High power five-cylinder piston pump

Abstract

The application discloses a high-power five-cylinder plunger pump, wherein the stroke of the high-power five-cylinder plunger pump is 10in, the cylinder spacing is 11.5in, and the braking power is 5000HP. The high-power five-cylinder plunger pump has the beneficial effects of high power and large displacement, can be applied to electric drive fracturing and turbine fracturing, can select a whole power end assembly or a split power end assembly according to specific operation conditions, so that the arrangement mode of a fracturing unit or a fracturing vehicle is more optimally realized, and the size of the cylinder spacing can stably guarantee the operation of 5000HP braking power.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of plunger pump, in particular to a high-power five-cylinder plunger pump. BACKGROUND

[0002] With the continuous development of oil and gas field super-high pressure, super-deep well, horizontal well, its operating conditions are also more and more bad, requires fracturing equipment can high pressure, large displacement operation, some well site also requires continuous operation for a long time, in the case of total well site pressure, the smaller the power displacement of a single fracturing equipment, the more the number of fracturing equipment required to meet the total pressure demand.

[0003] At present, the well site area of oil and gas exploitation is required to be smaller and smaller, and reducing the number of fracturing equipment is one of the effective means; the actual well site access is also more rugged, the more the number of fracturing equipment, the longer the well site layout time, time and effort, so the smaller the power displacement of a single fracturing equipment, the more serious the contradiction between the well site area and the well site access, and the goal of "small well site large operation" is more and more imminent.

[0004] As the core component of fracturing equipment, the common plunger pump on the market mainly includes 2800HP five-cylinder plunger pump, 3000HP three-cylinder plunger pump, 3300HP five-cylinder plunger pump and 4000HP three-cylinder plunger pump; 2800HP five-cylinder plunger pump is mainly configured on 2500 type fracturing equipment vehicle, (at present, 2500 type fracturing vehicle is the most commonly used and most done fracturing equipment in fracturing operation); 4000HP three-cylinder plunger pump is configured on 3100HP fracturing equipment vehicle, but 4000HP plunger pump is three-cylinder pump, and its displacement is much lower than that of 2800HP five-cylinder pump, under the same plunger specification and the same stroke, its displacement is only 82.54% of that of 2800HP five-cylinder pump; for the emerging electric fracturing operation in recent years, i.e. the fracturing operation form using electric motor as power source, the electric motor can select very large power, for example: the rated power can reach 3000KW, 4000KW, 5000KW, 6000KW, etc., but the plunger pump does not have such a large specification, if 2800HP plunger pump and 4000HP plunger pump are configured on electric fracturing equipment, the advantage of electric fracturing cannot be reflected, which is equivalent to a large horse pulling a small cart.

[0005] In addition, turbo fracturing is also the development trend of recent fracturing operation, (turbo fracturing is a fracturing operation form using turbo engine as power source), but the output rotation direction of turbo engine cannot match the input rotation direction of existing plunger pump, so a reversing mechanism is usually added before the input rotation direction of plunger pump, but this will increase the overall weight of turbo fracturing equipment, increase the risk of failure, increase the maintenance cost and other problems.

[0006] Therefore, a large-power, large-displacement plunger pump suitable for different working conditions and different fracturing operation forms is urgently needed. SUMMARY

[0007] The large-power five-cylinder plunger pump provided by the application has large power and large displacement, can be applied to electric drive fracturing and turbine fracturing, can select a whole power end assembly or a split power end assembly according to specific working conditions, and can realize the arrangement mode of a fracturing unit or a fracturing vehicle.

[0008] The large-power five-cylinder plunger pump provided by the application has large power and large displacement, can be applied to electric drive fracturing and turbine fracturing, can select a whole power end assembly or a split power end assembly according to specific working conditions, and can realize the arrangement mode of a fracturing unit or a fracturing vehicle.

