CN111441923A - 大功率五缸柱塞泵 - Google Patents
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Abstract
本发明公开了大功率五缸柱塞泵，所述大功率五缸柱塞泵的冲程为10in，缸间距为11.5in，制动功率为5000HP。有益效果：大功率，大排量；可适用于电驱压裂和涡轮压裂中；可根据具体的作业工况选择整体式动力端总成或分体式动力端总成，从而更优的实现压裂单元或压裂车的排布方式；缸间距的尺寸为长冲程的5000HP制动功率稳定作业保驾护航。
Description
技术领域
本发明涉及柱塞泵技术领域，具体涉及大功率五缸柱塞泵。
背景技术
随着油气田超高压、超深井、水平井的不断开发，其作业工况也越来越恶劣，要求压裂设备能高压力、大排量作业，有的井场还要求能长时间连续作业，在井场总压力一定的情况下，单台压裂设备的功率排量越小，那井场为满足总压力的需求，需要的压裂设备数量就越多。
目前油气开采的井场占地面积是要求越来越小化，减少压裂设备的数量是有效手段之一；实际的井场通路也多偏向崎岖化，压裂设备的数量越多，需要的井场布局时间越长，耗时耗力，所以单台压裂设备的功率排量越小与井场占地面积和井场通路之间的矛盾就越严重，“小井场大作业”的目标已经越来越迫在眉睫。
柱塞泵作为压裂设备中的核心部件，目前市场上常见的柱塞泵主要有2800HP五缸柱塞泵，3000HP三缸柱塞泵，3300HP五缸柱塞泵和4000HP三缸柱塞泵；2800HP五缸柱塞泵主要配置在2500型压裂设备车上，(目前2500型压裂车是压裂作业中最常用、做多的压裂设备)；4000HP三缸柱塞泵是配置在3100HP压裂设备车上，但4000HP柱塞泵是三缸泵其排量比2800HP五缸泵低很多，在相同柱塞规格、相同冲刺下其排量只是2800HP五缸泵的82.54％；针对于近几年新兴的电驱压裂作业，即采用电动机为动力源的压裂作业形式，电动机可以选择很大功率，例如：额定功率可以达到3000KW、4000kw、5000kw、6000kw等，但柱塞泵还没有这么大规格的，如果将2800HP柱塞泵和4000HP柱塞泵配置到电驱压裂设备上，体现不出电驱压裂的优势，相当于大马拉小车。
另外涡轮压裂也是近期压裂作业的发展趋势，(涡轮压裂即采用涡轮发动机为动力源的压裂作业形式)，但是涡轮发动机的输出转动方向与现有的柱塞泵输入转动方向无法匹配，故通常会在柱塞泵输入转动方向之前增设换向机构，但由此会带来涡轮压裂设备整体重量的增加，故障风险的增加，维护成本的增加等等问题。
为此亟待一种大功率，大排量，适应不同作业工况要求，还能适应不同压裂作业形式要求的柱塞泵。
发明内容
本发明的目的克服现有技术的不足，提供大功率五缸柱塞泵，大功率，大排量；可适用于电驱压裂和涡轮压裂中；可根据具体的作业工况选择整体式动力端总成或分体式动力端总成，从而更优的实现压裂单元或压裂车的排布方式；缸间距的尺寸为长冲程的5000HP制动功率稳定作业保驾护航。
本发明的目的是通过以下技术措施达到的：大功率五缸柱塞泵，所述大功率五缸柱塞泵的冲程为10in，缸间距为11.5in，制动功率为5000HP。
进一步地，所述大功率五缸柱塞泵包括动力端总成、液力端总成和减速箱总成，所述液力端总成和减速箱总成分别与动力端总成连接，所述减速箱总成包括平行级减速箱和行星级减速箱，所述行星级减速箱一端与平行级减速箱连接，所述行星级减速箱另一端与动力端总成连接。
进一步地，所述减速箱总成的减速比为12.2-12.5。
进一步地，所述平行级减速箱减速比为2.1-2.5，所述行星级减速箱减速比为5-5.8。
进一步地，所述减速箱总成的减速比适用于以电动机为动力源的压裂作业。
进一步地，所述减速箱总成的减速比为9.4-9.6。
进一步地，所述平行级减速箱减速比为1.6-1.8，所述行星级减速箱减速比为5.3-6.3。
