US20210095598A1 - Direct drive unit removal system and associated methods - Google Patents
Direct drive unit removal system and associated methods Download PDFInfo
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- US20210095598A1 US20210095598A1 US17/122,433 US202017122433A US2021095598A1 US 20210095598 A1 US20210095598 A1 US 20210095598A1 US 202017122433 A US202017122433 A US 202017122433A US 2021095598 A1 US2021095598 A1 US 2021095598A1
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- United States
- Prior art keywords
- ddu
- platform
- enclosure
- gearbox
- positioner assembly
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/20—Mounting or supporting of plant; Accommodating heat expansion or creep
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/25—Methods for stimulating production
- E21B43/26—Methods for stimulating production by forming crevices or fractures
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/25—Methods for stimulating production
- E21B43/26—Methods for stimulating production by forming crevices or fractures
- E21B43/2607—Surface equipment specially adapted for fracturing operations
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D15/00—Adaptations of machines or engines for special use; Combinations of engines with devices driven thereby
- F01D15/08—Adaptations for driving, or combinations with, pumps
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/32—Arrangement, mounting, or driving, of auxiliaries
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/36—Power transmission arrangements between the different shafts of the gas turbine plant, or between the gas-turbine plant and the power user
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
- F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
- F04B53/00—Component parts, details or accessories not provided for in, or of interest apart from, groups F04B1/00 - F04B23/00 or F04B39/00 - F04B47/00
- F04B53/22—Arrangements for enabling ready assembly or disassembly
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/28—Supporting or mounting arrangements, e.g. for turbine casing
- F01D25/285—Temporary support structures, e.g. for testing, assembling, installing, repairing; Assembly methods using such structures
Definitions
- This disclosure relates to embodiments of systems and methods for the removal and/or positioning of a direct drive unit housed in an enclosure, such as a direct drive turbine (DDT) when connected to a gearbox for driving a driveshaft, which, in turn, may be connected to a pump such as for use in a hydraulic fracturing system.
- a direct drive unit housed in an enclosure, such as a direct drive turbine (DDT) when connected to a gearbox for driving a driveshaft, which, in turn, may be connected to a pump such as for use in a hydraulic fracturing system.
- DDT direct drive turbine
- a method of removing a direct drive unit (DDU) housed in an enclosure includes a gearbox and a turbine engine connected to the gearbox for driving a driveshaft connected to a pump for use in high-pressure, high-power hydraulic fracturing operations.
- the method may include accessing the enclosure.
- the enclosure contains air inlet ducting connected to the turbine engine and air exhaust ducting connected to the turbine engine.
- the method may further include disconnecting the turbine engine from the air inlet ducting, disconnecting the turbine engine from at least one fuel line, disconnecting the gearbox from the driveshaft, disconnecting the turbine engine from an at least one exhaust flange connected to the air exhaust ducting, and operating a DDU positioner assembly to position the DDU for withdrawal from the enclosure, and removing the DDU from the enclosure.
- a direct drive unit (DDU) positioner assembly for positioning a DDU housed in an enclosure for removal from the enclosure.
- the DDU includes a gearbox and a turbine engine connected to the gearbox for driving a driveshaft connected to a pump for use in high-pressure, high-power hydraulic fracturing operations.
- the DDU positioner assembly may include a plurality of longitudinal rails extending in a longitudinal direction along the central axis of the DDU and a plurality of lateral rails extending in a lateral direction transverse to the longitudinal direction.
- the DDU positioner assembly may further include a platform slidably connected to the plurality of lateral rails.
- the plurality of longitudinal rails may be mounted on the platform and the DDU may be slidably connected to the longitudinal rails.
- the DDU may be movable in the longitudinal direction along the longitudinal rails and the platform may be movable in the lateral direction along the lateral rails.
- a direct drive unit (DDU) positioner assembly for positioning a DDU housed in an enclosure for removal from the enclosure.
- the DDU includes a gearbox and a turbine engine connected to the gearbox for driving a driveshaft connected to a pump for use in high-pressure, high-power, hydraulic fracturing operations.
- the DDU positioner assembly may include a platform connected to a support of the gearbox and mounted on an enclosure base of the enclosure.
- the enclosure base may have a plurality of lubrication grooves for facilitating sliding movement of the platform relative to the enclosure base.
- the DDU positioner assembly may include a lubricator to convey lubricant to the lubrication grooves.
- the platform may be fixedly attached to the enclosure base by one or more fasteners during operation of the DDU and in slidable engagement with the enclosure base upon removal of the one or more fasteners.
- FIG. 1A is a schematic diagram of a pumping unit according to an embodiment of the disclosure.
- FIG. 1B is a schematic diagram of a layout of a fluid pumping system according to an embodiment of the disclosure.
- FIG. 2 is a perspective view of an enclosure for housing a direct drive unit (DDU) according to an embodiment of the disclosure.
- DDU direct drive unit
- FIG. 3 is a top plan view of the enclosure housing the DDU according to an embodiment of the disclosure.
- FIG. 4 is a side elevation view of the DDU mounted on a DDU positioner assembly according to a first embodiment of the disclosure.
- FIG. 5 is an end elevation view of the DDU of FIG. 4 according to a first embodiment of the disclosure.
- FIG. 6A is a perspective view of the DDU of FIG. 4 in a first position according to a first embodiment of the disclosure.
- FIG. 6B is a perspective view of the DDU of FIG. 6A moved to a second position according to a first embodiment of the disclosure.
- FIG. 6C is a perspective view of the DDU of FIG. 6B moved to a third position according to a first embodiment of the disclosure.
- FIG. 7 is a side elevation view of the DDU mounted on a DDU positioner assembly according to a second embodiment of the disclosure.
- FIG. 8A is a perspective view of the DDU of FIG. 7 in a first position according to a second embodiment of the disclosure.
- FIG. 8B is a perspective view of the DDU of FIG. 8A moved to a second position according to a second embodiment of the disclosure.
- FIG. 8C is a perspective view of the DDU of FIG. 8B moved to a third position according to a second embodiment of the disclosure.
- FIG. 9 is an enlarged detail of a portion of the DDU positioner assembly according to a second embodiment of the disclosure.
- FIG. 10 is a detail of a portion of the DDU positioner assembly according to a second embodiment.
- FIG. 11 is a side elevation view of the DDU mounted on a DDU positioner assembly according to a third embodiment of the disclosure.
- FIG. 12A is a perspective view of the DDU of FIG. 11 in a first position according to a third embodiment of the disclosure.
- FIG. 12B is a perspective view of the DDU of FIG. 12A moved to a second position according to a third embodiment of the disclosure.
- FIG. 12C is a perspective view of the DDU of FIG. 12B moved to a third position according to a third embodiment of the disclosure.
- this disclosure is directed to a direct drive unit (DDU) positioner assembly, positioning system, removal system, and/or associated mechanisms that will allow a DDU including a gearbox and a turbine engine connected to the gearbox to be detached from surrounding equipment and removed through the side of an enclosure housing the direct drive unit.
- the system will allow for inspections, maintenance, or even a complete exchange of the direct drive unit with another if necessary.
- DDU direct drive unit
- FIG. 1A illustrates a schematic view of a pumping unit 11 for use in a high-pressure, high power, fluid pumping system 13 ( FIG. 1B ) for use in hydraulic fracturing operations according to one embodiment of the disclosure.
- FIG. 1B shows a typical pad layout of the pumping units 11 (indicated as FP 1 , FP 2 , FP 3 , FP 4 , FP 5 , FP 6 , FP 7 , FP 8 ) with the pumping units all operatively connected to a manifold M that is operatively connected to a wellhead W.
- the system 13 is a hydraulic fracturing application that may be sized to achieve a maximum rated horsepower of 24,000 HP for the pumping system 13 , including a quantity of eight (8) 3000 horsepower (HP) pumping units 11 that may be used in one embodiment of the disclosure.
