Extended-range fracturing pump truck and control method

Abstract

The invention relates to the technical field of fracturing, in particular to an extended-range fracturing pump truck and a control method. The pump truck comprises a chassis, and the chassis is provided with an engine located at the front end of the chassis; the plunger pump is located at the rear end of the chassis, and the plunger pump is used for being connected with an external working device; the generator set is in transmission connection with the output end of the engine so as to generate power by utilizing kinetic energy of the engine; the motor set is in transmission connection with the input end of the plunger pump, and the motor set is used for driving the plunger pump to work by utilizing the electric energy generated by the generator set; and the control box is used for controlling the output power of each generator in the generator set through a generator controller and controlling the output power of each motor in the motor set through a motor controller, so that the plunger pump keeps working, and the purposes of saving energy, reducing consumption and ensuring stable working are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of fracturing, and in particular to an extended-range fracturing pump truck and a control method thereof. Background Art

[0002] At present, the fracturing equipment used in oil and gas field exploitation is mostly divided into two types: diesel engine driven and electric drive. Among them, the diesel engine drives the fracturing pump to perform fracturing operations, and drives the fracturing pump through the gearbox and the universal shaft to fractur the oil layer, but the diesel engine drive always has defects such as high fuel consumption, large working vibration, large noise pollution and large body size. In addition, the gearbox cost is high. The electric drive fracturing equipment generally uses a three-phase asynchronous motor, with a motor of more than 600Kw, a large frequency conversion cabinet size, and high custom development costs.

[0003] Therefore, there is an urgent need to provide a new type of extended-range drive continuous fracturing pump truck to solve the problems existing in the prior art to a certain extent. Summary of the invention

[0004] The purpose of the present invention is to provide an extended-range fracturing pump truck and a control method. The present invention uses an engine as a power source, and drives the plunger pump to work through a transmission route composed of a generator set and an electric motor set, so that the chassis space is effectively utilized, the transmission efficiency is improved and the energy consumption is reduced. At the same time, by controlling the output power of the generator set and the electric motor set, the plunger pump can be effectively prevented from shutting down during operation to protect the execution end of the plunger pump, thereby achieving the purpose of energy saving and consumption reduction and ensuring stable operation.

[0005] In order to solve the above problems, the present invention adopts the following technical solutions: In a first aspect, the present invention provides an extended-range fracturing pump truck, which includes a chassis, and the chassis is provided with: engine; Plunger pump; used to connect external working device; A generator set is drivingly connected to the output end of the engine to generate electricity using the kinetic energy of the engine; An electric motor group is drivingly connected to the input end of the plunger pump, and the electric motor group is used to drive the plunger pump to work by utilizing the electric energy generated by the generator group; A control box is used to control the output power of each generator in the generator set through a generator controller, and is used to control the output power of each motor in the motor set through a motor controller, so as to keep the plunger pump working.

[0006] Optionally, it also includes a transfer case, which is arranged on the chassis and connected between the engine and the generator set, and the transfer case is used to transfer the power of the engine to each generator in the generator set.

[0007] Optionally, it further includes a high-voltage distribution box disposed on the chassis, and the high-voltage distribution box is connected to the generator controller and the motor controller; the electric energy generated by the generator set is transmitted to the high-voltage distribution box through the generator controller, and the high-voltage distribution box then transmits the electric energy to the motor set through the motor controller.

[0008] Optionally, it further includes a battery disposed on the chassis, and the battery is connected to the high-voltage distribution box, and the battery is used to jointly provide electric energy with the generator set.

[0009] Optionally, the motor set is drivingly connected to the plunger pump through a drive reduction box and a transmission shaft.

[0010] Optionally, it further includes a radiator disposed on the chassis and located in front of the engine.

[0011] Optionally, each generator in the generator set and each motor in the motor set are connected in parallel; the generator is a permanent magnet synchronous generator, and the motor is a permanent magnet synchronous motor.

[0012] In a second aspect, the present invention provides a control method for an extended-range fracturing pump truck, which is carried out by using the extended-range fracturing pump truck described above, and includes: Detect the operating states of each generator and / or motor; If there is a generator with an operating fault among the generators and / or motors, adjust the output powers of the generators and / or motors according to a preset rule so that the plunger pump can keep working.

[0013] Optionally, the adjusting the output powers of the generators and / or motors according to a preset rule includes: reducing the output power of the generator and / or motor with an operating fault to zero, and increasing the output powers of the remaining normal-operating generators and / or motors to meet the required power of the plunger pump.

