Stacked Fracturing Power Unit Layout for Remote Transport
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Solution Overview
Problem
The challenge is to design a fracturing device that is compact and portable, suitable for transportation to remote areas, as existing devices are large and cumbersome due to their transverse arrangement of power units.
Innovation Solution
The fracturing device incorporates a power unit with a muffling compartment, a turbine engine, and an air intake unit, along with auxiliary systems like electric motors, lubricating systems, and a firefighting system, arranged in a compact three-layer structure to reduce size and facilitate transportation, with the turbine engine driven by natural gas for environmental benefits and reduced power supply pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the power units are arranged transversely with large size, then the device has sufficient power and space for components, but the device becomes cumbersome and difficult to transport to remote areas
Solution Approach 1:
The patent transitions from a traditional transverse arrangement to a three-layer stacked configuration, utilizing the vertical dimension to organize components. The power unit, control unit, and working unit are arranged in distinct horizontal layers stacked vertically, transforming the spatial layout from two-dimensional horizontal expansion to three-dimensional vertical stacking, thereby reducing the device's footprint while maintaining component separation and functionality.
Solution Approach 2:
The patent implements a nested structure where the turbine engine is positioned within the accommodation space of the muffling compartment. The air intake unit is integrated into the power unit structure, and various auxiliary systems are compactly arranged within the layered framework, creating a space-efficient nested configuration that maximizes power density while minimizing overall device size.
2Ease of operation
If the device size is reduced for easier transportation, then transportability improves, but the space for power units and auxiliary systems becomes limited
Solution Approach 1:
By utilizing vertical stacking of three functional layers, the patent achieves compact horizontal footprint suitable for transportation while maintaining adequate vertical space for power units and auxiliary systems. The layered arrangement allows sufficient volume for turbine engine, air intake, control systems, and working units without requiring large horizontal expansion.
Solution Approach 2:
The patent combines multiple functions within integrated units. The power unit integrates the turbine engine, air intake unit, and muffling compartment into a single functional module. The control unit and working unit are similarly integrated, reducing the number of separate components and optimizing space utilization within the compact three-layer structure.
3Object-generated harmful factors
If the turbine engine is used instead of traditional power sources, then environmental benefits and reduced power supply pressure are achieved, but the design complexity of the power unit increases
Solution Approach 1:
The turbine engine serves multiple functions: it provides mechanical power for the fracturing pump, drives the generator for electrical power, and its exhaust can be utilized for heating or other processes. This multi-functionality reduces the need for separate power sources and auxiliary systems, thereby simplifying the overall power unit design despite the advanced technology involved.
Solution Approach 2:
The turbine engine system is designed to be self-sufficient, utilizing natural gas directly from the wellhead or storage tanks as fuel, eliminating the need for external power supply infrastructure. The integrated generator produces electricity on-site, and the muffling compartment handles exhaust noise containment, creating a self-contained power system that reduces environmental impact without requiring complex external support systems.
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 configuration allows for a compact, noise-reduced, and efficient fracturing device that is easier to transport and maintain, with enhanced safety features like automatic firefighting and reduced power demand at the work site, while maintaining high power density and efficiency.
Implementation Method 1
the turbine engine is driven by natural gas
Data Source
AI summary
A fracturing device includes a power unit, and the power unit includes a muffling compartment, a turbine engine, and an air intake unit. The air intake unit is communicated with the turbine engine through an intake pipe and configured to provide a combustion-supporting gas to the turbine engine; the air intake unit is at a top of the muffling compartment and the muffling compartment has an accommodation space, the turbine engine is within the accommodation space.