- HP 3000 horsepower
- the fluid pumping system 13 may include associated service equipment such as hoses, connections, and assemblies, among other devices and tools.
- each of the pumping units 11 are mounted on a trailer 15 for transport and positioning at the jobsite.
- Each pumping unit 11 includes an enclosure 21 that houses a direct drive unit (DDU) 23 including a gas turbine engine 25 operatively connected to a gearbox 27 .
- DDU direct drive unit
- the pumping unit 11 has a driveshaft 31 operatively connected to the gearbox 27 .
- the pumping unit 11 includes a high-pressure, high-power, reciprocating positive displacement pump 33 that is operatively connected to the DDU 23 via the driveshaft 31 .
- the pumping unit 11 is mounted on the trailer 15 adjacent the DDU 23 .
- the trailer 15 includes other associated components such as a turbine exhaust duct 35 operatively connected to the gas turbine engine 25 , air intake duct 37 operatively connected to the gas turbine, and other associated equipment hoses, connections, etc. to facilitate operation of the fluid pumping unit 11 .
- the gas turbine engine 25 is a Vericor Model TF50F bi-fuel turbine; however, the direct drive unit 23 may include other gas turbines or suitable drive units, systems, and/or mechanisms suitable for use as a hydraulic fracturing pump drive without departing from the disclosure.
- the gas turbine engine 25 is cantilever mounted to the gearbox 27 with the gearbox supported by the floor 41 of the enclosure 21 .
- the gearbox 27 may be a reduction helical gearbox that has a constant running power rating of 5500 SHP and intermittent power output of 5850 SHP, or other suitable gearbox.
- FIG. 2 illustrates the enclosure 21 that houses the direct drive unit 23 in an interior space 46 of the enclosure.
- the enclosure has access doors 45 for removal of the DDU 23 from the enclosure and/or other components within the enclosure.
- the enclosure 21 provides sound attenuation of the DDU 23 during operation.
- the direct drive unit 23 and the enclosure 21 has a longitudinal axis L 1 and a lateral axis L 2 transverse to the longitudinal axis.
- FIG. 3 illustrates a top view of the enclosure 21 with the DDU 23 shown attached to the driveshaft 31 that extends through an opening 48 in a first longitudinal end 47 of the enclosure.
- An air exhaust assembly 35 extends through a second longitudinal end 49 of the enclosure.
- the DDU 23 has a central axis CL extending in the longitudinal direction L 1 that extends through the centerline of the unit and is aligned with the centerline of the driveshaft 31 .
- the gearbox 27 includes an outlet flange 50 that is connected to the driveshaft 31 .
- the gas turbine engine 25 has two air inlet ports 51 , 53 on a respective lateral side of the central axis CL and an exhaust duct flange 54 that connects the gas turbine engine to the air exhaust assembly 35 at the longitudinal end 49 of the enclosure 21 .
- the access doors 45 are mounted on a first lateral side 55 of the enclosure 21 , but the enclosure may have additional access doors on a second lateral side 57 of the enclosure, or the access doors may be positioned only on the second lateral side without departing from the scope of this disclosure.
- the gas turbine engine 25 may include polymer expansion joints 61 , 63 connected to air inlet ports 51 , 53 , to facilitate the removal of the gas turbine engine from the enclosure 21 .
- the gas turbine engine 25 may include various fuel lines, communication lines, hydraulic and pneumatic connections, and other connections or accessories needed for operation of the gas turbine engine without departing from the disclosure.
- Such connections may utilize quick disconnect fittings and check valves to facilitate disconnection of the gas turbine engine 25 during removal of the DDU 23 from the enclosure 21 .
- Such connections such as fuel lines and hydraulic lines may run to a single bulkhead (not shown) within or near the enclosure to allow for quick disconnection by locating these connections in a common location.
- FIG. 4 is a side elevation view of the DDU 23 as viewed from the lateral side 55 of the enclosure 21 , with the DDU being mounted on a DDU positioner assembly or DDU positioning system 101 ( FIGS. 4-6C ) for positioning the DDU for withdrawal or removal from the enclosure through the access doors 45 .
- the DDU positioner assembly 101 comprises a platform 103 slidably mounted to overlie two lateral rails 105 , 107 mounted to overlie the floor 41 of the enclosure 21 and extending laterally across the enclosure generally between the lateral sides 55 , 57 .
- the DDU positioner assembly 101 comprises two longitudinal rails 109 , 111 mounted to overlie the platform 103 and extending in the longitudinal direction L 1 .
- the DDU 23 is slidably mounted on the longitudinal rails 109 , 111 for positioning the DDU in the longitudinal direction L 1 .
- the DDU positioner assembly 101 includes lateral guide rollers 115 , 117 mounted on a respective lateral rail 105 , 107 , and longitudinal guide rollers 121 , 123 mounted on a respective longitudinal rail 109 , 111 .
- the platform 103 is connected to the lateral guide rollers 115 , 117 to allow slidable movement and positioning of the DDU 23 mounted on the platform in the lateral direction L 2 via the lateral rails 105 , 107 .
- the longitudinal guide rollers 121 , 123 are connected to a mounting base 127 of the gearbox 27 to allow slidable movement and positioning of the DDU 23 in the longitudinal direction L 1 via the longitudinal rails 109 , 111 .
- the DDU positioner assembly 101 includes four lateral guide rollers 115 , 117 and four longitudinal guide rollers 121 , 123 , but more or less than eight guide rollers may be provided without departing from the scope of the disclosure. Further, more or less than two longitudinal rails 109 , 111 , and more or less than two lateral rails 105 , 107 may be provided without departing from the scope of the disclosure.
- the guide rollers 115 , 117 , 121 , 123 may be a caged ball type linear motion (LM) Guide, model number SPS20LR available from THK America Inc., or any similar make or model number without departing from the scope of the disclosure.
- the DDU positioner assembly 101 may be equipped with locking mechanisms 128 mounted on a respective guide roller 115 , 117 , 121 , 123 .
- the locking mechanisms 128 may be spring loaded and will default to the locked position to allow the DDU 23 to be secured in the operating position.
- the locking mechanism 128 may be otherwise located on the positioning system 101 without departing from the disclosure.
- Exemplary loading calculations for sizing the guide rails 105 , 107 , 109 , 111 are shown below and are based on the Vericor TF50F turbine parameters as follows: approximate turbine weight, 1475 lbs.; approximate fuel system weight, 85 lbs.; approximate gearbox weight, 4000 lbs.; for a total approximate weight of 5559 lbs.
- Various other parameters may be applicable based on the make, model, and size of the gas turbine engine 25 .
- the direct drive unit 23 including the gas turbine engine 25 cantilever mounted onto the gearbox 27 and extending in the longitudinal direction L 1 from the gearbox, there is added load put onto the rear lateral guide rollers 115 and the rear longitudinal guide rollers 121 , 123 (the guide rollers mounted closest to the gas turbine engine). Accordingly, an increased load rating may be applied to the rear guide rollers 115 , 121 , 123 if required.
- the calculation of the cantilever load and the reaction forces may be calculated with the formulas shown below, which may also be used for further design and implementation of the disclosed removal mechanisms.
- R A reaction force in A (N, lb)
- q uniform distributed load (N/m, N/mm, lb/in)
- L length of cantilever beam (m, mm, in).
- ⁇ B maximum deflection in B (m, mm, in).
- the longitudinal guide rollers 121 , 123 connected to the support structure 127 of the gearbox 27 are positioned between each pair of the lateral guide rollers 115 , 117 to ensure equal weight distribution over the platform 103 and to avoid cantilever loading the platform.
- Different configurations of platforms, sliders, rails and mounts are contemplated and considered within the scope of the disclosure.
- the configurations of the DDU positioner assembly 101 may vary to suit a particular DDU 23 with various alternative combinations of makes, model, and sizes of the gas turbine engine 25 and the gearbox 27 .
