U.S. patent application number 16/834419 was filed with the patent office on 2020-10-22 for super-power five-cylinder plunger pump.
The applicant listed for this patent is YANTAI JEREH PETROLEUM EQUIPMENT & TECHNOLOGIES CO., LTD.. Invention is credited to Haiping Cui, Wenping Cui, Hong Liu, Jixin Wang, Xiaosong Wei.
Application Number | 20200332788 16/834419 |
Document ID | / |
Family ID | 1000004752006 |
Filed Date | 2020-10-22 |
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United States Patent
Application |
20200332788 |
Kind Code |
A1 |
Cui; Haiping ; et
al. |
October 22, 2020 |
SUPER-POWER FIVE-CYLINDER PLUNGER PUMP
Abstract
The present invention discloses a super-power five-cylinder
plunger pump, including a power end assembly, a hydraulic end
assembly and a reduction gearbox assembly. The power end assembly
is designed as a segmented structure including a crankcase, a
crosshead case and a spacer frame. One end of the crosshead case is
connected to the crankcase, and the other end of the crosshead case
is connected to the spacer frame. The hydraulic end assembly is
disposed at an end of the spacer frame and is connected to the
crankcase through bolts sequentially passing through the spacer
frame and the crosshead case. The reduction gearbox assembly is
connected to the crankcase. A crankshaft in the crankcase is forged
from alloy steel and includes six axle journals and five
bellcranks. One bellcrank is disposed between every two adjacent
axle journals, and the distance between the center of rotation of
the bellcrank and the center of rotation of the crankshaft is 110
to 160 mm. Beneficial Effects: The super-power five-cylinder
plunger pump has a rated input power of 5000 hp to solve the
problem that there is no existing plunger pump of a specification
matching high-power electric motors in electric drive fracturing,
and solve the conflict between the limited well-site conditions in
the oil and gas fields and the need of multiple matched fracturing
equipment.
Inventors: |
Cui; Haiping; (Yantai,
CN) ; Liu; Hong; (Yantai, CN) ; Wang;
Jixin; (Yantai, CN) ; Cui; Wenping; (Yantai,
CN) ; Wei; Xiaosong; (Yantai, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
YANTAI JEREH PETROLEUM EQUIPMENT & TECHNOLOGIES CO.,
LTD. |
Yantai |
|
CN |
|
|
Family ID: |
1000004752006 |
Appl. No.: |
16/834419 |
Filed: |
March 30, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F04B 39/121 20130101;
F04B 1/00 20130101 |
International
Class: |
F04B 39/12 20060101
F04B039/12; F04B 1/00 20060101 F04B001/00 |
Foreign Application Data
Date |
Code |
Application Number |
Apr 19, 2019 |
CN |
201910319527.3 |
Claims
1. A super-power five-cylinder plunger pump, comprising a power end
assembly, a hydraulic end assembly and a reduction gearbox
assembly, wherein the power end assembly is designed as a segmented
structure comprising a crankcase, a crosshead case and a spacer
frame, one end of the crosshead case is connected to the crankcase
through bolts, and the other end of the crosshead case is connected
to the spacer frame through bolts, the hydraulic end assembly is
disposed at an end of the spacer frame and is connected to the
crankcase through bolts sequentially passing through the spacer
frame and the crosshead case, the reduction gearbox assembly is
connected to the crankcase through bolts, a crankshaft in the
crankcase is forged from alloy steel and comprises six axle
journals and five bellcranks, one bellcrank is disposed between
every two adjacent axle journals, and the distance between the
center of rotation of the bellcrank and the center of rotation of
the crankshaft is 110 to 160 mm.
2. The super-power five-cylinder plunger pump according to claim 1,
wherein an input angle of the reduction gearbox assembly can be
adjusted according to input requirements.
3. The super-power five-cylinder plunger pump according to claim 1,
wherein the reduction gearbox assembly comprises a planetary
reduction gearbox and a parallel reduction gearbox; the parallel
reduction gearbox and the planetary reduction gearbox both employ
bevel gear transmission; the planetary reduction gearbox comprises
one sun gear, four planetary gears and one gear ring, the four
planetary gears form a planetary gear mechanism, the sun gear is
located at the center of the planetary gear mechanism, the
planetary gears and the adjacent sun gear and gear ring are in a
normally engaged state; the parallel reduction gearbox comprises a
pinion and a bull gear, the pinion is connected to an input end,
the bull gear is coaxial with the sun gear of the planetary
reduction gearbox, and the reduction gearbox assembly has a
transmission ratio of 6.5:1 to 15:1.
