Stacked Prime Mover and Lube Oil Cooling for Compact Fracturing Pumps
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Solution Overview
Problem
Hydraulic fracturing operations face logistical challenges such as large equipment footprints, power and fuel management, and environmental impact, necessitating innovations to enhance efficiency and reduce environmental impact.
Innovation Solution
A fracturing pump transport system with a prime mover cooling assembly and lube oil cooling assembly that efficiently cools the prime mover and lube oil using air intakes and exhaust ventilators, positioned above the prime mover to improve heat transfer and reduce operating temperatures, while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling assemblies are mounted on the prime mover, then heat transfer efficiency is improved, but the equipment footprint increases
Solution Approach 1:
The lube oil cooling assembly is integrated with the prime mover cooling assembly by mounting the lube oil cooling assembly on top of the prime mover cooling assembly. This merging of cooling functions reduces the overall equipment footprint while maintaining effective cooling of both the prime mover and lube oil system
Solution Approach 2:
The cooling assemblies are arranged in a vertical configuration where the lube oil cooling assembly is positioned above the prime mover cooling assembly. This vertical stacking utilizes the vertical dimension to accommodate both cooling systems without increasing the horizontal footprint of the equipment
2Temperature
If cooling assemblies are positioned above the prime mover, then heat transfer efficiency is improved, but the device complexity increases
Solution Approach 1:
The exhaust ventilator serves multiple functions: it exhausts hot air from the prime mover cooling assembly and simultaneously provides cooling air to the lube oil cooling assembly. This multi-functionality reduces the number of separate components needed, thereby simplifying the overall cooling system while maintaining effective heat transfer
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 system reduces the operating temperature of the prime mover, enhances heat transfer efficiency, and minimizes the equipment footprint, thereby improving the operational efficiency and reducing environmental impact of hydraulic fracturing operations.
Implementation Method 1
cooling lube oil circulating through the pump
Implementation Method 2
drawing in air from one or more air intakes with one or more blowers positioned on top of the electric motor
Implementation Method 3
ventilating air heated from cooling the electric motor at a top side of the cooling assembly with one or more exhaust ventilators
Data Source
AI summary
A system and a method for cooling a prime mover and lube oil, comprising: a prime mover configured to drive a pump with a motor shaft; a prime mover cooling assembly that encases the prime mover, wherein the prime mover cooling assembly comprises: an air intake and an exhaust ventilator mounted above the prime mover; and a lube oil cooling assembly mounted above the prime mover, wherein the lube oil cooling assembly cools lube oil circulating within the pump and is mounted above the prime mover such that the lube oil cooling assembly does not hang off one or more sides of the prime mover and prime mover cooling assembly.