- the guide rails 105 , 107 , 109 , 111 are made from a steel composition that has been mill finished and shot blasted to protect the rail from the high heat environment within the turbine enclosure 21 and ensure strength retention under the exposed temperatures.
- the platform 103 is constructed out of a composite material; however, other materials are contemplated and considered within the scope of the disclosure, such as but not limited to, steel or stainless steel.
- the guide rails 105 , 107 , 109 , 111 , platform 103 , and/or other components of the DDU positioner assembly 101 may be made of various other suitable materials without departing from the scope of the disclosure.
- FIGS. 6A-6B illustrate an exemplary method of removing the direct drive unit 23 from the enclosure 21 utilizing the DDU positioner assembly 101 .
- FIG. 6A shows the DDU 23 in a first/operating position for operation with the pump 33 of the pumping unit 11 .
- the method includes accessing the enclosure 21 and disconnecting the gas turbine engine 25 from the air inlet ducting 37 .
- the flanges 51 , 53 may be disconnected from the air inlet ducting 37 and the expansion joints 61 , 63 flexed to allow separation of the DDU 23 from the air inlet ducting.
- the gas turbine engine 25 may be disconnected from the air exhaust ducting 35 by disconnecting the exhaust duct flange 54 from the air exhaust ducting.
- Corresponding hoses, piping, wiring, and cabling including fuel lines, electrical lines, hydraulic lines, control lines or any other connection that is needed for operation of the gas turbine engine 25 may also be disconnected so that the gas turbine engine is free to move without damaging any of the operational connections needed for operation of the gas turbine engine.
- the air bleed off valve ducting may be removed from the turbine engine 25 and secured at a location free of interference with movement of the turbine engine.
- some hoses, piping, wiring, etc. may include enough slack or flexibility so that the DDU 23 may be initially moved before complete disconnection of the connections from the gas turbine engine 25 are required for removal of the DDU from the enclosure 21 .
- the gearbox 27 may be disconnected from the driveshaft 31 by disconnecting the outlet flange 50 from the driveshaft.
- the driveshaft 31 may be a slip-fit driveshaft allowing the driveshaft to contract to facilitate disconnection from the DDU 23 .
- the driveshaft 31 may be a 390 Series, GWB Model 390.80 driveshaft available Dana Corporation, or other suitable driveshaft.
- the gearbox 27 may be disconnected from any other connections needed for operation of the DDU 23 to obtain freedom of movement of the gearbox without damaging any of the operating connections.
- the DDU positioner assembly 101 is operated to position the direct drive unit 23 for withdrawal from the enclosure 21 .
- the DDU 23 is positioned in a second position where the DDU is first moved in the longitudinal direction L 1 in the direction of arrow A 1 by sliding the DDU along the longitudinal rails 109 , 111 .
- the longitudinal locks 128 associated with the longitudinal guide rollers 121 , 123 must be released to allow the movement of the DDU in the longitudinal direction.
- the longitudinal locks 128 may be reengaged to lock the longitudinal guide rollers 121 , 123 and prevent further or additional unwanted movement of the DDU 23 along the longitudinal rails 109 , 111 , and the lateral locks 128 associated with the lateral guide rollers 115 , 117 may be disengaged to allow lateral movement of the DDU 23 .
- the platform 103 may be moved to a third position by moving in the lateral direction L 2 in the direction of arrow A 2 ( FIG. 6C ) by sliding movement of the lateral guide rollers 115 , 117 along the lateral guide rails 105 , 107 .
- the DDU 23 is mounted to the platform 103 and moves with the platform in the lateral direction L 2 to the third position of FIG. 6C .
- the lateral guide rails 105 , 107 may extend to the access doors 45 in either side 55 , 57 of the enclosure 21 .
- lateral guide rail extensions 107 ′ FIG.
- a lifting mechanism e.g., a forklift, crane, or other suitable lifting mechanism
- the various method steps described herein for the method of positioning or removing the DDU 23 may be otherwise performed in an alternative order or simultaneously, or more or less steps may be used without departing from the scope of the disclosure.
- FIGS. 7-10 illustrates a second embodiment of a DDU positioner assembly or system 201 for positioning the direct drive unit 23 housed in the enclosure 21 .
- the DDU 23 includes a gas turbine engine 25 and a gearbox 27 identical to the first embodiment of the disclosure, but the DDU positioner assembly 201 may be used to position a DDU that is alternatively configured without departing from the disclosure.
- like or similar reference numbers will be used to describe identical or similar features between the two embodiments.
- the DDU positioner assembly 201 includes a platform 203 that supports the gearbox 27 and has a top surface 205 , a bottom surface 207 , two sides 208 , and two ends 210 .
- the gearbox 27 is fixedly mounted to the top surface 205 of the platform 203 .
- the platform 203 is slidably mounted on the base 41 of the enclosure 21 with the bottom surface 207 of the platform being in slidable engagement with the floor of the enclosure.
- a first or operating position ( FIGS. 7 and 8A ) of the direct drive unit 23 the platform 203 is fixedly attached to the base 41 by a plurality of fasteners 211 .
- the platform 203 Upon removal of the fasteners 211 , the platform 203 is capable of slidable movement with respect to the base 41 .
- the platform 203 is connected to the support structure 127 of the gearbox 27 so that the drive unit 23 moves with the platform.
- the platform 203 has two lifting openings 215 , 217 extending between respective sides 208 of the platform. As shown in FIG.
- the lifting opening 215 towards the front of the gearbox 27 (closest to the drive shaft flange 50 ) is spaced a first distance D 1 from a centerline CT of the gearbox and the lifting opening 217 towards the rear of the gearbox (closest to the gas turbine engine 25 ) is spaced a second distance from the centerline CT of the gearbox, with the distance D 2 being greater than the distance D 2 .
- the rear lifting opening 217 is farther from the centerline CT of the gearbox 27 because of the cantilever mounted gas turbine engine 25 that shifts the center of gravity of the DDU 23 from the centerline CT of the gearbox in the longitudinal direction toward the gas turbine engine.
- the platform 203 may be otherwise configured and/or arranged without departing from the scope of the disclosure.
- the DDU positioner assembly 201 includes a lubricator or lubrication system 221 ( FIG. 9 ) to convey lubricant (e.g., grease or other suitable lubricant) from a lubricant reservoir 244 to a location between the bottom surface 207 of the platform 201 and the base 41 of the enclosure.
- the DDU positioner assembly 201 includes a lubrication portion 225 ( FIG. 10 ) of the base 41 below the platform 203 . As shown in FIG. 10 , the portion 225 of the base 41 includes a plurality of lubrication grooves 227 .
- the lubrication grooves 227 are in fluid communication with the lubricator 221 so that the lubricator provides lubricant to the grooves to facilitate sliding engagement between the platform 203 and the portion 225 of the base 41 .
- the lubricator 221 includes a source of lubricant 244 , tubing 243 , and other required components (e.g., pump, controls, etc.) for delivering the lubricant to the lubrication portion 225 at a sufficiently high pressure for lubricant to fill the grooves 227 of the lubrication portion 225 .
- the lubricator 221 may be an automatic lubricator such as a model TLMP lubricator available from SKF Corporation, or the lubricator may be any other suitable lubricator including other automatic lubricators or manual lubricators without departing from the scope of the disclosure.
- the lubrication portion 225 of the base 41 is an integral portion with the base or the floor of the enclosure 21 , but the lubrication portion 225 may be a separate pad or component that is mounted between the base and the platform without departing from the disclosure.
- the lubricator 221 may be mounted inside the enclosure 21 or at least partially outside the enclosure without departing from the scope of the disclosure.
- the DDU positioner assembly 201 includes drive fasteners 241 mounted at one end 210 of the platform 203 .
- the drive fasteners 241 include a bracket 245 mounted to the floor 41 of the enclosure 21 and an impact screw 247 operatively connected to the bracket and the platform 203 .