4. The super-power five-cylinder plunger pump according to claim 1,
wherein a support column of an arch structure is disposed on the
spacer frame.
5. The super-power five-cylinder plunger pump according to claim 1,
wherein a crosshead mechanism is disposed in the crosshead case, a
connecting rod mechanism is disposed in the crankcase and the
crosshead case, one end of the connecting rod mechanism is
connected to the crankshaft, and the other end of the connecting
rod mechanism is connected to the crosshead mechanism, the
connecting rod mechanism comprises a connecting rod cap, a
connecting rod bearing bush and a connecting rod body, the
connecting rod cap is connected to the connecting rod body through
bolts, the connecting rod bearing bush is located in a cylindrical
space formed by the connecting rod cap being connected to the
connecting rod body, each of two sides of the connecting rod
bearing bush is provided with a flange structure, and the flange
structure has a large width-to-diameter ratio.
Description
TECHNICAL FIELD
[0001] The present invention relates to the field of oil and gas
drilling and exploitation equipment, and specifically to a
super-power five-cylinder plunger pump.
BACKGROUND
[0002] With the continuous development of ultrahigh-pressure,
ultra-deep wells and horizontal wells in oil and gas fields,
working conditions are becoming harsher. As a result, high-pressure
high-displacement operations are needed, imposing higher
requirements on plunger pumps. A plunger pump which can output high
power and high pressure is required in order to enable a single
fracturing equipment to output high pressure and high displacement.
Especially for the exploitation of unconventional oils and gases
such as shale gas, the working conditions are harsh, and long-time,
high-displacement, high-pressure operations are required. A higher
frequency of operations indicates higher requirements on the
fracturing equipment and also on the plunger pump, which is the
core component of the fracturing equipment. Electric fracturing
driven by electric motors has emerged in recent years. Electric
motors with high power, for example, a rated power of 3000 kW, 4000
kW, 5000 kW, 6000 kW, etc., may be used. However, currently there
is no plunger pump of a specification matching such high-power
electric motors. Fracturing pumps common in the market mainly
include 2800 HP five-cylinder plunger pumps, 3000 HP three-cylinder
plunger pumps, 3300 HP five-cylinder plunger pumps and 4000 HP
three-cylinder plunger pumps. 2800 HP five-cylinder plunger pumps
are mainly deployed on Model 2500 fracturing trucks, which
currently are the most commonly used equipment in fracturing but
have the disadvantages of low displacement for single equipment in
the case of high-pressure operations. For the exploitation of shale
gas, more than ten fracturing trucks need to work at the same time
in order to reach the required total displacement, and such a large
number of fracturing trucks working at the same time occupy much
space in the well-sites, resulting in a conflict with the limited
well-site conditions in the oil and gas fields. 4000 HP
three-cylinder plunger pumps are generally deployed on 3100 HP
fracturing trucks. However, the 4000 HP plunger pump is a
three-cylinder pump providing a displacement much lower than that
of a 2800 HP five-cylinder pump. When the same plunger
specification and the same number of strokes are used, the
displacement of a 4000 HP plunger pump is only 82.54% of that of a
2800 HP five-cylinder pump. Deploying 2800 HP plunger pumps and
4000 HP plunger pumps on electric drive fracturing equipment is
just like using a big horse to drag a small wagon, failing to
present the advantages of electric drive fracturing. Therefore, it
is necessary to develop a high-power plunger pump suitable for use
in the newly-developing electric drive fracturing equipment.
SUMMARY
[0003] To overcome the deficiencies in the prior art, an objective
of the present invention is to provide a super-power five-cylinder
plunger pump, which has a rated input power of 5000 hp to solve the
problem that there is no existing plunger pump of a specification
matching high-power electric motors in electric drive fracturing,
and solve the conflict between the limited well-site conditions in
the oil and gas fields and the need of multiple matched fracturing
equipment.
[0004] The objective of the present invention is achieved by the
following technical measures: A super-power five-cylinder plunger
pump, including a power end assembly, a hydraulic end assembly and
a reduction gearbox assembly, wherein the power end assembly is
designed as a segmented structure including a crankcase, a
crosshead case and a spacer frame, one end of the crosshead case is
connected to the crankcase through bolts, the other end of the
crosshead case is connected to the spacer frame through bolts, the
hydraulic end assembly is disposed at an end of the spacer frame
and is connected to the crankcase through bolts sequentially
passing through the spacer frame and the crosshead case, the
reduction gearbox assembly is connected to the crankcase through
bolts, a crankshaft in the crankcase is forged from alloy steel and
includes six axle journals and five bellcranks, one bellcrank is
disposed between every two adjacent axle journals, and the distance
between the center of rotation of the bellcrank and the center of
rotation of the crankshaft is 110 to 160 mm.
