CN110656919A - 一种单机单泵电驱压裂半挂车 - Google Patents
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Abstract
本发明公开了提供一种单机单泵电驱压裂半挂车，将传统的供电半挂车以及压裂半挂车优化融合，实现了一台半挂车同时具备供电和压裂的功能，无需供电半挂车与压裂半挂车成套使用，实际使用时更灵活，大大优化油气田井场布局；运输方便；只需一组高压电缆接高压供电便可达到工作状态，接线安装更快捷；采用电驱压裂相较与柴油驱动压裂，噪音小，无废气排放污染；驱动源为电力，相对于柴油使用成本更低。
Description
技术领域
本发明涉及电驱压裂设备技术领域，具体涉及一种单机单泵电驱压裂半挂车。
背景技术
在全球的油气田压裂作业现场，柱塞泵的动力驱动方式主要有二种：
第一种是柴油发动机连接变速箱经传动轴驱动压裂柱塞泵工作。也就是说，动力源是柴油发动机，传动装置是变速箱和传动轴，执行元件是柱塞泵。.
该配置模式存在以下缺点：
(1)、体积大重量大：柴油机驱动变速箱经传动轴驱动柱塞泵，体积大，重量大，运输受限，功率密度小。
(2)、不环保：柴油发动机驱动的压裂设备在井场运行过程中，会产生发动机废气污染和噪音污染，噪音超过105dBA，严重影响周围居民的正常生活。
(3)、不经济：柴油发动机驱动的压裂设备，设备初期的采购成本比较高，设备运行时单位功率燃料消耗费用高，发动机和变速箱的日常维护保养费用也很高。
第二种是电动机连接传动轴或者联轴器驱动柱塞泵工作。也就是说，动力源是电动机，传动装置是传动轴或者联轴器，执行元件是柱塞泵，也就是电驱压裂。
电驱压裂在某些电力设施配套较完善的地方应用还是相对比较广泛的，现有的电驱压裂设备，通常是采用配备专门的供电设备来提供驱动电源，供电设备与电驱压裂设备之间通常是一对一，或者由一个大功率供电设备拖几台电驱压裂设备(以下简称一对多)，但无论是一对一还是一对多，在井场的实际使用时，都需要消耗过多的时间去排布电驱压裂设备与供电设备(即电驱压裂设备与供电设备需要成套配合使用)；还需要将每台电驱压裂设备与供电设备连接，以使电驱压裂设备进入工作状态；以上过程都比较耗时耗力，且设备之间的连接线缆也较多，相对繁琐。
为此亟待一种经济、环保、体积小、连接简单的电驱压裂设备。
发明内容
本发明的目的克服现有技术的不足，提供一种单机单泵电驱压裂半挂车，将传统的供电半挂车以及压裂半挂车优化融合，实现了一台半挂车同时具备供电和压裂的功能，无需供电半挂车与压裂半挂车成套使用，实际使用时更灵活，大大优化油气田井场布局；运输方便；只需一组高压电缆接高压供电便可达到工作状态，接线安装更快捷；采用电驱压裂相较与柴油驱动压裂，噪音小，无废气排放污染；驱动源为电力，相对于柴油使用成本更低。采用5000hp以上的五缸柱塞泵，尤其是7000hp时，大大提升了本单机单泵电驱压裂半挂车的输出功率，而且在单车输出功率大的前提下，单位面积下的井场功率密度也大大提升了。五缸柱塞泵的动力端壳体采用整体焊接结构，使得动力端总成的结构强度更高，支撑稳定性更好，可减少整泵振动。五缸柱塞泵的缸间距为13-14in，为五缸柱塞泵大功率的输出提供保障，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。对曲轴箱体、十字头箱体和液力端总成的多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。
本发明的目的是通过以下技术措施达到的：一种单机单泵电驱压裂半挂车，包括半挂车体，柱塞泵，散热器，供电单元和电动机，所述供电单元，电动机，散热器和柱塞泵集成在半挂车体上，电动机为1台，散热器为1台，柱塞泵为1台，供电单元为电动机提供电力，电动机与柱塞泵连接，散热器为柱塞泵的润滑油提供冷却。
进一步地，所述供电单元包括变压单元和变频单元，所述变频单元与变压单元相连，所述变压单元设在半挂车体靠近电动机的一端，所述变频单元设在半挂车体的鹅颈上。