[0009] Further, the large-power five-cylinder plunger pump comprises a power end assembly, a hydraulic end assembly and a reduction gearbox assembly, the hydraulic end assembly and the reduction gearbox assembly are connected with the power end assembly respectively, the reduction gearbox assembly comprises a parallel stage reduction gearbox and a planetary stage reduction gearbox, one end of the planetary stage reduction gearbox is connected with the parallel stage reduction gearbox, and the other end of the planetary stage reduction gearbox is connected with the power end assembly.

[0010] Further, the reduction ratio of the reduction gearbox assembly is 12.2-12.5.

[0011] Further, the reduction ratio of the parallel stage reduction gearbox is 2.1-2.5, and the reduction ratio of the planetary stage reduction gearbox is 5-5.8.

[0012] Further, the reduction ratio of the reduction gearbox assembly is suitable for a fracturing operation with a motor as a power source.

[0013] Further, the reduction ratio of the reduction gearbox assembly is 9.4-9.6.

[0014] Further, the reduction ratio of the parallel stage reduction gearbox is 1.6-1.8, and the reduction ratio of the planetary stage reduction gearbox is 5.3-6.3.

[0015] Further, the reduction ratio of the reduction gearbox assembly is suitable for a fracturing operation with a turbine engine as a power source.

[0016] Further, the reduction gearbox assembly is installed at the left end or the right end of the power end assembly according to actual use requirements.

[0017] Further, when the high-power five-cylinder plunger pump is used in a fracturing operation powered by an electric motor, the reduction gearbox assembly is installed at the left end or the right end of the power end assembly; when the high-power five-cylinder plunger pump is used in a fracturing operation powered by a turbine engine, the reduction gearbox assembly is installed at the right end of the power end assembly.

[0018] Further, the power end assembly adopts a whole power end assembly or a split power end assembly according to actual use requirements.

[0019] Further, the power end assembly comprises a power end shell, a cross head support box and a retainer, which are sequentially arranged; when the power end assembly is a whole power end assembly, the power end shell and the cross head support box are a whole; when the power end assembly is a split power end assembly, the power end shell and the cross head support box are independent structures, and the power end shell and the cross head support box are fixed by bolts.

[0020] Compared with the prior art, the beneficial effects of the present application are as follows: 10in stroke ensures large displacement, i.e. ensures high power, and improves operation efficiency; 11.5in cylinder spacing increases the load bearing area of the connecting rod cross head assembly (connecting rod, cross head and bearing), provides sufficient load bearing capacity for a 5000HP five-cylinder plunger pump, ensures stable large displacement output of the five-cylinder plunger pump, improves the power of the five-cylinder plunger pump, i.e. improves the fracturing capacity of a single fracturing device, so that the total number of fracturing devices in a well site can be reduced, the contradiction between small well site area and many fracturing devices is effectively solved, and well site arrangement can be quickly completed with time and labor saved. Two transmission ratios solve the problem that there is no high-power plunger pump matching the existing high-power power source in electric drive fracturing and turbine fracturing, and the turbine engine and the selected electric motor can be better matched according to different transmission ratios. Without increasing the reversing mechanism, the biggest problem is solved at the minimum cost, i.e. the right end of the reduction gearbox assembly is installed, so that the output rotation direction of the turbine engine is matched with the input rotation direction of the crankshaft, thereby realizing the driving of the five-cylinder plunger pump without increasing the weight, the risk of failure and the maintenance cost. The whole power end assembly or the split power end assembly can be selected according to specific operation conditions, so that the arrangement mode of the fracturing unit or the fracturing vehicle is more optimally realized.

[0021] The present application will be described in detail below in combination with the drawings and specific embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0022] Figure 1 is a structural schematic view of the high-power five-cylinder plunger pump (right end installation).

[0023] Figure 2 is a structural schematic view of the high-power five-cylinder plunger pump (left end installation).

[0024] Figure 3 is the cross-sectional view of the high-power five-cylinder piston pump.

[0025] Figure 4 is the schematic diagram of the power end assembly in a split structure.