[0014] Optionally, if all the remaining normal-operating generators or all the motors are difficult to meet the required power of the plunger pump, reduce the load connected to the plunger pump, and the remaining all generators or all motors keep working.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. The driving method adopted by the fracturing pump truck of the present invention is different from the two forms of diesel engine drive and electric drive. It utilizes the coordinated control of the generator controller and the motor controller. First, the kinetic energy of the engine is converted into electrical energy by the generator, and then the electrical energy is converted into kinetic energy by the motor to drive the plunger pump to work. Compared with mechanical transmission, it improves the transmission efficiency, reduces energy consumption, takes into account the high-power requirements of the pump truck operation and the requirements of energy conservation and environmental protection, and has a low vehicle weight, low use cost, high reliability, and strong practicability.

[0016] 2. In the fracturing pump truck of the present invention, a generator set and a motor set are adopted to meet the required power of the plunger pump. By controlling the output power of each generator and each motor, it can ensure that the plunger pump keeps working in case of a failure, thereby avoiding damage to the execution end caused by the interruption of the plunger pump operation. Description of the Drawings

[0017] Figure 1 It is a schematic structural diagram of the range-extended fracturing pump truck in Embodiment 1; Figure 2 It is a working principle diagram of the range-extended fracturing pump truck in Embodiment 1. Detailed Embodiments

[0018] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "center", "longitudinal", "lateral", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus cannot be understood as a limitation to the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the quantity of the indicated technical features. Thus, the features defined with "first", "second", etc. may explicitly or implicitly include one or more of such features. In the description of the present invention, unless otherwise stated, the meaning of "plurality" is two or more. In the description of the present invention, it should be noted that unless otherwise clearly defined and limited, the terms "installed", "connected", "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, an electrical connection; it can be directly connected, or indirectly connected through an intermediate medium, and it can be the internal communication of two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood through specific situations.

[0019] Among the prior arts known to the inventors of the present application, most of the existing fracturing equipment is to set a platform engine on the chassis, and then the platform engine drives the plunger pump to work through the gearbox and the drive shaft. This method has the following problems during use: 1. The plunger pump is affected by the gearbox speed ratio and the displacement is severely limited; 2. The mechanical transmission causes the layout of the whole vehicle to be restricted by the transmission route, and the plunger pump cannot be arranged longitudinally; 3. The chassis space of the vehicle cannot be effectively utilized, and the whole vehicle is relatively long.

[0020] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solution of the present invention, and cannot be used to limit the protection scope of the present invention. Example 1

[0021] Combination Figure 1 This embodiment provides an extended-range fracturing pump truck, characterized in that it includes a chassis 1, which is a common heavy truck load-bearing chassis, and its driving power is provided by the engine of the heavy truck. The chassis 1 includes a cab, and when it needs to be moved, it can be directly moved as a whole. However, the cab and the chassis 1 can also be connected in a split type, and the chassis 1 is a trailer structure, which can be connected to the cab to achieve mobile transfer.

[0022] The chassis 1 is provided with an engine 3, a plunger pump 13, a generator set 5, an electric motor set 6 and a control box; wherein the engine 3 is arranged at the rear of the cab of the chassis 1, and the plunger pump 13 is used to connect an external working device; the generator set 5 is transmission-connected to the output end of the engine 3 to generate electricity using the kinetic energy of the engine 3; the electric motor set 6 is transmission-connected to the plunger pump 13 through a driving reduction box 7 and a transmission shaft 12, and the electric motor set 6 is used to use the electric energy generated by the generator set 5 to provide a large amount of torque power to drive the plunger pump 13 to work; the control box is used to control the output power of each generator in the generator set 5 through a generator controller 8, and is used to control the output power of each motor in the motor set 6 through a motor controller to keep the plunger pump 13 working, and each generator in the generator set 5 and each motor in the motor set 6 are arranged in parallel; the generator is a permanent magnet synchronous generator, and the motor is a permanent magnet synchronous motor.

[0023] It can be understood that the present embodiment uses the engine 3 as the power source and transmits the power through the generator set 5 and the motor set 6, thereby improving the situation where the displacement is severely limited. At the same time, compared with mechanical transmission, the layout of the whole vehicle can be more reasonable, and the plunger pump 13 can be arranged longitudinally. In addition, the space of the vehicle chassis 1 of the vehicle can also be effectively utilized, the length of the whole vehicle is shortened, the weight of the whole vehicle is low, and the use cost of the whole vehicle is low. Moreover, the use of such a transmission method enables the control box to control the output power of each generator and / or each motor in real time, and in the event of a fault, adjust each generator and / or each motor according to preset rules to ensure that the plunger pump 13 keeps working, thereby avoiding damage to the working device of the execution end due to sudden interruption, and the reliability of the whole vehicle operation is high.