- the drive fasteners 241 may have other components and be otherwise arranged without departing from the disclosure. Further, more or less than two drive fasteners 241 may be provided without departing from the disclosure.
- FIGS. 8A-9 illustrate an exemplary method of removing the DDU 23 from the enclosure 21 utilizing the DDU positioner assembly 201 of the second embodiment.
- the method is similar to the method of the first embodiment, in that the gas turbine engine 25 is disconnected from the air inlet ducting 37 , the air exhaust ducting 35 , and from other corresponding connections and components in a similar manner as discussed above for the first embodiment so that the gas turbine engine is free to move without damaging any of the operational connections and components needed for operation of the gas turbine engine.
- the gearbox 27 is disconnected from the driveshaft 31 in a similar manner as the first embodiment, so that the DDU 23 has clearance for movement in the longitudinal direction L 1 without interference with the driveshaft.
- FIG. 8A shows the direct drive unit 23 in the first/operating position.
- the DDU positioner assembly 201 is operated to position the DDU 23 for withdrawal from the enclosure 21 .
- the fasteners 211 fixedly attaching the platform 203 to the base 41 are removed.
- the lubricator 221 is operated to convey lubricant to the lubrication grooves 227 of the lubrication portion 225 of the base 41 .
- the drive fasteners 241 may be operated to move the platform 203 in the longitudinal direction L 1 to a second position ( FIG. 8B ).
- the platform 203 is slid in the longitudinal direction L 1 in the direction of arrow A 3 ( FIG. 8B ).
- the lubricant provided in the lubrication grooves 227 and between the lubrication portion 225 and the bottom surface 207 of the platform reduces the sliding friction and allows the rotation of the impact screws 247 in the bracket 245 to advance the platform in the direction of arrow A 3 .
- the platform 203 is moved in the direction of arrow A 3 a sufficient amount to allow access to the lifting openings 215 , 217 by a lifting mechanism (e.g., forklift) 261 ( FIG. 8C ).
- the lifting mechanism 261 may include a forklift or other lifting mechanism that may access the interior 46 of the enclosure through the enclosure access doors 45 .
- the lifting mechanism 261 is inserted into the lifting openings 215 , 217 of the platform 203 , and the DDU 23 is lifted and/or slid in the direction of arrow A 4 .
- the lifting mechanism 261 may move the DDU 23 to the third position ( FIG.
- FIGS. 11-12C illustrate a third embodiment of a DDU positioner assembly or system 301 for positioning the direct drive unit 23 housed in the enclosure 21 .
- the DDU 23 includes a gas turbine engine 25 and a gearbox 27 identical to the first and second embodiments of the disclosure, but the DDU positioner assembly 301 may be used to position a DDU that is alternatively configured without departing from the disclosure as will be understood by those skilled in the art.
- the DDU positioner assembly 301 is generally similar to the DDU positioner assembly 201 of the second embodiment, except the drive fasteners 241 have been removed and an actuator 341 is added to the DDU positioner assembly of the third embodiment. As such, like or similar reference numbers will be used to describe identical or similar features between the second and third embodiments.
- the DDU positioner assembly 301 includes the actuator 341 that has a first end 345 connected to the base 41 of the enclosure 21 and a second end 347 connected to the end 210 of the platform 203 .
- the actuator 341 is a hydraulic cylinder that has a piston rod 351 that is extendible from a cylinder body 349 upon operation of the actuator.
- the actuator 341 may be controlled by a manual control valve or the actuator may be configured for remote operation by connection to corresponding automated control valves.
- one actuator 341 is shown, but the DDU positioner assembly 301 may include more than one actuator without departing from the scope of the disclosure. Further, the actuator 341 may be otherwise located for attachment to the platform 203 without departing from the scope of the disclosure.
- FIGS. 12A-12C illustrate an exemplary method of removing the DDU 23 from the enclosure 21 utilizing the DDU positioner assembly 301 of the second embodiment.
- the method is similar to the method of the utilizing the DDU positioner assembly 201 of the second embodiment, in that the gas turbine engine 25 is disconnected from the air inlet ducting 37 , the air exhaust ducting 35 , and from other corresponding connections and components in a similar manner as discussed above for the first embodiment so that the gas turbine engine is free to move without damaging any of the operational connections and components needed for operation of the gas turbine engine.
- the gearbox 27 is disconnected from the driveshaft 31 in a similar manner as the first embodiment, so that the DDU 23 has clearance for movement in the longitudinal direction L 1 without interference with the driveshaft.
- the DDU positioner assembly 301 of the third embodiment includes the lubricator 221 ( FIG. 9 ) for providing lubrication to lubrication grooves 227 of the lubrication portion 225 of the base 41 to facilitate sliding of the platform 203 in the longitudinal direction L 1 , so that the DDU positioner assembly of the third embodiment operates in a similar manner as the DDU positioner assembly 201 of the second embodiment.
- FIG. 12A shows the direct drive unit 23 in the first/operating position.
- the DDU positioner assembly 301 is operated to position the DDU 23 for withdrawal from the enclosure 21 .
- the fasteners 211 fixedly attaching the platform 203 to the base 41 are removed.
- the lubricator 221 is operated to convey lubricant to the lubrication grooves 227 of the lubrication portion 225 of the base 41 .
- the actuator 341 may be operated to move the platform 203 in the longitudinal direction L 1 to a second position ( FIG. 12B ).
- the extension of the piston rod 351 of the actuator 341 exerts a force on the platform 203 to slide the platform in the longitudinal direction L 1 in the direction of arrow A 3 ( FIG. 12B ).
- the lubricant provided in the lubrication grooves 227 and between the lubrication portion 225 and the bottom surface 207 of the platform reduces the sliding friction and allows the actuator 341 to advance the platform in the direction of arrow A 3 .
- the platform 203 is moved in the direction of arrow A 3 a sufficient distance to allow access to the lifting openings 215 , 217 by a lifting mechanism (e.g., forklift) 261 ( FIG. 8C ).
- the lifting mechanism 261 may include a forklift or other lifting mechanism that may access the interior 46 of the enclosure through the enclosure access doors 45 .
- the lifting mechanism 261 is inserted into the lifting openings 215 , 217 of the platform 203 , and the DDU 23 is lifted and/or slid in the direction of arrow A 4 .
- the actuator 341 Prior to moving the platform 203 in the direction of arrow A 4 , the actuator 341 may be disconnected from the platform ( FIG.
- the first end 347 of the actuator being separated from the platform and the second end 345 of the actuator remaining attached to the floor 41 of the enclosure.
- the second end 345 of the actuator 341 may be disconnected from the floor 41 of the enclosure and the first end 341 of the actuator may remain attached to the platform 203 , or both ends of the actuator may be disconnected and the actuator removed without departing from the enclosure.
- the lifting mechanism 261 may move the DDU 23 to the third position ( FIG. 12C ), or transfer the DDU onto an adjacent supporting structure or vehicle (e.g., maintenance inspection platform or other suitable structure), or completely remove the platform 203 and DDU 23 from the enclosure.
- the various method steps described herein for the method of positioning or removing the DDU 23 by operating the DDU positioner assembly 301 may be otherwise performed in an alternative order or simultaneously, or more or less steps may be used without departing from the scope of the disclosure.
Abstract
Description
- This application is a divisional of U.S. Non-Provisional application Ser. No. 15/929,924, filed May 29, 2020, titled “DIRECT DRIVE UNIT REMOVAL SYSTEM AND ASSOCIATED METHODS,” which claims the benefit of and priority to U.S. Provisional Application No. 62/899,975, filed Sep. 13, 2019, titled “TURBINE REMOVAL SYSTEM,” the entire disclosures of each of which are incorporated herein by reference.
- This disclosure relates to embodiments of systems and methods for the removal and/or positioning of a direct drive unit housed in an enclosure, such as a direct drive turbine (DDT) when connected to a gearbox for driving a driveshaft, which, in turn, may be connected to a pump such as for use in a hydraulic fracturing system.