进一步地，所述变压单元为舱体式结构，在舱体内设置了高压开关和变压器，所述高压开关和变压器连接。
进一步地，所述变频单元为舱体式结构，在变频单元舱体内设变频器，所述变频器的输入端与变压单元连接，所述变频器的输出端与电动机连接。
进一步地，所述柱塞泵为五缸柱塞泵，所述五缸柱塞泵包括动力端总成，液力端总成和减速箱总成，所述动力端总成的一端与液力端总成连接，所述动力端总成另一端与减速箱总成连接，所述动力端总成包括曲轴箱体，十字头箱体和间隔架，所述曲轴箱体，十字头箱体和间隔架依次连接。
进一步地，所述五缸柱塞泵的冲程为10″以上。
进一步地，所述五缸柱塞泵功率为5000hp以上。
进一步地，所述五缸柱塞泵功率为7000hp。
进一步地，所述五缸柱塞泵的缸间距为13-14in。
进一步地，所述曲轴箱体和十字头箱体采用整体焊接构成动力端壳体，动力端壳体与间隔架连接，所述动力端壳体包括立板，轴承座，前端板，后盖板，底板，支撑板和上盖板，所述立板的数量为6个，轴承座的数量为6个，一个立板对应连接一个轴承座，6个立板平行设置构成一个动力端腔体，在所述动力端腔体的底部安装底板，在所述动力端腔体的顶部安装上盖板，在所述动力端腔体的前端安装前端板，在所述动力端腔体的后端安装后盖板，在相邻两个平行设置的立板之间设支撑板。
进一步地，所述曲轴箱体的底部设曲轴支撑体，所述曲轴支撑体用于支承曲轴箱体。
进一步地，所述十字头箱体的底部设十字头支撑体，所述十字头支撑体用于支承十字头箱体。
进一步地，所述间隔架的底部设液力支撑体，所述液力支撑体用于支承液力端总成。
与现有技术相比，本发明的有益效果是：将传统的供电半挂车以及压裂半挂车优化融合，实现了一台半挂车同时具备供电和压裂的功能，无需供电半挂车与压裂半挂车成套使用，实际使用时更灵活，大大优化油气田井场布局；运输方便；只需一组高压电缆接高压供电便可达到工作状态，接线安装更快捷；采用电驱压裂相较与柴油驱动压裂，噪音小，无废气排放污染；驱动源为电力，相对于柴油使用成本更低。采用5000hp以上的五缸柱塞泵，尤其是7000hp时，大大提升了本单机单泵电驱压裂半挂车的输出功率，而且在单车输出功率大的前提下，单位面积下的井场功率密度也大大提升了。五缸柱塞泵的动力端壳体采用整体焊接结构，使得动力端总成的结构强度更高，支撑稳定性更好，可减少整泵振动。五缸柱塞泵的缸间距为13-14in，为五缸柱塞泵大功率的输出提供保障，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。对曲轴箱体、十字头箱体和液力端总成的多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。
下面结合附图和具体实施方式对本发明作详细说明。
附图说明
图1是单机单泵电驱压裂半挂车的结构示意图。
图2是五缸柱塞泵的结构示意图。
图3是动力端壳体的结构示意图。
其中，1.半挂车体，2.变频单元，3.变压单元，4.电动机，5.柱塞泵，6.散热器，7.动力端总成，8.减速箱总成，9.液力端总成，10.驱动法兰，11.动力端壳体，12.曲轴支撑体，13.十字头支撑体，14.液力支撑体，15.后盖板，16.立板，17.轴承座，18.底板，19.支撑板，20.前端板，21.上盖板。
具体实施方式
实施例，如图1至3所示，一种单机单泵电驱压裂半挂车，包括半挂车体1，柱塞泵5，散热器6，供电单元和电动机4，所述供电单元，电动机4，散热器6和柱塞泵5集成在半挂车体1上，电动机4为1台，散热器6为1台，柱塞泵5为1台，供电单元为电动机4提供电力，电动机4与柱塞泵5连接，散热器6为柱塞泵5的润滑油提供冷却。所述供电单元包括变压单元3和变频单元2，所述变频单元2与变压单元3相连，所述变压单元3设在半挂车体1靠近电动机4的一端，所述变频单元2设在半挂车体1的鹅颈上。半挂车体1的车轴数量为4个。该半挂车上还可设置电气控制柜，以实现该半挂车的本地操控。将传统的供电半挂车以及压裂半挂车优化融合，实现了一台半挂车同时具备供电和压裂的功能。相比现有供电半挂车与压裂半挂车成套配合使用，(如供电半挂车一托多台压裂半挂车时，接线相对繁琐，现场会造成大量接线堆积，线与线错综复杂，每辆供电半挂车与多辆压裂半挂车的排布等都需要耗费大量时间)，现场使用时，供电半挂车与压裂半挂车的分别运输，分别移动，再分别接线安装，本单机单泵电驱压裂半挂车只需一次移动，只需一组高压电缆与高压电源连接，即可实现工作状态。采用电驱压裂相较与柴油驱动压裂，噪音小，无废气排放污染；驱动源为电力，相对于柴油使用成本更低。
