Electric Fracturing Pump Braking for High-Pressure Burst Shutdown
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Solution Overview
Problem
Existing electric drive fracturing devices lack a braking system, leading to the inability to rapidly shut down during high-pressure manifold system failures, resulting in environmental pollution and personal safety hazards.
Innovation Solution
Incorporating a braking system with a brake trigger component and execution components, such as high-pressure shutoff valves, shutoff valves in the low-pressure manifold system, brake calipers, and frequency converters, to enable rapid emergency braking and energy recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no braking system is equipped in the electric drive fracturing device, then the device structure remains simple, but rapid emergency shutdown cannot be achieved when high-pressure manifold system bursts occur
Solution Approach 1:
The braking system is pre-configured with brake execution components (brake calipers, brake discs) and control components that are ready to activate immediately upon detecting high-pressure system failures. The system performs preliminary preparation by positioning braking elements and establishing control circuits before emergencies occur, enabling instant response without adding complex operational procedures.
Solution Approach 2:
The control system acts as an intermediary between the brake trigger component (pressure sensor) and the brake execution component. When the pressure sensor detects abnormal pressure indicating a burst, it transmits a brake signal through the control system, which then activates the brake calipers. This intermediary control mechanism enables automated rapid shutdown without requiring direct mechanical linkages or complex manual intervention systems.
2Object-affected harmful factors
If the electric drive fracturing device lacks rapid braking capability, then the device operates continuously, but operating medium is discharged to the well site causing environmental pollution and material waste
Solution Approach 1:
The braking system enables the device to rapidly skip through the emergency response time by immediately activating brake calipers when high-pressure system failures are detected. This rushing through of the shutdown process prevents the continuous operation that would otherwise lead to operating medium discharge, thereby eliminating environmental pollution and material waste hazards associated with delayed response.
Solution Approach 2:
The pressure sensor continuously monitors the high-pressure manifold system and provides feedback to the control system. When abnormal pressure indicating a burst condition is detected, the sensor sends a brake signal through the control system to activate the brake execution component. This closed-loop feedback mechanism ensures immediate detection and response to failures, preventing operating medium discharge before it can cause environmental harm.
3Reliability
If a braking system with brake calipers and brake discs is added to the electric drive fracturing device, then rapid emergency braking is achieved, but the device weight and floor area increase
Solution Approach 1:
The brake execution components (brake calipers and brake discs) are designed to serve multiple functions: providing emergency braking capability for rapid shutdown, and potentially serving as part of the normal operational control system. This multi-functionality justifies the added weight by enabling the braking system to handle both emergency and routine stopping requirements, reducing the need for separate dedicated emergency braking components.
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
Enables immediate emergency shutdowns, reducing safety hazards and environmental pollution, and allows for the recycling of braking energy.
Implementation Method 1
The brake execution component is a brake caliper and a brake disc, and the brake disc is arranged on an output shaft of the electric motor or an input shaft of the plunger pump... the brake caliper is configured to clamp and rub the brake disc after receiving the brake signal
Implementation Method 2
through a frequency converter provided with a brake battery, it is also possible to recycle and utilize the braking energy while achieving braking
Data Source
AI summary
An electric drive fracturing device and a braking method therefor are provided. The electric drive fracturing device includes an electric drive fracturing device body and a braking system. The electric drive fracturing device body includes a plunger pump and a control system. The braking system includes a brake trigger component and a brake execution component. The brake trigger component transmits a brake signal to the control system, and after receiving the brake signal transmitted by the brake trigger component, the control system controls the brake execution component to perform a braking action to stop the plunger pump. In the present invention, a braking system is arranged in the electric drive fracturing device, so that rapid braking of the electric drive fracturing device can be implemented, and emergency braking can be performed immediately when a problem such as bursting of a high-pressure manifold system occurs on site.