Gas Turbine Fracking Pump Trailer Torque Converter
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Solution Overview
Problem
Conventional hydraulic fracturing operations using diesel engines face issues with low reliability, high equipment footprint, vibration-induced stresses, limited control over fluid flow rate, and safety concerns during pressure testing due to the need for frequent gear shifting in multi-speed transmissions.
Innovation Solution
A mobile fracking pump trailer equipped with a gas turbine engine connected via a torque converter and reduction gearing, eliminating the need for gear shifting and allowing continuous variable speed control, reducing equipment footprint, and minimizing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diesel engines with multi-speed transmission are used to drive fracking pumps, then the equipment can be compact and road-transportable, but the system suffers from low reliability, high vibration-induced stresses, and limited control over fluid flow rate due to frequent gear shifting
Solution Approach 1:
The patent removes the multi-speed transmission system from the drive train, extracting the problematic gear shifting mechanism that caused reliability issues and vibration. The gas turbine engine directly drives the fracking pump through a single-speed connection, eliminating the transmission complexity while maintaining road-transportability through the modular trailer design.
Solution Approach 2:
The patent replaces the mechanical multi-speed transmission system with an electrical control system. The gas turbine engine's speed and power output are controlled electronically to match the fracking pump's requirements, substituting mechanical gear shifting with electronic speed control and electrical power management.
2Reliability
If gas turbine engine is used instead of diesel engine, then reliability increases and vibration is reduced, but the equipment size and weight increase
Solution Approach 1:
The patent divides the fracking equipment into modular components mounted on separate trailers - the gas turbine engine on one trailer and the fracking pump on another trailer. This segmentation allows the heavy gas turbine to be transported separately and connected to the pump at the worksite, making the system transportable despite the increased weight of individual components.
Solution Approach 2:
The patent transitions from horizontal integration (all components on one trailer) to vertical/separated integration (components on separate trailers connected via hoses and power transmission). This dimensional change in the system architecture allows heavy equipment to be transported and assembled in a different spatial configuration.
3Adaptability or versatility
If multi-speed transmission is used to control pump speed, then fluid flow rate control is achieved, but frequent gear shifting causes safety concerns during pressure testing and increases maintenance requirements
Solution Approach 1:
The patent replaces mechanical gear shifting with electronic speed control of the gas turbine engine. The engine speed is controlled electronically to match the fracking pump's requirements, providing smooth, continuous speed adjustment without mechanical intervention. This eliminates gear shifting entirely, improving safety during pressure testing and reducing maintenance requirements.
Solution Approach 2:
The patent implements dynamic speed control of the gas turbine engine to match the varying demands of the fracking pump. The engine operates at variable speeds controlled by an electronic system, allowing continuous adaptation to changing fluid flow rate requirements without the discrete steps inherent in mechanical transmissions.
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
The solution provides higher pumping power with reduced equipment footprint, increased reliability, and improved safety during pressure testing by maintaining continuous operation without gear shifting, thus overcoming the limitations of diesel engine-based systems.
Implementation Method 1
a torque converter assembly comprising a torque converter that fluidly couples the engine output shaft and the fracking pump input shaft, the torque converter operable at a desired torque converter input speed and providing a variable torque converter output speed
Implementation Method 2
an electrical machine connected to the first power takeoff for selectively driving the engine output shaft through the first reduction gearing when energized by an offboard electrical power source to start the gas turbine engine in a starting mode, and for extracting power from the engine output shaft through the first reduction gearing for generating electricity provided to the electrical system
Data Source
AI summary
A mobile fracking pump trailer 100 includes a gas turbine engine 102 and fracking pump 104, and torque converter 114 that fluidly couples the gas turbine engine 102 to the fracking pump 104. The mobile fracking pump trailer 100 further includes a first reduction gearing 118 connected between the gas turbine engine 102 and the torque converter 114 and a first power takeoff 120 connected to first reduction gearing 118. An electrical machine 128 is connected to the first power takeoff 120 for selectively starting the gas turbine engine 102 and generating electrical power to power the mobile fracking pump trailer 100 after the gas turbine engine 102 has been started.