[0024] Furthermore, the chassis 1 is also provided with a radiator 2, a transfer case 4, a high-voltage distribution box 10, a drive reduction box 7, a battery 9, a high-voltage distribution box 10, and a transmission shaft 12.

[0025] The radiator 2 is transmission-connected to the engine 3 , and the radiator 2 can accelerate the air circulation of the engine 3 through the rotation of the fan, thereby achieving cooling of the engine 3 .

[0026] The transfer case 4 is disposed on the chassis 1 and connected between the engine 3 and the generator set 5. The transfer case 4 is used to transfer the power of the engine 3 to each generator in the generator set 5.

[0027] The high-voltage distribution box 10 is arranged on the chassis 1, and the high-voltage distribution box 10 is connected to the generator controller 8 and the motor controller; the electric energy generated by the generator set 5 is transmitted to the high-voltage distribution box 10 through the generator controller 8, and the high-voltage distribution box 10 then transmits the electric energy to the motor set 6 through the motor controller.

[0028] The battery 9 is arranged on the chassis 1 and connected to the high-voltage distribution box 10, and the battery 9 is used to provide electric energy together with the generator set 5. The purpose of setting the battery 9 here is that when the load fluctuates suddenly, the generator may be difficult to respond in time. Here, the battery 9 outputs power to make up for the momentary power shortage to prevent the motor from turning around. At the same time, a charging interface (for external charging) connected to the battery 9 is also arranged on the base.

[0029] In another specific embodiment, electronic components for detecting multiple channels of pressure, temperature, and vibration are installed at positions such as the lubricating oil circuit and key operating components (bearings, connecting rod tiles, crosshead copper sleeves, etc.) of the plunger pump 13, so as to be able to detect information such as the bearing temperature, connecting rod tile temperature, temperature at the copper sleeve of the pump casing, and working time of the pump body in a timely and effective manner. By comparing with the conventional operation database, relevant alarm signals are formed. Through the instrument display on the system, the information is real-time fed back to the computer and the operator. Intelligent operation controls such as emergency shutdown are realized in the case of untimely manual processing, simplifying the requirements for the operator, increasing the service life of the plunger pump 13, and at the same time, such comprehensive information can also be remotely transmitted to the user's mobile phone client.

[0030] Specifically, the working principle of an extended-range fracturing pump truck in this embodiment is as follows: The engine 3 transmits kinetic energy to the generator through the transfer case 4, and the generator then converts the kinetic energy into electrical energy. The generator controller 8 and the battery 9 then transmit the electrical energy to the high-voltage distribution box 10. The high-voltage distribution box 10 is connected to the motor controller 11 to transmit the electrical energy to the motor, and the motor then converts the electrical energy into kinetic energy to complete the extended-range process. Subsequently, the motor transmits the kinetic energy to the plunger pump 13 through the drive reduction box 7 and the transmission shaft 12. The plunger pump 13 converts the kinetic energy into pressure energy and injects it into the bottom of the well through the manifold system to complete the construction operation.

[0031] The extended-range fracturing pump truck in this embodiment, through extended-range energy conversion, rational layout of the complete vehicle-mounted system, and intelligent control, has neither the limitation of the traditional mechanical drive vehicle route layout nor the disadvantage of high energy conversion loss. At the same time, there is no charging and range anxiety of electric drive, extending the continuous working duration of the equipment and achieving the purpose of reducing fuel consumption and pollution. Embodiment 2

[0032] This embodiment provides a control method for an extended-range fracturing pump truck, which is carried out by using the extended-range fracturing pump truck described in Embodiment 1 and includes: Step S1, detecting the operating states of each generator and / or motor; Step S2, if there is a generator with an operating fault among the generators and / or motors, adjusting the output powers of the generators and / or motors according to a preset rule so that the plunger pump 13 can continue to work.

[0033] The extended-range fracturing pump truck in this embodiment uses the generator set 5 and the motor set 6 as the transmission route and monitors it in real time. When it is detected that a generator or a motor fails, the intelligent control box or the control system can control the multi-motor combination to intelligently process various fault situations.

