Hydraulic Fracturing Pump Power Ends for Compact Capacity Scaling
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Solution Overview
Problem
Hydraulic fracturing units face challenges in increasing pumping capacity due to physical dimension constraints, leading to potential component wear and failure from increased shock and vibration, and proppant settling during high-pressure operations.
Innovation Solution
The hydraulic fracturing pump is designed with a crankshaft and plungers that reciprocate in offset planes, allowing for increased pumping capacity while maintaining dimensions for transportation, and incorporates a drive assembly with planetary gear trains to mitigate shock and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If hydraulic fracturing units increase pumping capacity, then fracturing fluid flow into wellheads is enhanced, but physical dimension constraints prevent transportation
Solution Approach 1:
The pump is divided into multiple independent power ends, each with its own crankshaft and plunger assembly. These modular power ends can be arranged in series or parallel configurations, allowing the pumping capacity to be increased by adding more segments rather than enlarging a single unit, thus maintaining transportation dimensions while achieving higher overall capacity.
Solution Approach 2:
Instead of increasing pumping capacity by enlarging the pump in linear dimensions, the design uses multiple power ends arranged in a multi-dimensional configuration. The capacity is scaled by adding units in different spatial arrangements (series/parallel combinations) rather than increasing the size of individual components, thereby maintaining a compact footprint suitable for transportation.
2Productivity
If hydraulic fracturing units increase pumping capacity, then fracturing fluid flow into wellheads is enhanced, but shock and vibration increase causing component wear and failure
Solution Approach 1:
Adjacent crankshafts are configured with counterbalancing arrangements where the reciprocating masses of plungers and connecting rods on one crankshaft offset the inertial forces generated by adjacent crankshafts. This counterweight principle reduces the net shock and vibration transmitted to the pump frame and surrounding components, thereby improving reliability while maintaining high pumping capacity.
Solution Approach 2:
The crankshafts are positioned asymmetrically with respect to the pump frame, and their rotation phases are offset from each other. This asymmetric arrangement ensures that the peak forces from different power ends do not coincide, distributing the mechanical loads more evenly over time and reducing cumulative shock and vibration that would otherwise lead to component wear and failure.
3Stress or pressure
If hydraulic fracturing units operate at high pressure, then fracturing operation is effective, but proppant settling occurs reducing fluid flow
Solution Approach 1:
The multiple power ends are synchronized to provide continuous pumping action without interruption or pulsation. By coordinating the reciprocating motions of adjacent plungers, the system maintains a steady, continuous flow of fracturing fluid through the wellhead, preventing flow interruptions that would allow proppant to settle and ensuring uninterrupted productive operation at high pressure.
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 design enhances fracturing fluid flow into wellheads with higher capacity, reduces premature component wear, and minimizes shock and vibration, thereby improving operational efficiency and reliability.
Implementation Method 1
incorporates a drive assembly with planetary gear trains to mitigate shock and vibration
Implementation Method 2
The hydraulic fracturing pump is designed with a crankshaft and plungers that reciprocate in offset planes
Data Source
AI summary
Systems and methods to enhance the flow of fracturing fluid into a wellhead during a high and the second plungers may pump a second fracturing fluid different from the first fracturing fluid.