[0026] Figure 5 is the schematic diagram of the power end assembly in an integrated structure.

[0027] Figure 6 is the schematic diagram of the connecting rod and crosshead assembly.

[0028] Figure 7 is the schematic diagram of the crankshaft.

[0029] Figure 8 is the schematic diagram of the reduction gearbox assembly.

[0030] Figure 9 is the schematic diagram of the parallel stage reduction gearbox.

[0031] Figure 10 is the schematic diagram of the planetary stage reduction gearbox.

[0032] wherein, 1. power end assembly, 2. hydraulic end assembly, 3. reduction gearbox assembly, 4. input flange, 5. power end housing, 6. bearing, 7. crankshaft, 8. connecting rod and crosshead assembly, 9. crank journal, 10. crank web, 11. piston, 12. valve chest, 13. crosshead support housing, 14. cage, 15. connecting bolt, 16. parallel stage reduction gearbox, 17. planetary stage reduction gearbox, 18. bull gear, 19. pinion gear, 20. planetary gear, 21. gear ring, 22. sun gear. DETAILED DESCRIPTION

[0033] As shown in Figures 1 to 10 , the high-power five-cylinder piston pump has a stroke of 10 in, a cylinder spacing of 11.5 in, and a brake power of 5000 HP. The stroke of 10 in ensures a large displacement, i.e., a high power, and improves the work efficiency. The cylinder spacing of 11.5 in increases the bearing area of the connecting rod and crosshead assembly 8 (connecting rod, crosshead, and bearing shell), providing sufficient bearing capacity for the five-cylinder piston pump of 5000 HP, ensuring stable large displacement output, and increasing the power of the five-cylinder piston pump, i.e., increasing the fracturing capacity of a single fracturing device, so that the total number of fracturing devices in the well site can be reduced, effectively solving the contradiction between the small well site area and the large number of fracturing devices, and also enabling the well site layout to be quickly completed with time and labor saved.

[0034] The high-power five-cylinder plunger pump comprises a power end assembly 1, a hydraulic end assembly 2 and a reduction gearbox assembly 3, the hydraulic end assembly 2 and the reduction gearbox assembly 3 are connected with the power end assembly 1 respectively, the hydraulic end assembly 2 is connected with the power end assembly 1 through connecting bolts 15, the reduction gearbox assembly 3 is connected with the power end assembly 1 through bolts, the reduction gearbox assembly 3 is externally provided with an input flange 4, and a power source is connected to the input flange 4. The reduction gearbox assembly 3 comprises a parallel stage reduction gearbox 16 and a planetary stage reduction gearbox 17, one end of the planetary stage reduction gearbox 17 is connected with the parallel stage reduction gearbox 16, and the other end of the planetary stage reduction gearbox 17 is connected with the power end assembly 1. The input angle of the reduction gearbox assembly 3 can be adjusted according to input requirements, and the required multi-angle adjustment of the five-cylinder plunger pump transmission in the fracturing equipment can be met. The reduction gearbox assembly 3 adopts helical tooth meshing, the planetary stage reduction gearbox 17 comprises a sun gear 22, four planetary gears 20 and a gear ring 21, the four planetary gears 20 form a planetary gear mechanism, the planetary gear mechanism is arranged in the interior of the gear ring 21, and the sun gear 22 is located in the center of the planetary gear mechanism. The parallel stage reduction gearbox 16 comprises a large gear 18 and a small gear 19, the small gear 19 is connected with the input flange 4, and the large gear 18 is coaxially connected with the sun gear 22 of the planetary stage reduction gearbox 17. The input flange 4 inputs a rotating speed, the rotating speed is transmitted to the large gear 18 through the small gear 19 to realize one-stage reduction, the rotating speed is transmitted to the sun gear 22 through the large gear 18, and the sun gear 22 transmits the rotating speed to the planetary gears 20 to realize two-stage reduction, so that a large transmission ratio is obtained. The hydraulic end assembly 2 comprises a valve box 12 and a plunger 11, and the plunger 11 is arranged in the interior of the valve box 12.