- Traditional fracturing pumping fleets have had fuel supplied from a single fuel source. In such units, when a unit runs low on fuel (for example diesel), that unit is shutdown while another stand by unit is brought in, refueled, and then put into service. Some inefficiencies included in this process are that the unit once low on primary fuel must be stopped, refueled while another unit is simultaneously being introduced into its place to make up for the loss of the pumping power that the unit provides. This may affect the pumping performance during a section as well as requiring human intervention to perform the refueling, lining up suction and discharge valves. This may require multiple personnel to relay back the information so the process is performed in the correct series of steps. Using a single fuel source also limits the ability for the fracturing fleet to make it continuously through a section when low on fuel which results in delays in pumping completion.
- In addition, in cases where the unit needs to be taken offline for maintenance or replacement, significant disassembly is required to remove the unit from its enclosure and to install a replacement unit, potentially resulting in excessive downtime. In some cases, the entire trailer and enclosure need to be removed from the site so a new, fully equipped trailer may be moved into place.
- Accordingly, it may be seen that a need exists for more efficient ways of accessing the drive units for maintenance purposes and/or replacement with minimum disruption to the system operations and the surrounding equipment. The present disclosure addresses these and other related and unrelated problems in the art.
- According to one embodiment of the disclosure, a method of removing a direct drive unit (DDU) housed in an enclosure. The DDU includes a gearbox and a turbine engine connected to the gearbox for driving a driveshaft connected to a pump for use in high-pressure, high-power hydraulic fracturing operations. The method may include accessing the enclosure. The enclosure contains air inlet ducting connected to the turbine engine and air exhaust ducting connected to the turbine engine. The method may further include disconnecting the turbine engine from the air inlet ducting, disconnecting the turbine engine from at least one fuel line, disconnecting the gearbox from the driveshaft, disconnecting the turbine engine from an at least one exhaust flange connected to the air exhaust ducting, and operating a DDU positioner assembly to position the DDU for withdrawal from the enclosure, and removing the DDU from the enclosure.
- According to another embodiment of the disclosure, a direct drive unit (DDU) positioner assembly is disclosed for positioning a DDU housed in an enclosure for removal from the enclosure. The DDU includes a gearbox and a turbine engine connected to the gearbox for driving a driveshaft connected to a pump for use in high-pressure, high-power hydraulic fracturing operations. The DDU positioner assembly may include a plurality of longitudinal rails extending in a longitudinal direction along the central axis of the DDU and a plurality of lateral rails extending in a lateral direction transverse to the longitudinal direction. The DDU positioner assembly may further include a platform slidably connected to the plurality of lateral rails. The plurality of longitudinal rails may be mounted on the platform and the DDU may be slidably connected to the longitudinal rails. The DDU may be movable in the longitudinal direction along the longitudinal rails and the platform may be movable in the lateral direction along the lateral rails.
- According to yet another embodiment of the disclosure, a direct drive unit (DDU) positioner assembly is disclosed for positioning a DDU housed in an enclosure for removal from the enclosure. The DDU includes a gearbox and a turbine engine connected to the gearbox for driving a driveshaft connected to a pump for use in high-pressure, high-power, hydraulic fracturing operations. The DDU positioner assembly may include a platform connected to a support of the gearbox and mounted on an enclosure base of the enclosure. The enclosure base may have a plurality of lubrication grooves for facilitating sliding movement of the platform relative to the enclosure base. The DDU positioner assembly may include a lubricator to convey lubricant to the lubrication grooves. The platform may be fixedly attached to the enclosure base by one or more fasteners during operation of the DDU and in slidable engagement with the enclosure base upon removal of the one or more fasteners.
- Those skilled in the art will appreciate the benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures. It is within the scope of the present disclosure that the above-discussed aspects be provided both individually and in various combinations.
- According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.
-
FIG. 1A is a schematic diagram of a pumping unit according to an embodiment of the disclosure. -
FIG. 1B is a schematic diagram of a layout of a fluid pumping system according to an embodiment of the disclosure. -
FIG. 2 is a perspective view of an enclosure for housing a direct drive unit (DDU) according to an embodiment of the disclosure. -
FIG. 3 is a top plan view of the enclosure housing the DDU according to an embodiment of the disclosure. -
FIG. 4 is a side elevation view of the DDU mounted on a DDU positioner assembly according to a first embodiment of the disclosure. -
FIG. 5 is an end elevation view of the DDU ofFIG. 4 according to a first embodiment of the disclosure. -
FIG. 6A is a perspective view of the DDU ofFIG. 4 in a first position according to a first embodiment of the disclosure. -
FIG. 6B is a perspective view of the DDU ofFIG. 6A moved to a second position according to a first embodiment of the disclosure. -
FIG. 6C is a perspective view of the DDU ofFIG. 6B moved to a third position according to a first embodiment of the disclosure. -
FIG. 7 is a side elevation view of the DDU mounted on a DDU positioner assembly according to a second embodiment of the disclosure. -
FIG. 8A is a perspective view of the DDU ofFIG. 7 in a first position according to a second embodiment of the disclosure. -
FIG. 8B is a perspective view of the DDU ofFIG. 8A moved to a second position according to a second embodiment of the disclosure. -
FIG. 8C is a perspective view of the DDU ofFIG. 8B moved to a third position according to a second embodiment of the disclosure. -
FIG. 9 is an enlarged detail of a portion of the DDU positioner assembly according to a second embodiment of the disclosure. -
FIG. 10 is a detail of a portion of the DDU positioner assembly according to a second embodiment. -
FIG. 11 is a side elevation view of the DDU mounted on a DDU positioner assembly according to a third embodiment of the disclosure. -
FIG. 12A is a perspective view of the DDU ofFIG. 11 in a first position according to a third embodiment of the disclosure. -
FIG. 12B is a perspective view of the DDU ofFIG. 12A moved to a second position according to a third embodiment of the disclosure. -
FIG. 12C is a perspective view of the DDU ofFIG. 12B moved to a third position according to a third embodiment of the disclosure. - Corresponding parts are designated by corresponding reference numbers throughout the drawings.
- Generally, this disclosure is directed to a direct drive unit (DDU) positioner assembly, positioning system, removal system, and/or associated mechanisms that will allow a DDU including a gearbox and a turbine engine connected to the gearbox to be detached from surrounding equipment and removed through the side of an enclosure housing the direct drive unit. The system will allow for inspections, maintenance, or even a complete exchange of the direct drive unit with another if necessary.