所述变压单元3为舱体式结构，在舱体内设置了高压开关和变压器，所述高压开关和变压器连接。所述变频单元2为舱体式结构，在变频单元2舱体内设变频器，所述变频器的输入端与变压单元3连接，具体的，所述变频器的输入端与变压器连接，所述变频器的输出端与电动机4连接。
所述柱塞泵5为五缸柱塞泵，所述五缸柱塞泵包括动力端总成7，液力端总成9和减速箱总成8，所述动力端总成7的一端与液力端总成9连接，所述动力端总成7另一端与减速箱总成8连接，所述动力端总成7包括曲轴箱体，十字头箱体和间隔架，所述曲轴箱体，十字头箱体和间隔架依次连接。
所述五缸柱塞泵的冲程为10″以上。长冲程设计可更好地实现大排量的作业需求，提高作业效率。
所述五缸柱塞泵功率为5000hp以上。更优的，所述五缸柱塞泵功率为7000hp。所述五缸柱塞泵的缸间距为13-14in，为五缸柱塞泵大功率的输出提供保障，大功率五缸柱塞泵可有效解决页岩气压裂井场面积狭小与所需压裂设备较多的问题，可减少设备的使用，便于井场布置。
所述曲轴箱体和十字头箱体采用整体焊接构成动力端壳体11，动力端壳体11与间隔架连接，所述动力端壳体11包括立板16，轴承座17，前端板20，后盖板15，底板18，支撑板19和上盖板21，所述立板16的数量为6个，轴承座17的数量为6个，一个立板16对应连接一个轴承座17，6个立板16平行设置构成一个动力端腔体，在所述动力端腔体的底部安装底板18，在所述动力端腔体的顶部安装上盖板21，在所述动力端腔体的前端安装前端板20，在所述动力端腔体的后端安装后盖板15，在相邻两个平行设置的立板16之间设支撑板19。对五缸柱塞泵动力端总成7中的曲轴箱体和十字头箱体采用整体焊接结构，使得动力端总成7的结构强度更高，支撑稳定性更好，可减少整泵振动。在曲轴箱体内设曲轴，在十字头箱体内设十字头、十字头盖和十字头轴瓦，在曲轴箱体与十字头箱体之间设连杆、连杆盖和连杆轴瓦，曲轴采用五曲拐六轴颈的设置，曲轴的一端减速箱总成8连接，曲轴的另一端通过连杆盖和连杆轴瓦与连杆连接，连杆的另一端通过十字头盖和十字头轴瓦与十字头连接，十字头的另一端连接有拉杆，拉杆的另一端通过柱塞和卡箍连接液力端阀箱。曲轴通过六道圆柱滚子轴承安装在动力端壳体11轴承座17上，可实现曲轴转动。支撑板19上固定安装滑轨，2个滑轨形成半圆空间，十字头安装与半圆空间内，可实现直线运动。减速箱总成8包括行星级减速箱和平行级减速箱，传动齿轮均为斜齿轮。行星减速箱包括一个太阳轮、四个行星轮、一个行星架和一个内齿圈，组成行星齿轮机构，太阳轮位于行星齿轮机构中心；平行级减速箱包括小齿轮和大齿轮，小齿轮与输入端相连，大齿轮与行星减速箱太阳轮连接，通过减速箱实现降速增扭。在行星级减速箱外设驱动法兰10，通过驱动法兰10外接动力源，实现动力输入。平行级减速箱与曲轴的连接，实现动力输出。
所述曲轴箱体的底部设曲轴支撑体12，所述曲轴支撑体12用于支承曲轴箱体。所述十字头箱体的底部设十字头支撑体13，所述十字头支撑体13用于支承十字头箱体。所述间隔架的底部设液力支撑体14，所述液力支撑体14用于支承液力端总成9。对曲轴箱体、十字头箱体和液力端总成9的多点支撑设计，可以提高五缸柱塞泵的支撑强度，减少振动，更好地保证高负荷作业，运行更平稳。
柱塞泵5的工作原理：外部动力或转速通过驱动法兰10带动减速箱总成8转动，经行星级减速箱和平行级减速箱的二级变速将动力和扭矩传递给曲轴，曲轴在动力端壳体11内转动，带动连杆、十字头、拉杆运动，将曲轴的旋转运动转变为拉杆的往复直线运动，拉杆通过卡箍带动柱塞在阀箱内进行往复运动，从而实现低压液体的吸入和高压液体的排出，实现液体的泵送。