[0035] The reduction ratio of the reduction gearbox assembly 3 is 12.2-12.5. The reduction ratio of the parallel stage reduction gearbox 16 is 2.1-2.5, and the reduction ratio of the planetary stage reduction gearbox 17 is 5-5.8. The reduction ratio of the reduction gearbox assembly 3 is suitable for the fracturing operation with the motor as the power source, i.e. electric drive fracturing. The reduction ratio of the reduction gearbox assembly 3 is 9.4-9.6. The reduction ratio of the parallel stage reduction gearbox 16 is 1.6-1.8, the reduction ratio of the planetary stage reduction gearbox 17 is 5.3-6.3, and the reduction ratio of the reduction gearbox assembly 3 is suitable for the fracturing operation with the turbine engine as the power source, i.e. turbine fracturing. The two kinds of transmission ratios solve the problem that there is no high-power plunger pump matched with the existing high-power power source in the electric drive fracturing and turbine fracturing, and also adapt to different fracturing operation forms according to different transmission ratios, and the turbine engine and the selected motor can be better matched.

[0036] Through the setting of different reduction ratios, the applicability of the 5000HP high-power five-cylinder plunger pump is increased, i.e. the 5000HP high-power five-cylinder plunger pump can be applied to the electric drive fracturing operation and the turbine fracturing operation. The displacement output of a single electric drive fracturing device and a single turbine fracturing device is increased, and the technical difficulty that the "small well site" is difficult to perform large operation is well solved.

[0037] The reduction gearbox assembly 3 is installed at the left end or the right end of the power end assembly 1 according to actual use requirements. Compared with the existing five-cylinder piston pump, the connection mode of the right end is added, that is, the reduction gearbox assembly 3 is connected with the right end of the crankshaft 7 in the power end assembly 1.

[0038] When the high-power five-cylinder piston pump is used in the fracturing operation with the motor as the power source, the reduction gearbox assembly 3 is installed at the left end or the right end of the power end assembly 1. Since the output rotation direction of the motor can be adjusted, whether the reduction gearbox assembly 3 is installed at the left end or the right end of the power end assembly 1, it is only necessary to adjust the output rotation direction of the motor according to the input rotation direction requirement of the crankshaft 7. When the high-power five-cylinder piston pump is used in the fracturing operation with the turbine engine as the power source, the reduction gearbox assembly 3 is installed at the right end of the power end assembly 1. Without increasing the reversing mechanism, the greatest problem is solved at the minimum cost, that is, the right end of the reduction gearbox assembly 3 is installed, so that the output rotation direction of the turbine engine matches the input rotation direction of the crankshaft 7, thereby enabling the turbine fracturing equipment to drive the five-cylinder piston pump without increasing the weight, the risk of failure and the maintenance cost.

[0039] The power end assembly 1 adopts the integral power end assembly 1 or the split power end assembly 1 according to actual use requirements. The integral power end assembly 1 is suitable for high-pressure continuous operation of well site fracturing and whole skid installation arrangement due to its high stiffness, strong bearing capacity and stable structure. The split power end assembly 1 is lighter than the integral power end assembly 1, and is suitable for intermittent operation of well site fracturing and can provide more carrier forms for the fracturing equipment, such as vehicle-mounted, semi-trailer, skid-mounted and the like. The two power end assemblies 1 can better meet different operation requirements and carrying requirements of the field.

