Plunger Pump Lubrication Layout for Quieter Fracturing Units
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Solution Overview
Problem
Existing fracturing apparatuses, particularly those using diesel engines, suffer from large size, high weight, environmental pollution, high operating costs, and complex system maintenance due to numerous components, leading to operational inefficiencies and noise pollution.
Innovation Solution
A fracturing apparatus with an electric motor-driven plunger pump and a power end lubricating system that includes a lubricating oil tank, lubrication pumps, and motors located within the tank, along with a control system for temperature and pressure regulation, reducing noise and improving operational efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a diesel engine is used to drive the plunger pump, then sufficient power can be provided, but the apparatus becomes large in size, heavy in weight, and produces environmental pollution and noise
Solution Approach 1:
The patent replaces the diesel engine mechanical system with an electric motor system. The electric motor directly drives the plunger pump through a simplified transmission system (reducing gears only), eliminating the complex diesel engine components while providing sufficient power. This substitution reduces device complexity, size, and environmental impact while maintaining the required power output for fracturing operations.
2Adaptability or versatility
If numerous components are used in the fracturing apparatus, then functional requirements can be met, but maintenance costs increase and operational efficiency decreases
Solution Approach 1:
The patent extracts and eliminates unnecessary components from the system. By removing the diesel engine, fuel system, exhaust system, and other non-essential components, the design retains only the critical elements needed for fracturing function (electric motor, plunger pump, transmission gears, and lubrication system). This reduction in components simplifies maintenance while preserving essential functional capabilities.
Solution Approach 2:
The lubricating oil tank is designed to serve multiple functions: it stores lubricating oil for the transmission gears, acts as a noise reduction chamber, and provides structural support. This multi-functionality reduces the need for separate components, thereby simplifying maintenance while maintaining comprehensive functional capability.
3Ease of operation
If the lubrication system components are located outside the oil tank, then accessibility for maintenance is improved, but noise increases and structural complexity increases
Solution Approach 1:
The patent nests the lubrication system components (transmission gears and lubrication pump) inside the lubricating oil tank. The gears are immersed in the lubricating oil, which serves as both lubricant and noise-dampening medium. The lubrication pump is also positioned within the tank to draw oil directly from the reservoir. This nested arrangement reduces noise significantly while the tank's removable lid provides adequate maintenance accessibility.
Solution Approach 2:
The lubricating oil acts as an intermediary medium that serves multiple purposes: it lubricates the gears, dampens noise from gear operation, and cools the transmission components. By using the oil as both functional lubricant and noise reduction medium, the system achieves noise control without sacrificing component functionality or maintenance accessibility.
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 apparatus achieves reduced noise, simplified structure, lower maintenance costs, and enhanced operational efficiency, while providing effective lubrication and temperature control, thereby extending component life and facilitating transportation.
Implementation Method 1
a power end lubricating system that includes: a lubricating oil tank defining an accommodation space, at least one lubrication pump having a lubrication pump oil inlet and a lubrication pump oil outlet that are coupled to each other
Implementation Method 2
the power end oil outlet is coupled to the accommodation space of the lubricating oil tank through an oil return pipeline
Implementation Method 3
at least one lubrication motor configured for providing power for the at least one lubrication pump. The lubrication pump oil inlet is coupled to the accommodation space of the lubricating oil tank
Data Source
AI summary
A fracturing apparatus includes: a plunger pump having a hydraulic end and a power end, wherein the power end comprises a power end oil outlet and at least one power end oil inlet that are coupled to each other; a power end lubricating system, including a lubricating oil tank defining an accommodation space, at least one lubrication pump having a lubrication pump oil inlet and a lubrication pump oil outlet that are coupled to each other, and at least one lubrication motor configured to provide power for the at least one lubrication pump; a temperature detector disposed on any one of the oil return pipeline, the power end oil outlet, and the lubricating oil tank; and a control system connected to the temperature detector and the power end lubricating system and configured to control the power end lubricating system.