Pivoting Support Assembly for High-Power Pump Maintenance
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Solution Overview
Problem
High-power hydraulic fracturing pumps become challenging to assemble and disassemble due to their larger and heavier components, making it difficult to lift, orient, and position them during assembly, disassembly, and maintenance, which hinders efficient operation and maintenance processes.
Innovation Solution
A pivoting support assembly with actuators and pivotable connectors is used to facilitate the assembly and disassembly of high-power pumps by reorienting pump frames and components, allowing for easier installation and removal of crankshafts and connecting rods, and a connecting rod-crosshead-bushing assembly to support and lift heavy components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the pumping capacity of hydraulic fracturing units is increased by using larger and heavier pumps, then the output and efficiency are improved, but the difficulty of assembly and disassembly increases significantly
Solution Approach 1:
The pump system is divided into modular components (pump frame, crankshaft, connecting rods, cylinders) that can be assembled and disassembled separately. This segmentation allows heavy components to be handled individually rather than as one large assembly, reducing the operational difficulty despite increased pump size and weight.
Solution Approach 2:
The patent introduces a vertical dimension to the assembly process by using overhead cranes and hoisting mechanisms. Heavy components are lifted vertically into position rather than being maneuvered horizontally, which solves the problem of handling larger and heavier pump parts during assembly and disassembly.
2Device complexity
If manual handling methods are used for heavy pump components, then equipment complexity is reduced, but operational safety and efficiency deteriorate
Solution Approach 1:
Overhead cranes and hoisting mechanisms serve as intermediary equipment between workers and heavy pump components. These intermediaries bear the load of heavy parts during assembly and disassembly, eliminating the need for workers to manually handle components that exceed safe lifting limits, thereby maintaining operational safety without significantly increasing system complexity.
3Device complexity
If traditional assembly methods are used for high-power pumps, then equipment cost is reduced, but assembly time and labor requirements increase
Solution Approach 1:
Pump components are pre-positioned on the pump frame in an overhead configuration before final assembly. This preliminary arrangement allows components to be staged and prepared in advance, reducing the time required during actual assembly operations. The overhead positioning system enables workers to access components from above, streamlining the assembly process without requiring expensive automated assembly equipment.
Data Source
AI summary
Apparatuses, assemblies, and methods for facilitating assembly and disassembly of high-power fluid pumps may include a pivoting support assembly to facilitate assembly and disassembly of the pump. The pivoting support assembly may include a base, a first support connected to the base and configured to be connected to a pump frame of the pump, and a second support connected to the first support and configured to be connected to the pump frame of the pump. The pivoting support assembly further may include a first actuator connected to the base and the first support, and a second actuator connected to the first support and the second support. The first actuator may be configured to pivot the first support to re-orient the pump frame for installation of a crankshaft, and the second actuator may be configured to pivot the second support to re-orient the pump frame for installation of a connecting rod.