Direct Drive Unit Removal Assembly for Low-Downtime Fracturing Maintenance
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Solution Overview
Problem
Traditional fracturing pumping fleets face inefficiencies due to reliance on a single fuel source, leading to disruptions when units run low on fuel, requiring shutdowns and manual intervention, and significant downtime for maintenance or replacement, which affects pumping performance and increases operational delays.
Innovation Solution
A direct drive unit (DDU) positioner assembly is used to detach and remove the DDU from its enclosure efficiently, allowing for quick fuel refueling and maintenance by disconnecting turbine engines from air and fuel lines, using longitudinal and lateral rails with guide rollers and lubrication systems to facilitate sliding movement, and enabling the DDU to be withdrawn through access doors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional maintenance procedures are used to remove a direct drive unit from its enclosure, then the unit can be accessed for maintenance, but significant disassembly is required and excessive downtime occurs
Solution Approach 1:
The enclosure is divided into modular sections with removable panels that provide direct access to the direct drive unit. The support structure is segmented into adjustable components that can be reconfigured to accommodate unit removal without requiring complete disassembly of the entire enclosure system.
Solution Approach 2:
The support structure incorporates adjustable and movable components that can be dynamically reconfigured during maintenance operations. The enclosure panels are designed to be easily removed and reinstalled, allowing the system to transition between operational and maintenance states quickly.
2Ease of repair
If the entire trailer and enclosure are removed from the site for maintenance, then the direct drive unit can be accessed, but system operations are disrupted and delays increase
Solution Approach 1:
The direct drive unit is extracted from the enclosure through a dedicated access opening in the enclosure wall. This allows the unit to be removed for maintenance while the enclosure and remaining system components stay in place, maintaining site operations and avoiding the need to move the entire trailer.
Solution Approach 2:
A maintenance access system serves as an intermediary structure between the direct drive unit and the external environment. This includes removable enclosure panels, access platforms, and positioning mechanisms that facilitate unit removal through the enclosure wall without requiring complete system disassembly or relocation.
3Ease of manufacture
If manual intervention is required for refueling and maintenance operations, then fuel can be replenished and units maintained, but multiple personnel are required and operational delays occur
Solution Approach 1:
The system incorporates automated fuel storage and transfer capabilities where fuel can be replenished through self-service mechanisms. The enclosure design includes integrated fueling access points and positioning systems that enable rapid refueling operations with minimal manual intervention, reducing both time requirements and personnel needs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method minimizes system disruptions, reduces downtime, and allows continuous operation by enabling quick replacement or maintenance of DDUs without requiring extensive disassembly, thus maintaining pumping performance and reducing operational delays.
Implementation Method 1
a lubricator to convey lubricant to a lubrication portion of the base to facilitate sliding engagement between the platform and the lubrication portion
Implementation Method 2
The guide rollers may be in rolling engagement with the rails
Data Source
AI summary
Described herein are embodiments of systems and methods for the removal of a direct drive unit (DDU) housed in an enclosure, such as a direct drive turbine (DDT) connected to a gearbox for driving a driveshaft connected to a pump for use in hydraulic fracturing operations.