Single-Mass Flywheel Layout for Reciprocating Pump Torque Shock Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Reciprocating pumps in fracturing operations generate high and low frequency torsional vibrations that cause shock loading and premature wear in driveline components, leading to potential failure due to synchronization of natural sinusoidal waveforms and torsional resonance.
Innovation Solution
The implementation of single mass flywheels and torsional vibration dampeners in the drive-train system to absorb torque shocks and reduce torsional resonance, which are sized to match the kinetic energy of torque variances caused by hydraulic fluid pulsation, thereby reducing upstream shock loading and resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If reciprocating pumps operate to pump fluid slugs, then fluid pumping function is achieved, but torsional vibrations and shock loading are generated in the driveline
Solution Approach 1:
A single mass flywheel is introduced as an intermediary component between the reciprocating pump and the driveline. The flywheel absorbs torque shocks and dampens torsional vibrations generated by the pump's reciprocating motion, protecting the driveline from harmful vibrations while maintaining the pump's productivity.
Solution Approach 2:
The flywheel's moment of inertia is specifically designed and tuned to match the kinetic energy of torque variances caused by hydraulic fluid pulsation. By adjusting the flywheel's mass and radius of gyration, the system optimizes vibration dampening effectiveness across different operating conditions and pump speeds.
2Productivity
If multiple reciprocating pumps are connected to a common discharge line, then fluid pumping capacity is increased, but pumps synchronize causing pressure spikes and torsional distortion of higher amplitude
Solution Approach 1:
Each pump is equipped with its own single mass flywheel that acts as an independent intermediary, disrupting the synchronization between multiple pumps. The flywheels absorb and dampen the synchronized torsional vibrations, preventing the amplification of pressure spikes and torsional distortion that would otherwise occur when multiple pumps operate in unison.
Solution Approach 2:
The system converts the harmful synchronized vibrations from multiple pumps into useful rotational energy stored in the flywheels. The kinetic energy of the flywheels is used to smooth out the torsional distortions, transforming the harmful synchronous operation into a beneficial vibration-dampening effect.
3Device complexity
If driving equipment with low natural damping effects is used, then equipment simplicity is maintained, but torsional resonance occurs shortening equipment life
Solution Approach 1:
The single mass flywheel serves as a passive intermediary damping device that adds torsional vibration suppression capability without requiring complex active control systems. The flywheel's inherent damping properties protect the driving equipment from torsional resonance, extending equipment life while maintaining structural simplicity.
4Object-affected harmful factors
If flywheel mass and dimensions are increased to dampen vibrations, then vibration dampening effectiveness is improved, but flywheel size and weight increase
Solution Approach 1:
The flywheel's moment of inertia is precisely calculated based on the kinetic energy of torque variances at different operating conditions. By optimizing the mass distribution and radius of gyration, the system achieves effective vibration dampening with the minimum necessary flywheel weight, avoiding excessive mass while maintaining protection effectiveness.
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
This solution effectively dampens high frequency/low amplitude and low frequency/high amplitude torsional vibrations, extending the life of driveline components and preventing failure by mitigating torsional resonance and shock loading.
Implementation Method 1
a single mass flywheel or a series of single mass flywheels along the drive-train system components between the gear box or transmission and input shaft of a reciprocating pump may be used to reduce output speed fluctuations that may cause vibrational and torsional effects on the gearbox and engine
Implementation Method 2
at least one torsional vibration dampener may be connected to the drive-train system to dampen the harmonic effects of the reciprocating pump
Implementation Method 3
at least one torsional vibration dampener may be connected to the drive-train system to dampen the harmonic effects of the reciprocating pump
Data Source
AI summary
A pump system may include a pump, a driveshaft, driving equipment, and a vibration dampening assembly configured to reduce pump-imposed high frequency/low amplitude and low frequency/high amplitude torsional vibrations. The pump may have an input shaft connected to the driveshaft. The driving equipment may include an output shaft having an output flange connected to the driveshaft. The driving equipment may be configured to rotate the driveshaft to rotate the input shaft of the pump therewith. The vibration dampening assembly may include one or more flywheels operably connected to the input shaft and configured to rotate therewith.