[0005] Further, an input angle of the reduction gearbox assembly
can be adjusted according to input requirements.
[0006] Further, the reduction gearbox assembly includes a planetary
reduction gearbox and a parallel reduction gearbox; the parallel
reduction gearbox and the planetary reduction gearbox both employ
bevel gear transmission; the planetary reduction gearbox includes
one sun gear, four planetary gears and one gear ring, the four
planetary gears form a planetary gear mechanism, the sun gear is
located at the center of the planetary gear mechanism, the
planetary gears and the adjacent sun gear and gear ring are in a
normally engaged state; the parallel reduction gearbox includes a
pinion and a bull gear, the pinion is connected to an input end,
the bull gear is coaxial with the sun gear of the planetary
reduction gearbox, and the reduction gearbox assembly has a
transmission ratio of 6.5:1 to 15:1.
[0007] Further, a support column of an arch structure is disposed
on the spacer frame.
[0008] Further, a crosshead mechanism is disposed in the crosshead
case, a connecting rod mechanism is disposed in the crankcase and
the crosshead case, one end of the connecting rod mechanism is
connected to the crankshaft, the other end of the connecting rod
mechanism is connected to the crosshead mechanism, the connecting
rod mechanism includes a connecting rod cap, a connecting rod
bearing bush and a connecting rod body, the connecting rod cap is
connected to the connecting rod body through bolts, the connecting
rod bearing bush is located in a cylindrical space formed by the
connecting rod cap being connected to the connecting rod body, each
of two sides of the connecting rod bearing bush is provided with a
flange structure, and the flange structure has a large
width-to-diameter ratio.
[0009] Compared with the prior art, the present invention has the
following beneficial effects:
[0010] 1. The super-power five-cylinder plunger pump has a braking
power of 5000 hp and a maximum output power of up to 4500 hp, which
is equivalent to a combination of two 2500 HP pumps. Such a
high-power, large-displacement design is applicable to various
complex working conditions and can reduce the number of equipment
required on site, save space on site and reduce equipment
costs.
[0011] 2. The segmented design makes the entire structure of the
power end assembly compact and easier to manufacture, thereby
facilitating the assembly and maintenance of the entire pump. The
use of high-strength steel plates and the reasonable structural
designs meet the strength and stiffness requirements of the cases.
For example, designing the support column of the spacer frame as an
arch structure increases the bearing strength and meet the strength
and stiffness requirements of the power end assembly for use under
heavy load. The segmented design facilitates the assembly and
maintenance and reduces the manufacturing costs as well as the
weight of the crankcase.
[0012] 3. The use of the 10 inches long-stroke design and the
five-cylinder design offers the following advantages: The 10 inches
long-stroke design can meet the requirements of high-displacement
operations, reduce the number of strokes required for the pump, and
extend the service life of various parts. The design of the
five-cylinder structure increases the output displacement of the
plunger pump. Compared with a three-cylinder pump, the
five-cylinder pump runs stably without vibration, thereby reducing
the vibration of the entire pump and extending the service
life.
[0013] 4. The reduction gearbox assembly uses the planetary
reduction gearbox and the parallel reduction gearbox in combination
to obtain a large transmission ratio. The transmission ratio may be
up to 6.5:1 to 15:1. A large speed ratio can reduce an input torque
and improve the service life of the reduction gearbox, thereby
effectively ensuring the matching between turbo-engine drive and
electric-motor drive. The large reduction transmission ratio can
reduce the number of strokes of the plunger pump, and reduce the
number of fatigue cycles for various rotary parts, thereby
extending the service life of various parts. Moreover, an input
angle of the reduction gearbox assembly can be adjusted according
to input requirements, thereby satisfying the multi-angle
adjustment and adapting various mounting requirements.
[0014] 5. The increase in the size of the bellcrank of the
crankshaft ensures that the plunger pump can output higher
pressure.
[0015] 6. Because the connecting rod bearing bush has flange
structures at two sides and the flange structure has a
width-to-diameter ratio, thus enabling a higher bearing capacity
and a good positioning effect.
[0016] The present invention will be described in detail below with
reference to the accompanying drawings and specific
implementations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic structural diagram of the present
invention.
[0018] FIG. 2 is a schematic structural diagram of a power end
assembly according to the present invention.
[0019] FIG. 3 is a schematic structural diagram of a reduction
gearbox assembly according to the present invention.