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FIG. 1A illustrates a schematic view of apumping unit 11 for use in a high-pressure, high power, fluid pumping system 13 (FIG. 1B ) for use in hydraulic fracturing operations according to one embodiment of the disclosure.FIG. 1B shows a typical pad layout of the pumping units 11 (indicated as FP1, FP2, FP3, FP4, FP5, FP6, FP7, FP8) with the pumping units all operatively connected to a manifold M that is operatively connected to a wellhead W. By way of an example, thesystem 13 is a hydraulic fracturing application that may be sized to achieve a maximum rated horsepower of 24,000 HP for thepumping system 13, including a quantity of eight (8) 3000 horsepower (HP) pumpingunits 11 that may be used in one embodiment of the disclosure. It will be understood that thefluid pumping system 13 may include associated service equipment such as hoses, connections, and assemblies, among other devices and tools. As shown inFIG. 1 , each of thepumping units 11 are mounted on atrailer 15 for transport and positioning at the jobsite. Eachpumping unit 11 includes anenclosure 21 that houses a direct drive unit (DDU) 23 including agas turbine engine 25 operatively connected to agearbox 27. Thepumping unit 11 has adriveshaft 31 operatively connected to thegearbox 27. Thepumping unit 11 includes a high-pressure, high-power, reciprocatingpositive displacement pump 33 that is operatively connected to theDDU 23 via thedriveshaft 31. In one embodiment, thepumping unit 11 is mounted on thetrailer 15 adjacent theDDU 23. Thetrailer 15 includes other associated components such as aturbine exhaust duct 35 operatively connected to thegas turbine engine 25,air intake duct 37 operatively connected to the gas turbine, and other associated equipment hoses, connections, etc. to facilitate operation of thefluid pumping unit 11. - In the illustrated embodiment, the
gas turbine engine 25 is a Vericor Model TF50F bi-fuel turbine; however, thedirect drive unit 23 may include other gas turbines or suitable drive units, systems, and/or mechanisms suitable for use as a hydraulic fracturing pump drive without departing from the disclosure. Thegas turbine engine 25 is cantilever mounted to thegearbox 27 with the gearbox supported by thefloor 41 of theenclosure 21. Thegearbox 27 may be a reduction helical gearbox that has a constant running power rating of 5500 SHP and intermittent power output of 5850 SHP, or other suitable gearbox. It should also be noted that, while the disclosure primarily describes the systems and mechanisms for use withdirect drive units 23 to operate fracturingpumping units 33, the disclosed systems and mechanisms may also be directed to other equipment within the well stimulation industry such as, for example, blenders, cementing units, power generators and related equipment, without departing from the scope of the disclosure. -
FIG. 2 illustrates theenclosure 21 that houses thedirect drive unit 23 in aninterior space 46 of the enclosure. In one embodiment, the enclosure hasaccess doors 45 for removal of theDDU 23 from the enclosure and/or other components within the enclosure. Theenclosure 21 provides sound attenuation of theDDU 23 during operation. - As shown in
FIG. 3 , thedirect drive unit 23 and theenclosure 21 has a longitudinal axis L1 and a lateral axis L2 transverse to the longitudinal axis.FIG. 3 illustrates a top view of theenclosure 21 with theDDU 23 shown attached to thedriveshaft 31 that extends through anopening 48 in a firstlongitudinal end 47 of the enclosure. Anair exhaust assembly 35 extends through a secondlongitudinal end 49 of the enclosure. TheDDU 23 has a central axis CL extending in the longitudinal direction L1 that extends through the centerline of the unit and is aligned with the centerline of thedriveshaft 31. Thegearbox 27 includes anoutlet flange 50 that is connected to thedriveshaft 31. Thegas turbine engine 25 has twoair inlet ports exhaust duct flange 54 that connects the gas turbine engine to theair exhaust assembly 35 at thelongitudinal end 49 of theenclosure 21. In one embodiment, theaccess doors 45 are mounted on a firstlateral side 55 of theenclosure 21, but the enclosure may have additional access doors on a secondlateral side 57 of the enclosure, or the access doors may be positioned only on the second lateral side without departing from the scope of this disclosure. Thegas turbine engine 25 may includepolymer expansion joints air inlet ports enclosure 21. Thegas turbine engine 25 may include various fuel lines, communication lines, hydraulic and pneumatic connections, and other connections or accessories needed for operation of the gas turbine engine without departing from the disclosure. Such connections may utilize quick disconnect fittings and check valves to facilitate disconnection of thegas turbine engine 25 during removal of theDDU 23 from theenclosure 21. Further, such connections such as fuel lines and hydraulic lines may run to a single bulkhead (not shown) within or near the enclosure to allow for quick disconnection by locating these connections in a common location. -
FIG. 4 is a side elevation view of theDDU 23 as viewed from thelateral side 55 of theenclosure 21, with the DDU being mounted on a DDU positioner assembly or DDU positioning system 101 (FIGS. 4-6C ) for positioning the DDU for withdrawal or removal from the enclosure through theaccess doors 45. In one embodiment, theDDU positioner assembly 101 comprises aplatform 103 slidably mounted to overlie twolateral rails floor 41 of theenclosure 21 and extending laterally across the enclosure generally between thelateral sides DDU positioner assembly 101 comprises twolongitudinal rails platform 103 and extending in the longitudinal direction L1. TheDDU 23 is slidably mounted on thelongitudinal rails DDU positioner assembly 101 includeslateral guide rollers lateral rail longitudinal guide rollers longitudinal rail platform 103 is connected to thelateral guide rollers DDU 23 mounted on the platform in the lateral direction L2 via thelateral rails longitudinal guide rollers base 127 of thegearbox 27 to allow slidable movement and positioning of theDDU 23 in the longitudinal direction L1 via thelongitudinal rails DDU positioner assembly 101 includes fourlateral guide rollers longitudinal guide rollers longitudinal rails lateral rails guide rollers DDU positioner assembly 101 may be equipped with lockingmechanisms 128 mounted on arespective guide roller mechanisms 128 may be spring loaded and will default to the locked position to allow theDDU 23 to be secured in the operating position. Thelocking mechanism 128 may be otherwise located on thepositioning system 101 without departing from the disclosure. - Exemplary loading calculations for sizing the
guide rails gas turbine engine 25. - Because of the arrangement the
direct drive unit 23 including thegas turbine engine 25 cantilever mounted onto thegearbox 27 and extending in the longitudinal direction L1 from the gearbox, there is added load put onto the rearlateral guide rollers 115 and the rearlongitudinal guide rollers 121, 123 (the guide rollers mounted closest to the gas turbine engine). Accordingly, an increased load rating may be applied to therear guide rollers - Maximum Reaction at the fixed end may be expressed as: RA=qL.
- where: RA=reaction force in A (N, lb), q=uniform distributed load (N/m, N/mm, lb/in), and
- L=length of cantilever beam (m, mm, in).
- Maximum Moment at the fixed end may be expressed as MA=−q L2/2
- Maximum Deflection at the end may be expressed as δB=q L4/(8 E I).
- where: δB=maximum deflection in B (m, mm, in).