[0034] In a specific embodiment, the number of both the generator and the motor is three. Under normal conditions, the three motors together meet the required power of the plunger pump 13, usually equally divided. The generator set 5 needs to meet the power requirements of the motors. Usually, the output power of the generator set 5 is designed to meet the normal operation requirements of the three motors of the motor group. When the load fluctuates, it can be compensated by the battery 9.

[0035] When a fault occurs, the output power of the faulty generator needs to be reduced to zero, that is, directly shut down, and the output power of the remaining normal generators needs to be increased to meet the required power of the plunger pump 13; the adjustment method of the motor is the same as that of the generator. Taking the number of the generator set 5 and the motor group 6 as three as an example, when one of them fails, the output power of the other two generators or motors is increased so that the plunger pump 13 can keep working. If two of them fail, at this time, the remaining generator or motor cannot meet the power requirements of the plunger pump 13 even at the maximum output power. At this time, it is necessary to reduce the external load connected to the plunger pump 13 so that the plunger pump 13 can keep working.

[0036] The above is only the preferred embodiment of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the technical principle of the present invention, several improvements and deformations can be made, and these improvements and deformations should also be regarded as the protection scope of the present invention.

Claims

1. An extended-range fracturing pump truck, characterized in that: The invention comprises a chassis (1), wherein the chassis (1) is provided with: An engine (3) located at the front end of the chassis (1); A plunger pump (13) is located at the rear end of the chassis (1), and the plunger pump (13) is used to connect to an external working device; A generator set (5) drivingly connected to the output end of the engine (3) to generate electricity using the kinetic energy of the engine (3); An electric motor group (6) is drivingly connected to an input end of the plunger pump (13), and the electric motor group (6) is used to drive the plunger pump (13) to work by utilizing the electric energy generated by the generator group (5); A control box is used to control the output power of each generator in the generator set (5) through a generator controller (8), and is used to control the output power of each motor in the motor set (6) through a motor controller (11).

2. The extended-range fracturing pump truck according to claim 1, characterized in that: Also includes: A transfer case (4) is arranged on the chassis (1) and connected between the engine (3) and the generator set (5); the transfer case (4) is used to transmit power from the engine (3) to each generator in the generator set (5).

3. The extended-range fracturing pump truck according to claim 1, characterized in that: Also includes: A high-voltage distribution box (10) is arranged on the chassis (1), and the high-voltage distribution box (10) is connected to the generator controller (8) and the motor controller (11); the electric energy generated by the generator set (5) is transmitted to the high-voltage distribution box (10) through the generator controller (8), and the high-voltage distribution box (10) then transmits the electric energy to the motor set (6) through the motor controller (11).

4. The extended-range fracturing pump truck according to claim 3, characterized in that: Also includes: A battery (9) is disposed on the chassis (1), the battery (9) is connected to the high-voltage distribution box (10), and the battery (9) is used to provide electrical energy together with the generator set (5).

5. The extended-range fracturing pump truck according to claim 1, characterized in that: The motor group (6) is connected to the plunger pump (13) via a drive reduction box (7) and a transmission shaft (12).

6. The extended-range fracturing pump truck according to claim 1, characterized in that: Also includes: A radiator (2) is arranged on the chassis (1) and is located in front of the engine (3).

7. The extended-range fracturing pump truck according to claim 1, characterized in that: Each generator in the generator set (5) and each motor in the motor set (6) are arranged in parallel; the generator is a permanent magnet synchronous generator, and the motor is a permanent magnet synchronous motor.

8. A control method for an extended-range fracturing pump truck, characterized in that: The method comprises: using an extended-range fracturing pump truck according to any one of claims 1 to 7, comprising: Detect the operating status of each generator and / or motor; If a generator and / or motor among the generators and / or motors fails in operation, the output power of each generator and / or motor is adjusted according to a preset rule so that the plunger pump (13) keeps working.

9. The control method of the extended-range fracturing pump truck according to claim 8, characterized in that: The adjusting the output power of each generator and / or motor according to a preset rule comprises: reducing the output power of a generator and / or motor with a malfunction to zero, and increasing the output power of the remaining generators and / or motors operating normally to meet the required power of the plunger pump (13).

10. The control method of the extended-range fracturing pump truck according to claim 9, characterized in that: If all the remaining generators or all the motors that are operating normally are unable to meet the power demand of the plunger pump (13), the load connected to the plunger pump (13) is reduced, and all the remaining generators or all the motors remain in operation.

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