary gears 33 and coaxial with the large gear 36 of the parallel-stage reduction gearbox 30. During operation, the drive flange 4 is connected to an external power source to drive the input shaft to rotate. The power is transmitted to the large gear 36 through the small gear 37 to achieve a first-stage reduction, and then transmitted to the sun gear 34 through the large gear 36. The sun gear 34 drives the planetary carrier 35 through the planetary gears 33 to achieve a second-stage reduction, and finally the power is transmitted to the crankshaft 6 through the spline 38. The two-stage speed change can achieve a large transmission ratio, effectively reducing the input torque and reducing the number of strokes of the pump.

[0032] Working principle: External power or speed drives the reduction gearbox assembly 2 to rotate through the driving flange 4, and after the secondary speed change, the power and torque are transmitted to the crankshaft 6 through the spline 38. The crankshaft 6 and the bearing 7 rotate in the power end housing 5, driving the connecting rod body 9, the crosshead 11, and the pull rod 13 to move, and converting the rotational motion of the crankshaft 6 into the reciprocating linear motion of the pull rod 13. The pull rod 13 drives the plunger 18 to reciprocate in the valve box 19 through the clamp 17, thereby realizing the suction of low-pressure liquid and the discharge of high-pressure liquid, and realizing the pumping of liquid.

[0033] Those skilled in the art will appreciate that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A five-cylinder plunger pump with multi-point support, characterized in that: The invention comprises a power end assembly, a hydraulic end assembly and a reduction gearbox assembly, wherein the power end assembly comprises a crankcase, a crosshead case and a spacer, wherein the crankcase, the crosshead case and the spacer are connected in sequence, the hydraulic end assembly is fixed on the spacer, the reduction gearbox assembly is fixed on the crankcase, a crankshaft support body is provided at the bottom of the crankcase, the crankshaft support body is used to support the crankcase, a crosshead support body is provided at the bottom of the crosshead case, the crosshead support body is used to support the crosshead case, a hydraulic support body is provided at the bottom of the spacer, and the hydraulic support body is used to support the hydraulic end assembly; the crankcase and the crosshead case are integrally welded to form a power end housing, and the power end housing is provided with a hydraulic support body. The body is connected to the spacer, and the power end housing includes a vertical plate, a bearing seat, a front end plate, a rear cover plate, a bottom plate, a support plate and an upper cover plate. The number of the vertical plates is 6, and the number of the bearing seats is 6. One vertical plate is connected to one bearing seat. The 6 vertical plates are arranged in parallel to form a power end cavity. The bottom plate is installed at the bottom of the power end cavity, the upper cover plate is installed at the top of the power end cavity, the front end plate is installed at the front end of the power end cavity, and the rear cover plate is installed at the rear end of the power end cavity. A support plate is provided between two adjacent parallel vertical plates, and a slide rail is fixed to the support plate. The two slide rails form a semicircular space; the cylinder spacing of the five-cylinder plunger pump is 13-14 inches.

2. The multi-point supported five-cylinder plunger pump according to claim 1, characterized in that: A crosshead assembly is arranged in the crosshead housing, a connecting rod assembly is arranged between the crankcase and the crosshead housing, a crankshaft is arranged in the crankcase, one end of the connecting rod assembly is connected to the crankshaft through a connecting rod bearing, and the other end of the connecting rod assembly is connected to the crosshead assembly through a crosshead bearing. Both the connecting rod bearing and the crosshead bearing are steel back bearings with alloy plating.

Images