[0040] The power end assembly 1 comprises a power end housing 5, a cross head support box 13 and a retainer 14, which are sequentially arranged, the power end housing 5 and the cross head support box 13 are integrated when the power end assembly 1 is integrated, the power end housing 5 and the cross head support box 13 are both independent structures when the power end assembly 1 is split, and the power end housing 5 and the cross head support box 13 are fixed by bolts. A crankshaft assembly is arranged in the power end housing 5, a connecting rod and cross head assembly 8 is arranged in the cross head support box 13, the crankshaft assembly is connected with one end of the connecting rod and cross head assembly 8, the other end of the connecting rod and cross head assembly 8 drives a plunger 11 to do reciprocating motion in a valve box 12 through the transmission of a pull rod, so as to realize the suction of low-pressure liquid and the discharge of high-pressure liquid. The crankshaft assembly comprises a crankshaft 7 and a bearing 6, the crankshaft 7 is connected with the power end housing 5 through the bearing 6, the crankshaft 7 comprises six crank necks 9 and five crank webs 10, one crank web 10 is arranged between two adjacent crank necks 9, the distance between the crank web 10 and the rotation center of the crankshaft 7 is 5in, and the bearing 6 is a cylindrical roller bearing.

[0041] Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, the above-mentioned embodiments and the description in the specification are only to illustrate the principles of the present application, and various changes and improvements can be made without departing from the spirit and scope of the present application, and these changes and improvements all fall within the scope of the present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A high power five cylinder piston pump characterized by: The large power five-cylinder plunger pump has a stroke of 10in, a cylinder spacing of 11.5in and a braking power of 5000HP, and comprises a power end assembly, a hydraulic end assembly and a reduction gearbox assembly, wherein the hydraulic end assembly and the reduction gearbox assembly are connected with the power end assembly respectively, the reduction gearbox assembly is externally provided with an input flange, the power source is connected with the input flange, and the reduction gearbox assembly is installed at the left end or the right end of the power end assembly according to actual use requirements; when the large power five-cylinder plunger pump is used in a fracturing operation with a motor as the power source, the reduction gearbox assembly is installed at the left end or the right end of the power end assembly; when the large power five-cylinder plunger pump is used in a fracturing operation with a turbine engine as the power source, the reduction gearbox assembly is installed at the right end of the power end assembly so as to match the output rotation direction of the turbine engine with the input rotation direction of the crankshaft of the power end assembly.

2. The large capacity five cylinder piston pump of claim 1 wherein: The reduction gearbox assembly comprises a parallel stage reduction gearbox and a planetary stage reduction gearbox, one end of the planetary stage reduction gearbox is connected with the parallel stage reduction gearbox, and the other end of the planetary stage reduction gearbox is connected with the power end assembly.

3. The large capacity five cylinder piston pump of claim 2 wherein: The reduction ratio of the reduction gearbox assembly is 12.2-12.

5.

4. The large capacity five cylinder piston pump of claim 3 wherein: The reduction ratio of the parallel stage reduction gearbox is 2.1-2.5, and the reduction ratio of the planetary stage reduction gearbox is 5-5.

8.

5. A high power five-cylinder piston pump according to claim 3 or 4, characterized in that: The reduction ratio of the reduction gearbox assembly is suitable for a fracturing operation with a motor as the power source.

6. The large capacity five cylinder piston pump of claim 2 wherein: The reduction ratio of the reduction gearbox assembly is 9.4-9.

6.

7. The high power five cylinder piston pump of claim 6, wherein: The reduction ratio of the parallel stage reduction gearbox is 1.6-1.8, and the reduction ratio of the planetary stage reduction gearbox is 5.3-6.

3.

8. A high power five-cylinder piston pump according to claim 2 or 6, characterized in that: The reduction ratio of the reduction gearbox assembly is suitable for a fracturing operation with a turbine engine as the power source.

9. The high power five cylinder piston pump of claim 1 wherein: The power end assembly adopts a monolithic power end assembly or a split power end assembly according to actual use requirements.

10. The high power five cylinder piston pump of claim 9, wherein: The power end assembly comprises a power end shell, a crosshead support box and a retainer, which are sequentially arranged, wherein when the power end assembly is monolithic, the power end shell and the crosshead support box are monolithic, and when the power end assembly is split, the power end shell and the crosshead support box are independent structures and are fixed by bolts.

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