Offset Plunger Fracturing Pump Layout for High-Capacity Low-Vibration Flow
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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 configuration that includes multiple plungers offset at non-zero angles and connected to a crankshaft, allowing for increased pumping capacity while mitigating shock and vibration through balanced plunger operations and sequential force cancellation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pumping capacity of hydraulic fracturing units is increased, then the flow rate of fracturing fluid into the formation is improved, but the shock and vibration during operation increases leading to component wear and failure
Solution Approach 1:
The pump system is divided into multiple independent plunger assemblies (first plurality and second plurality of plungers) that operate in parallel. Each plunger assembly processes a portion of the fracturing fluid, allowing the system to achieve high pumping capacity through aggregation of multiple smaller units rather than relying on a single large plunger that would generate excessive shock and vibration.
Solution Approach 2:
The offset arrangement of plunger planes is designed to create opposing vibration patterns that cancel each other out. The second plurality of plungers is positioned at an offset angle relative to the first plurality, generating counteracting forces that preemptively neutralize the shock and vibration produced during high-capacity pumping operations.
2Productivity
If the pumping capacity is increased to reduce the number of hydraulic fracturing units needed, then the set-up and tear-down time is reduced, but the physical dimension constraints prevent further capacity increases
Solution Approach 1:
Instead of increasing plunger size or stroke length in linear dimensions, the invention utilizes angular/rotational dimension by arranging plungers at offset angles around the crankshaft. This allows multiple plungers to be packed into a compact footprint, achieving high pumping capacity without exceeding transportation dimension constraints.
Solution Approach 2:
Multiple plunger assemblies are merged into a single integrated pump unit sharing a common crankshaft and power source. This consolidation achieves the pumping capacity of multiple separate units while reducing the overall physical footprint and eliminating the need for multiple independent hydraulic fracturing units.
3Productivity
If high-pressure pumping is used to fracture the formation, then the flow paths for hydrocarbons are created, but the proppant settling occurs during the operation
Solution Approach 1:
The reciprocating motion of multiple plungers creates periodic pressure pulses that continuously agitate the fracturing fluid and suspended proppants. This periodic action prevents proppant settling by repeatedly disrupting gravitational separation, maintaining uniform suspension throughout the high-pressure pumping operation.
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 enhances fracturing fluid flow into wellheads with higher capacity, reduces premature component wear, and minimizes operational shocks and vibrations, thereby improving efficiency and reliability of hydraulic fracturing units.
Implementation Method 1
a crankshaft and a plurality of plungers connected to the crankshaft and configured to reciprocate relative to the crankshaft as the crankshaft rotates
Implementation Method 2
each of the plurality of plungers configured to reciprocate in a first plane and draw-in fracturing fluid at a first pressure and discharge the fracturing fluid at a second pressure greater than the first pressure
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.