Turbine Fracturing Drivetrain Layout for Stable 5000 HP Pumping
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Solution Overview
Problem
Current turbine fracturing equipment in oil and gas fields lacks stability and high-power output due to immature integration of turbine engines with high-power plunger pumps, resulting in insufficient performance for continuous and high-power operations.
Innovation Solution
A continuous high-power turbine fracturing equipment design featuring a turbine engine coaxially arranged with a reduction gearbox and a transmission shaft, with a 2° to 4° angle, and a dual lubrication system driven by an auxiliary power system, ensuring stable operation of the plunger pump at 5000 HP or above.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If turbine engine is integrated with high-power plunger pump, then power output is improved, but stability and reliability deteriorate due to immature technology integration
Solution Approach 1:
A reduction gearbox is introduced as an intermediary component between the turbine engine and the plunger pump. The gearbox includes a first reduction gear stage and a second reduction gear stage, which mediate the power transmission and enable stable integration of the turbine engine with the high-power plunger pump system.
Solution Approach 2:
The patent specifies precise parameter ranges for stable operation: the angle between the turbine engine output shaft and the transmission shaft is controlled at 2° to 4°, the rotation speed of the turbine engine is maintained at 5000-6000 rpm, and the reduction ratio of the gearbox is optimized to achieve continuous power output of 5000 HP or above while ensuring system stability.
2Productivity
If continuous high-power operation is achieved, then productivity is improved, but device complexity increases due to dual lubrication system and auxiliary power system
Solution Approach 1:
The lubrication system is segmented into two independent subsystems: a high-pressure lubrication system with a high-pressure pump for lubricating connecting rod bearing bushes and crosshead bearing bushes, and a low-pressure lubrication system with a low-pressure pump for lubricating crankshaft bearings, crosshead sliding rails, and reduction gearbox components. This segmentation enables continuous high-power operation while managing system complexity through functional separation.
Solution Approach 2:
The auxiliary power system serves multiple functions: it powers the high-pressure pump, low-pressure pump, and other auxiliary components of the lubrication system, thereby reducing the need for separate dedicated power sources for each component and managing overall system complexity.
3Reliability
If precise angle alignment (2° to 4°) is maintained between reduction gearbox and transmission shaft, then reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The reduction gearbox and transmission shaft are pre-aligned during assembly to achieve the optimal 2° to 4° angle. This preliminary action ensures that the precise alignment is established before operation, reducing the need for continuous adjustment and maintaining transmission stability throughout the equipment's service life.
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 equipment achieves stable and efficient high-power output, reducing failure incidence and meeting the demands of continuous high-power operations in oil and gas fields by providing a robust working platform and effective lubrication for the turbine engine, reduction gearbox, and plunger pump.
Implementation Method 1
a lubrication system driven by an auxiliary power system to ensure that the turbine engine, the reduction gearbox and the plunger pump all run under appropriate circumstances
Data Source
AI summary
The present invention discloses a continuous high-power turbine fracturing equipment, including a turbine engine, a reduction gearbox, a and a plunger pump, the turbine engine is arranged coaxially with the reduction gearbox, the reduction gearbox is connected to the plunger pump through the transmission shaft, the angle between a central line of the reduction gearbox and the transmission shaft is between 2° and 4°. The beneficial effects are as follows: chassis T1 materials are selected to provide a stable working platform for the equipment; the turbine engine is arranged coaxially with the reduction gearbox, the transmission shaft is disposed between the reduction gearbox and the plunger pump, and the angle between a central line of the reduction gearbox and the transmission shaft is between 2° and 4°, ensuring stable and efficient transmission of the turbine engine, thus reducing the incidence of failure; a lubrication system driven by an auxiliary power system ensures that the turbine engine, the reduction gearbox and the plunger pump all run under appropriate circumstances, and a dual lubrication system ensures that the plunger pump achieves a power operation continuously at 5000 HP or above; with all the above technical means, the requirements of continuous high-power operations for the fracturing equipment would finally be satisfied.