[0020] FIG. 4 is a cross-sectional view of the present
invention.
[0021] FIG. 5 is a schematic structural diagram illustrating
connection between a connecting rod mechanism and a crosshead
mechanism according to the present invention.
[0022] FIG. 6 is a schematic structural diagram of a crankshaft
according to the present invention.
[0023] FIG. 7 is a schematic structural diagram of a connecting rod
bearing bush according to the present invention.
[0024] FIG. 8 is a schematic structural diagram of a parallel
reduction gearbox according to the present invention.
[0025] FIG. 9 is a schematic structural diagram of a planetary
reduction gearbox according to the present invention.
[0026] Wherein: 1. power end assembly; 2. hydraulic end assembly;
3. reduction gearbox assembly; 4. crankcase; 5. crosshead case; 6.
spacer frame; 7. crankshaft; 8. axle journal; 9. bellcrank; 10.
cylindrical roller shaft; 11. valve housing; 12. plunger; 13.
bearing seat; 14. front end plate; 15. cover plate; 16. supporting
leg; 17. slide rail; 18. support column; 19. connecting rod cap;
20. connecting rod bearing bush; 21. connecting rod body; 22.
crosshead; 23. crosshead gland; 24. crosshead connecting screw; 25.
crosshead guide plate; 26. guide plate bolt; 27. pull rod; 28.
clamp; 29. planetary reduction gearbox; 30. parallel reduction
gearbox; 31. flange structure; 32. bull gear; 33. pinion; 34.
planetary gear; 35. gear ring; and 36. sun gear.
DESCRIPTION OF THE EMBODIMENTS
[0027] As shown in FIGS. 1 to 9, an embodiment provides a
super-power five-cylinder plunger pump, including a power end
assembly 1, a hydraulic end assembly 2 and a reduction gearbox
assembly 3. The power end assembly 1 is designed as a segmented
structure. The segmented design makes the entire structure of the
power end assembly 1 compact and easier to manufacture, thereby
facilitating the assembly and maintenance of the entire pump and
reducing the manufacturing costs. The power end assembly 1 includes
a crankcase 4, a crosshead case 5 and a spacer frame 6. One end of
the crosshead case 5 is connected to the crankcase 4 through
hexagon bolts, and the other end of the crosshead case 5 is
connected to the spacer frame 6 through bolts. The hydraulic end
assembly 2 is disposed at an end of the spacer frame 6 and is
connected to the crankcase 4 through bolts sequentially passing
through the spacer frame 6 and the crosshead case 5. The reduction
gearbox assembly 3 is connected to the crankcase 4 through bolts. A
crankshaft 7 in the crankcase 4 is forged from alloy steel and
includes six axle journals 8 and five bellcranks 9, one bellcrank 9
being disposed between every two adjacent axle journals 8, to form
a five-cylinder structure. The design of the five-cylinder
structure increases the output displacement of the plunger pump.
Compared with a three-cylinder pump, the five-cylinder pump runs
stably without vibration, thereby reducing the vibration of the
entire pump and extending the service life. The distance between
the bellcrank 9 and the center of rotation of the crankshaft 7 is
110 to 160 mm, ensuring that the plunger pump can output higher
pressure to achieve a long stroke of up to 10 inches, thereby
meeting the requirements of high-displacement operations, reducing
the number of strokes of the pump, and extending the service life
of various parts.
[0028] The hydraulic end assembly 2 includes a valve housing 11 and
a plunger 12. The plunger 12 is disposed in the valve housing 11.
The crankcase 4 is formed by welding steel plates. Six bearing
seats 13, a front end plate 14, a cover plate 15, a supporting leg
16, and the like are mainly combined and welded together. After
welding is completed, the bearing seat 20 and the front end plate
21 are formed through fine finishing. The crosshead case 5 is
formed by welding steel plates. An arc-shaped slide rail 17 is
fixed on the crosshead case 5. The arc-shaped slide rail 17 is
forged from alloy steel. A support column 18 of an arch structure
is disposed on the spacer frame 6 to increase the supporting
strength. Each of the crosshead case 5 and the spacer frame 6 is
provided with a through hole. The valve housing 11 at the hydraulic
end is connected to the crankcase 4 through bolts sequentially
passing through the spacer frame 6 and the crosshead case 5. A
cylindrical roller shaft 10 is mounted on the axle journals 8. An
outer ring of the cylindrical roller shaft 10 is mounted on the
bearing seats 13.