- In one embodiment, the
longitudinal guide rollers support structure 127 of thegearbox 27 are positioned between each pair of thelateral guide rollers platform 103 and to avoid cantilever loading the platform. Different configurations of platforms, sliders, rails and mounts are contemplated and considered within the scope of the disclosure. The configurations of theDDU positioner assembly 101 may vary to suit aparticular DDU 23 with various alternative combinations of makes, model, and sizes of thegas turbine engine 25 and thegearbox 27. - In one embodiment, the
guide rails turbine enclosure 21 and ensure strength retention under the exposed temperatures. In one embodiment, theplatform 103 is constructed out of a composite material; however, other materials are contemplated and considered within the scope of the disclosure, such as but not limited to, steel or stainless steel. The guide rails 105, 107, 109, 111,platform 103, and/or other components of theDDU positioner assembly 101 may be made of various other suitable materials without departing from the scope of the disclosure. -
FIGS. 6A-6B illustrate an exemplary method of removing thedirect drive unit 23 from theenclosure 21 utilizing theDDU positioner assembly 101.FIG. 6A shows theDDU 23 in a first/operating position for operation with thepump 33 of thepumping unit 11. The method includes accessing theenclosure 21 and disconnecting thegas turbine engine 25 from theair inlet ducting 37. Theflanges air inlet ducting 37 and theexpansion joints DDU 23 from the air inlet ducting. Thegas turbine engine 25 may be disconnected from theair exhaust ducting 35 by disconnecting theexhaust duct flange 54 from the air exhaust ducting. Corresponding hoses, piping, wiring, and cabling including fuel lines, electrical lines, hydraulic lines, control lines or any other connection that is needed for operation of thegas turbine engine 25 may also be disconnected so that the gas turbine engine is free to move without damaging any of the operational connections needed for operation of the gas turbine engine. For example, the air bleed off valve ducting may be removed from theturbine engine 25 and secured at a location free of interference with movement of the turbine engine. Alternatively, some hoses, piping, wiring, etc. may include enough slack or flexibility so that theDDU 23 may be initially moved before complete disconnection of the connections from thegas turbine engine 25 are required for removal of the DDU from theenclosure 21. Thegearbox 27 may be disconnected from thedriveshaft 31 by disconnecting theoutlet flange 50 from the driveshaft. In one embodiment, thedriveshaft 31 may be a slip-fit driveshaft allowing the driveshaft to contract to facilitate disconnection from theDDU 23. In one embodiment, thedriveshaft 31 may be a 390 Series, GWB Model 390.80 driveshaft available Dana Corporation, or other suitable driveshaft. Thegearbox 27 may be disconnected from any other connections needed for operation of theDDU 23 to obtain freedom of movement of the gearbox without damaging any of the operating connections. - Once the
gas turbine engine 25 is disconnected from the respective connections and thegearbox 27 is disconnected from thedriveshaft 31, theDDU positioner assembly 101 is operated to position thedirect drive unit 23 for withdrawal from theenclosure 21. As shown inFIG. 6B , theDDU 23 is positioned in a second position where the DDU is first moved in the longitudinal direction L1 in the direction of arrow A1 by sliding the DDU along thelongitudinal rails DDU 23 in the longitudinal direction L1, thelongitudinal locks 128 associated with thelongitudinal guide rollers DDU 23 in the longitudinal direction L1 to the second position, thelongitudinal locks 128 may be reengaged to lock thelongitudinal guide rollers DDU 23 along thelongitudinal rails lateral locks 128 associated with thelateral guide rollers DDU 23. Next, theplatform 103 may be moved to a third position by moving in the lateral direction L2 in the direction of arrow A2 (FIG. 6C ) by sliding movement of thelateral guide rollers lateral guide rails DDU 23 is mounted to theplatform 103 and moves with the platform in the lateral direction L2 to the third position ofFIG. 6C . As shown inFIGS. 3 and 5 , thelateral guide rails access doors 45 in eitherside enclosure 21. In some embodiments, lateralguide rail extensions 107′ (FIG. 5 ) may be used to extend outside of theenclosure 21 to allow theplatform 103 andDDU 23 to be slid out of the enclosure onto an adjacent supporting structure or vehicle (e.g., maintenance inspection platform or other suitable structure), or theplatform 103 andDDU 23 may be accessed through theaccess doors 45 of theenclosure 21 by a lifting mechanism (e.g., a forklift, crane, or other suitable lifting mechanism) to fully remove the DDU from the enclosure. The various method steps described herein for the method of positioning or removing theDDU 23 may be otherwise performed in an alternative order or simultaneously, or more or less steps may be used without departing from the scope of the disclosure. -
FIGS. 7-10 illustrates a second embodiment of a DDU positioner assembly orsystem 201 for positioning thedirect drive unit 23 housed in theenclosure 21. In the illustrated embodiment, theDDU 23 includes agas turbine engine 25 and agearbox 27 identical to the first embodiment of the disclosure, but theDDU positioner assembly 201 may be used to position a DDU that is alternatively configured without departing from the disclosure. As such, like or similar reference numbers will be used to describe identical or similar features between the two embodiments. - In one embodiment, the
DDU positioner assembly 201 includes aplatform 203 that supports thegearbox 27 and has atop surface 205, abottom surface 207, twosides 208, and two ends 210. Thegearbox 27 is fixedly mounted to thetop surface 205 of theplatform 203. Theplatform 203 is slidably mounted on thebase 41 of theenclosure 21 with thebottom surface 207 of the platform being in slidable engagement with the floor of the enclosure. In a first or operating position (FIGS. 7 and 8A ) of thedirect drive unit 23, theplatform 203 is fixedly attached to thebase 41 by a plurality offasteners 211. Upon removal of thefasteners 211, theplatform 203 is capable of slidable movement with respect to thebase 41. Theplatform 203 is connected to thesupport structure 127 of thegearbox 27 so that thedrive unit 23 moves with the platform. In one embodiment, theplatform 203 has two liftingopenings respective sides 208 of the platform. As shown inFIG. 7 , thelifting opening 215 towards the front of the gearbox 27 (closest to the drive shaft flange 50) is spaced a first distance D1 from a centerline CT of the gearbox and thelifting opening 217 towards the rear of the gearbox (closest to the gas turbine engine 25) is spaced a second distance from the centerline CT of the gearbox, with the distance D2 being greater than the distance D2. The rear lifting opening 217 is farther from the centerline CT of thegearbox 27 because of the cantilever mountedgas turbine engine 25 that shifts the center of gravity of theDDU 23 from the centerline CT of the gearbox in the longitudinal direction toward the gas turbine engine. Theplatform 203 may be otherwise configured and/or arranged without departing from the scope of the disclosure. - In one embodiment, the
DDU positioner assembly 201 includes a lubricator or lubrication system 221 (FIG. 9 ) to convey lubricant (e.g., grease or other suitable lubricant) from alubricant reservoir 244 to a location between thebottom surface 207 of theplatform 201 and thebase 41 of the enclosure. TheDDU positioner assembly 201 includes a lubrication portion 225 (FIG. 10 ) of thebase 41 below theplatform 203. As shown inFIG. 10 , theportion 225 of thebase 41 includes a plurality oflubrication grooves 227. Thelubrication grooves 227 are in fluid communication with thelubricator 221 so that the lubricator provides lubricant to the grooves to facilitate sliding engagement between theplatform 203 and theportion 225 of thebase 41. Thelubricator 221 includes a source oflubricant 244,tubing 243, and other required components (e.g., pump, controls, etc.) for delivering the lubricant to thelubrication portion 225 at a sufficiently high pressure for lubricant to fill thegrooves 227 of thelubrication portion 225. In one embodiment, thelubricator 221 may be an automatic lubricator such as a model TLMP lubricator available from SKF Corporation, or the lubricator may be any other suitable lubricator including other automatic lubricators or manual lubricators without departing from the scope of the disclosure. In one embodiment, thelubrication portion 225 of thebase 41 is an integral portion with the base or the floor of theenclosure 21, but thelubrication portion 225 may be a separate pad or component that is mounted between the base and the platform without departing from the disclosure. Thelubricator 221 may be mounted inside theenclosure 21 or at least partially outside the enclosure without departing from the scope of the disclosure. - In one embodiment, the
DDU positioner assembly 201 includesdrive fasteners 241 mounted at oneend 210 of theplatform 203. In the illustrated embodiment, thedrive fasteners 241 include abracket 245 mounted to thefloor 41 of theenclosure 21 and animpact screw 247 operatively connected to the bracket and theplatform 203. Thedrive fasteners 241 may have other components and be otherwise arranged without departing from the disclosure. Further, more or less than twodrive fasteners 241 may be provided without departing from the disclosure. -
FIGS. 8A-9 illustrate an exemplary method of removing theDDU 23 from theenclosure 21 utilizing theDDU positioner assembly 201 of the second embodiment. The method is similar to the method of the first embodiment, in that thegas turbine engine 25 is disconnected from theair inlet ducting 37, theair exhaust ducting 35, and from other corresponding connections and components in a similar manner as discussed above for the first embodiment so that the gas turbine engine is free to move without damaging any of the operational connections and components needed for operation of the gas turbine engine. Further, thegearbox 27 is disconnected from thedriveshaft 31 in a similar manner as the first embodiment, so that theDDU 23 has clearance for movement in the longitudinal direction L1 without interference with the driveshaft. -
