Integrated VFASIM Fracturing Pump Layout for Compact Well Sites
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Solution Overview
Problem
Traditional fracturing devices in oil/gas fields face issues with large volume, weight, and high cost due to their power transmission systems, which also result in noise and pollution, hindering the development of unconventional oil/gas energy.
Innovation Solution
The use of a Variable-Frequency Adjustable-Speed Integrated Machine (VFASIM) that is integrally installed with the plunger pump, eliminating the need for a rectifying transformer and allowing direct connection to a high-voltage power supply, resulting in a more compact and integrated fracturing device layout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diesel engine is used as the power source to drive the plunger pump through a gearbox and transmission shaft, then the fracturing device can operate reliably, but the device volume and weight increase significantly
Solution Approach 1:
The patent removes the gearbox and transmission shaft from the power transmission system, extracting the unnecessary mechanical transmission components. The diesel engine is directly coupled to the plunger pump, eliminating the intermediate transmission mechanisms while maintaining reliable operation through direct drive connection.
Solution Approach 2:
The patent merges the power source (diesel engine) and the actuating element (plunger pump) into a directly connected integrated system. By combining these components without intermediate transmission elements, the overall device volume is reduced while preserving functional reliability.
2Power
If a diesel engine is used as the power source, then the fracturing device can provide sufficient power, but noise and exhaust pollution are generated
Solution Approach 1:
The patent replaces the diesel engine (mechanical combustion system) with an electric motor (electrical system). This substitution eliminates exhaust emissions and significantly reduces noise pollution while maintaining the required power output for fracturing operations through direct electrical drive.
3Ease of operation
If a transducer with rectifying transformer is used to regulate voltage and speed, then the motor can be driven, but the transducer volume and weight increase
Solution Approach 1:
The patent removes the rectifying transformer from the transducer system, extracting the component that causes volume and weight increase. The transducer is redesigned to directly interface with the motor without the intermediate transformer, reducing overall size while maintaining speed and voltage regulation capabilities.
Solution Approach 2:
The patent merges the transducer and motor into a more integrated configuration, eliminating the need for separate rectifying transformer and reducing the number of external wirings. This integration reduces the overall volume occupied by the speed regulation system.
4Ease of operation
If multiple transducers are placed separately with independent wiring, then each motor can be controlled, but the well site layout occupies large area
Solution Approach 1:
The patent merges multiple transducers into a centralized or shared configuration, allowing multiple motors to be controlled from a common location. This reduces the scattered layout of individual transducers and minimizes the total area occupied at the well site while maintaining independent motor control capability.
Data Source
AI summary
The present disclosure provides a fracturing device driven by a variable-frequency adjustable-speed integrated machine (VFASIM), including the VFASIM and a plunger pump. The VFASIM includes a driving device for providing a driving force and an inverting device integrally installed on the driving device. The inverting device supplies power to the driving device. The plunger pump is integrally installed together with the VFASIM, the plunger pump is mechanically connected to the driving device of the VFASIM and driven by the driving device. According to the present disclosure, it is possible to achieve an overall layout with a high degree of integration. The present disclosure also provides a well site layout including a plurality of fracturing devices described above.