单机单泵电驱压裂半挂车工作原理：高压开关的输入端与高压电源通过一根电缆接通，高压开关的输出端与变压器接通，高压开关用以控制整个单机单泵电驱压裂半挂车的电源通断，高压电经变压器降压后给变频器供电，变频器驱动电动机4工作，电动机4驱动柱塞泵5工作，散热器6为柱塞泵5的润滑油提供冷却。
本行业的技术人员应该了解，本发明不受上述实施例的限制，上述实施例和说明书中描述的只是说明本发明的原理，在不脱离本发明精神和范围的前提下，本发明还会有各种变化和改进，这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (13)
1.一种单机单泵电驱压裂半挂车，其特征在于：包括半挂车体，柱塞泵，散热器，供电单元和电动机，所述供电单元，电动机，散热器和柱塞泵集成在半挂车体上，电动机为1台，散热器为1台，柱塞泵为1台，供电单元为电动机提供电力，电动机与柱塞泵连接，散热器为柱塞泵的润滑油提供冷却。
2.根据权利要求1所述的单机单泵电驱压裂半挂车，其特征在于：所述供电单元包括变压单元和变频单元，所述变频单元与变压单元相连，所述变压单元设在半挂车体靠近电动机的一端，所述变频单元设在半挂车体的鹅颈上。
3.根据权利要求2所述的单机单泵电驱压裂半挂车，其特征在于：所述变压单元为舱体式结构，在舱体内设置了高压开关和变压器，所述高压开关和变压器连接。
4.根据权利要求2所述的单机单泵电驱压裂半挂车，其特征在于：所述变频单元为舱体式结构，在变频单元舱体内设变频器，所述变频器的输入端与变压单元连接，所述变频器的输出端与电动机连接。
5.根据权利要求1所述的单机单泵电驱压裂半挂车，其特征在于：所述柱塞泵为五缸柱塞泵，所述五缸柱塞泵包括动力端总成，液力端总成和减速箱总成，所述动力端总成的一端与液力端总成连接，所述动力端总成另一端与减速箱总成连接，所述动力端总成包括曲轴箱体，十字头箱体和间隔架，所述曲轴箱体，十字头箱体和间隔架依次连接。
6.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述五缸柱塞泵的冲程为10″以上。
7.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述五缸柱塞泵功率为5000hp以上。
8.根据权利要求7所述的单机单泵电驱压裂半挂车，其特征在于：所述五缸柱塞泵功率为7000hp。
9.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述柱塞泵的缸间距为13-14in。
10.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述曲轴箱体和十字头箱体采用整体焊接构成动力端壳体，动力端壳体与间隔架连接，所述动力端壳体包括立板，轴承座，前端板，后盖板，底板，支撑板和上盖板，所述立板的数量为6个，轴承座的数量为6个，一个立板对应连接一个轴承座，6个立板平行设置构成一个动力端腔体，在所述动力端腔体的底部安装底板，在所述动力端腔体的顶部安装上盖板，在所述动力端腔体的前端安装前端板，在所述动力端腔体的后端安装后盖板，在相邻两个平行设置的立板之间设支撑板。
11.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述曲轴箱体的底部设曲轴支撑体，所述曲轴支撑体用于支承曲轴箱体。
12.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述十字头箱体的底部设十字头支撑体，所述十字头支撑体用于支承十字头箱体。
13.根据权利要求5所述的单机单泵电驱压裂半挂车，其特征在于：所述间隔架的底部设液力支撑体，所述液力支撑体用于支承液力端总成。
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| CN116480547A (zh) | 2023-07-25 |
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