FIG. 8A shows thedirect drive unit 23 in the first/operating position. Once thegas turbine engine 25 is disconnected from the respective components and connections and thegearbox 27 is disconnected from thedriveshaft 31 and any other connections, theDDU positioner assembly 201 is operated to position theDDU 23 for withdrawal from theenclosure 21. First, thefasteners 211 fixedly attaching theplatform 203 to the base 41 are removed. Thelubricator 221 is operated to convey lubricant to thelubrication grooves 227 of thelubrication portion 225 of thebase 41. After a sufficient amount of lubrication is located between theplatform 203 and thelubrication portion 225 of thebase 41, thedrive fasteners 241 may be operated to move theplatform 203 in the longitudinal direction L1 to a second position (FIG. 8B ). As the impact screws 247 of thedrive fasteners 241 are turned, theplatform 203 is slid in the longitudinal direction L1 in the direction of arrow A3 (FIG. 8B ). The lubricant provided in thelubrication grooves 227 and between thelubrication portion 225 and thebottom surface 207 of the platform reduces the sliding friction and allows the rotation of the impact screws 247 in thebracket 245 to advance the platform in the direction of arrow A3. Theplatform 203 is moved in the direction of arrow A3 a sufficient amount to allow access to the liftingopenings FIG. 8C ). Thelifting mechanism 261 may include a forklift or other lifting mechanism that may access theinterior 46 of the enclosure through theenclosure access doors 45. Thelifting mechanism 261 is inserted into the liftingopenings platform 203, and theDDU 23 is lifted and/or slid in the direction of arrow A4. Thelifting mechanism 261 may move theDDU 23 to the third position (FIG. 8C ), or transfer the DDU onto an adjacent supporting structure or vehicle (e.g., maintenance inspection platform or other suitable structure), or completely remove theplatform 203 andDDU 23 from the enclosure. The various method steps described herein for the method of positioning or removing theDDU 23 by operating theDDU positioner assembly 201 may be otherwise performed in an alternative order or simultaneously, or more or less steps may be used without departing from the scope of the disclosure. -
FIGS. 11-12C illustrate a third embodiment of a DDU positioner assembly orsystem 301 for positioning thedirect drive unit 23 housed in theenclosure 21. In the illustrated embodiment, theDDU 23 includes agas turbine engine 25 and agearbox 27 identical to the first and second embodiments of the disclosure, but theDDU positioner assembly 301 may be used to position a DDU that is alternatively configured without departing from the disclosure as will be understood by those skilled in the art. TheDDU positioner assembly 301 is generally similar to theDDU positioner assembly 201 of the second embodiment, except thedrive fasteners 241 have been removed and anactuator 341 is added to the DDU positioner assembly of the third embodiment. As such, like or similar reference numbers will be used to describe identical or similar features between the second and third embodiments. - As shown in
FIG. 11 , theDDU positioner assembly 301 includes theactuator 341 that has afirst end 345 connected to thebase 41 of theenclosure 21 and asecond end 347 connected to theend 210 of theplatform 203. In one embodiment, theactuator 341 is a hydraulic cylinder that has apiston rod 351 that is extendible from acylinder body 349 upon operation of the actuator. Theactuator 341 may be controlled by a manual control valve or the actuator may be configured for remote operation by connection to corresponding automated control valves. In the illustrated embodiment, oneactuator 341 is shown, but theDDU positioner assembly 301 may include more than one actuator without departing from the scope of the disclosure. Further, theactuator 341 may be otherwise located for attachment to theplatform 203 without departing from the scope of the disclosure. -
FIGS. 12A-12C illustrate an exemplary method of removing theDDU 23 from theenclosure 21 utilizing theDDU positioner assembly 301 of the second embodiment. The method is similar to the method of the utilizing theDDU positioner assembly 201 of the second embodiment, in that thegas turbine engine 25 is disconnected from theair inlet ducting 37, theair exhaust ducting 35, and from other corresponding connections and components in a similar manner as discussed above for the first embodiment so that the gas turbine engine is free to move without damaging any of the operational connections and components needed for operation of the gas turbine engine. Further, thegearbox 27 is disconnected from thedriveshaft 31 in a similar manner as the first embodiment, so that theDDU 23 has clearance for movement in the longitudinal direction L1 without interference with the driveshaft. Also, theDDU positioner assembly 301 of the third embodiment includes the lubricator 221 (FIG. 9 ) for providing lubrication tolubrication grooves 227 of thelubrication portion 225 of the base 41 to facilitate sliding of theplatform 203 in the longitudinal direction L1, so that the DDU positioner assembly of the third embodiment operates in a similar manner as theDDU positioner assembly 201 of the second embodiment. -
FIG. 12A shows thedirect drive unit 23 in the first/operating position. Once thegas turbine engine 25 is disconnected from the respective components and connections, and thegearbox 27 is disconnected from thedriveshaft 31 and any other connections, theDDU positioner assembly 301 is operated to position theDDU 23 for withdrawal from theenclosure 21. First, thefasteners 211 fixedly attaching theplatform 203 to the base 41 are removed. Thelubricator 221 is operated to convey lubricant to thelubrication grooves 227 of thelubrication portion 225 of thebase 41. After a sufficient amount of lubrication is located between theplatform 203 and thelubrication portion 225 of thebase 41, theactuator 341 may be operated to move theplatform 203 in the longitudinal direction L1 to a second position (FIG. 12B ). The extension of thepiston rod 351 of theactuator 341 exerts a force on theplatform 203 to slide the platform in the longitudinal direction L1 in the direction of arrow A3 (FIG. 12B ). The lubricant provided in thelubrication grooves 227 and between thelubrication portion 225 and thebottom surface 207 of the platform reduces the sliding friction and allows theactuator 341 to advance the platform in the direction of arrow A3. As with the previous embodiment, theplatform 203 is moved in the direction of arrow A3 a sufficient distance to allow access to the liftingopenings FIG. 8C ). Thelifting mechanism 261 may include a forklift or other lifting mechanism that may access theinterior 46 of the enclosure through theenclosure access doors 45. Thelifting mechanism 261 is inserted into the liftingopenings platform 203, and theDDU 23 is lifted and/or slid in the direction of arrow A4. Prior to moving theplatform 203 in the direction of arrow A4, theactuator 341 may be disconnected from the platform (FIG. 12C ) with thefirst end 347 of the actuator being separated from the platform and thesecond end 345 of the actuator remaining attached to thefloor 41 of the enclosure. Alternatively, thesecond end 345 of theactuator 341 may be disconnected from thefloor 41 of the enclosure and thefirst end 341 of the actuator may remain attached to theplatform 203, or both ends of the actuator may be disconnected and the actuator removed without departing from the enclosure. - The
lifting mechanism 261 may move theDDU 23 to the third position (FIG. 12C ), or transfer the DDU onto an adjacent supporting structure or vehicle (e.g., maintenance inspection platform or other suitable structure), or completely remove theplatform 203 andDDU 23 from the enclosure. The various method steps described herein for the method of positioning or removing theDDU 23 by operating theDDU positioner assembly 301 may be otherwise performed in an alternative order or simultaneously, or more or less steps may be used without departing from the scope of the disclosure. - Having now described some illustrative embodiments of the disclosure, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the disclosure. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and/or configurations will depend on the specific application in which the systems and techniques are used. Those skilled in the art should also recognize or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments of the disclosure. It is, therefore, to be understood that the embodiments described herein are presented by way of example only and that, within the scope of any appended claims and equivalents thereto; the embodiments of the disclosure may be practiced other than as specifically described.
- Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of this disclosure. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiment, and numerous variations, modifications, and additions further may be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.
Claims (12)
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US20220282726A1 (en) * | 2021-03-08 | 2022-09-08 | Yantai Jereh Petroleum Equipment & Technologies Co., Ltd. | Plunger pump base and plunger pump device |
US11952999B2 (en) * | 2021-03-08 | 2024-04-09 | Yantai Jereh Petroleum Equipment & Technologies Co., Ltd. | Plunger pump base and plunger pump device |
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US10895202B1 (en) | 2021-01-19 |
US20220316399A1 (en) | 2022-10-06 |
US10961912B1 (en) | 2021-03-30 |
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US20230151767A1 (en) | 2023-05-18 |
US20210207536A1 (en) | 2021-07-08 |
US20210140370A1 (en) | 2021-05-13 |
US20220170420A1 (en) | 2022-06-02 |
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