[0029] A crosshead mechanism is disposed in the crosshead case 5. A
connecting rod mechanism is disposed in the crankcase 4 and the
crosshead case 5. One end of the connecting rod mechanism is
connected to the crankshaft 7, and the other end of the connecting
rod mechanism is connected to the crosshead mechanism. The
connecting rod mechanism includes a connecting rod cap 19, a
connecting rod bearing bush 20 and a connecting rod body 21. The
connecting rod cap 19 is connected to the connecting rod body 21
through bolts. The connecting rod bearing bush 20 is located in a
cylindrical space formed by the connecting rod cap 19 being
connected to the connecting rod body 21. Each of two sides of the
connecting rod bearing bush 20 is provided with a flange structure
31. The flange structure has a large width-to-diameter ratio,
thereby providing a higher bearing capacity and a desirable
positioning effect. The crosshead mechanism includes a crosshead
22, a crosshead gland 23, crosshead connecting screws 24, a
crosshead guide plate 25 and guide plate bolts 26. The connecting
rod body 21, the connecting rod cap 19, the crosshead 22 and the
crosshead gland 23 are forged from alloy steel. One end of the
connecting rod mechanism is connected to the bellcrank 9, and the
other end of the connecting rod mechanism is connected to the
crosshead 22 through the crosshead gland 23. The crosshead guide
plate 25 is fixed on the crosshead 22 through the guide plate bolts
26. The crosshead guide plate 25 is arc-shaped and has an oil
groove on the surface thereof. The crosshead 22 is connected to the
plunger 12 of the hydraulic end assembly 2 through a pull rod 27
and a clamp 28. Further, the crosshead 22 is connected to the pull
rod 27 through screws.
[0030] An output end of the reduction gearbox assembly is connected
to the crankshaft 7. The reduction gearbox assembly includes a
planetary reduction gearbox 29 and a parallel reduction gearbox 30.
The parallel reduction gearbox 30 and the planetary reduction
gearbox 29 both employ bevel gear transmission. The planetary
reduction gearbox 29 includes one sun gear 36, four planetary gears
34 and one gear ring 35. The four planetary gears 34 form a
planetary gear mechanism. The sun gear 36 is located at the center
of the planetary gear mechanism. The planetary gears 34 and the
adjacent sun gear 36 and gear ring 35 are in a normally engaged
state. The parallel reduction gearbox 30 includes a bull gear 32
and a pinion 33. The pinion 33 is connected to an input end. The
bull gear 32 is coaxial with the sun gear 36 of the planetary
reduction gearbox 29. A rotational speed input at the input end is
transferred to the bull gear 32 through the pinion 33 to achieve
primary speed reduction, and the reduced speed is transferred to
the sun gear 36 through the bull gear 32 and then transferred to
the planetary gear 34 through the sun gear 36 to achieve secondary
speed reduction, thereby obtaining a large transmission ratio. The
transmission ratio may be up to 6.5:1 to 15:1. The planetary
reduction gearbox 29 uses four uniformly distributed planetary
gears 34 to transfer both motion and power at the same time. A
centrifugal inertia force generated from the revolution of the four
planetary gears 34 offsets the radial component of a counterforce
between tooth contours, to reduce the force received by the main
shaft and achieve high power transmission. A large speed ratio can
reduce the input torque and extend the service life of the
reduction gearbox, thereby effectively ensuring the matching
between turbo-engine drive and electric-motor drive. A large
reduction ratio can reduce the number of strokes of the plunger
pump, and reduce the number of fatigue cycles for various rotary
parts, thereby extending the service life of various parts.
Moreover, an input angle of the reduction gearbox assembly can be
adjusted according to input requirements, thereby satisfying the
multi-angle adjustment and adapting various mounting
requirements.
[0031] The reduction gearbox assembly 3 drives the crankshaft 7 to
rotate. The crankshaft 7 rotates in the bearing supported by the
bearing seat 13. The crankshaft 7 drives the connecting rod body
21. The connecting rod body 21 drives the crosshead 22. The
crosshead 22 reciprocally moves in the arc-shaped slide rail 17 of
the crosshead case 5. The crosshead 22 drives, through the pull rod
27, the plunger 12 to reciprocally move in the valve housing 11 of
the hydraulic end assembly 2, to take up and discharge liquid.
[0032] It will be appreciated to persons skilled in the art that
the present invention is not limited to the foregoing embodiments,
which together with the context described in the specification are
only used to illustrate the principle of the present invention.
Various changes and improvements may be made to the present
invention without departing from the spirit and scope of the
present invention. All these changes and improvements shall fall
within the protection scope of the present invention. The
protection scope of the present invention is defined by the
appended claims and equivalents thereof
* * * * *