进一步地，所述减速箱总成的减速比适用于以涡轮发动机为动力源的压裂作业。
进一步地，所述减速箱总成根据实际使用需求安装在动力端总成的左端或右端。
进一步地，当大功率五缸柱塞泵使用在以电动机为动力源的压裂作业时，所述减速箱总成安装在动力端总成的左端或右端，当大功率五缸柱塞泵使用在以涡轮发动机为动力源的压裂作业时，所述减速箱总成安装在动力端总成的右端。
进一步地，所述动力端总成根据实际使用需求，采用整体式动力端总成或分体式动力端总成。
进一步地，所述动力端总成包括动力端壳体，十字头支撑箱体和保持架，所述动力端壳体，十字头支撑箱体和保持架依次设置，当为整体式动力端总成时，动力端壳体和十字头支撑箱体为整体式，当为分体式动力端总成时，动力端壳体和十字头支撑箱体均为独立结构，动力端壳体和十字头支撑箱体通过螺栓固定。
与现有技术相比，本发明的有益效果是：10in的冲程，保证了大排量，即保证了大功率，提高作业效率。11.5in的缸间距，增大了连杆十字头总成(连杆、十字头和轴瓦)的承载面积，为5000HP的五缸柱塞泵提供了足够的承载力，保证其稳定的大排量输出，五缸柱塞泵的功率提升，即提升了单台压裂设备的压裂能力，使其可以减少井场的压裂设备总数量，有效解决了井场面积小与压裂设备较多的矛盾，还能省时省力的快速完成井场布置。两种传动比，解决了电驱压裂与涡轮压裂中没有大功率柱塞泵与现有大功率动力源匹配的问题，同时根据不同传动比适应不同压裂作业形式，还可以更好地匹配涡轮发动机和选型电动机。在不增加换向机构的前提下，仅以最小的代价解决最大的问题，即减速箱总成的右端安装，使涡轮发动机的输出转动方向与曲轴的输入转动方向匹配，从而使涡轮压裂设备在不增加重量，不增加故障风险，不增加维护成本的情况下，实现五缸柱塞泵的驱动。可根据具体的作业工况选择整体式动力端总成或分体式动力端总成，从而更优的实现压裂单元或压裂车的排布方式。
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是该大功率五缸柱塞泵(右端安装)的结构示意图。
图2是该大功率五缸柱塞泵(左端安装)的结构示意图。
图3是该大功率五缸柱塞泵的剖视图。
图4是动力端总成分体式结构示意图。
图5是动力端总成整体式结构示意图。
图6是连杆十字头总成的结构示意图。
图7是曲轴的结构示意图。
图8是减速箱总成的结构示意图。
图9是平行级减速箱的结构示意图。
图10是行星级减速箱的结构示意图。
其中，1.动力端总成，2.液力端总成，3.减速箱总成，4.输入法兰，5.动力端壳体，6.轴承，7.曲轴，8.连杆十字头总成，9.曲颈，10.曲拐，11.柱塞，12.阀箱，13.十字头支撑箱体，14.保持架，15.连接螺栓，16.平行级减速箱，17.行星级减速箱，18.大齿轮，19.小齿轮，20.行星齿轮，21.齿轮圈，22.太阳轮。
具体实施方式
如图1至10所示，大功率五缸柱塞泵，所述大功率五缸柱塞泵的冲程为10in，缸间距为11.5in，制动功率为5000HP。10in的冲程，保证了大排量，即保证了大功率，提高作业效率。11.5in的缸间距，增大了连杆十字头总成8(连杆、十字头和轴瓦)的承载面积，为5000HP的五缸柱塞泵提供了足够的承载力，保证其稳定的大排量输出，五缸柱塞泵的功率提升，即提升了单台压裂设备的压裂能力，使其可以减少井场的压裂设备总数量，有效解决了井场面积小与压裂设备较多的矛盾，还能省时省力的快速完成井场布置。
所述大功率五缸柱塞泵包括动力端总成1、液力端总成2和减速箱总成3，所述液力端总成2和减速箱总成3分别与动力端总成1连接，所述液力端总成2通过连接螺栓15与动力端总成1连接；所述减速箱总成3通过螺栓与动力端总成1连接，所述减速箱总成3外设有输入法兰4，通过输入法兰4外接动力源。所述减速箱总成3包括平行级减速箱16和行星级减速箱17，所述行星级减速箱17一端与平行级减速箱16连接，所述行星级减速箱17另一端与动力端总成1连接。减速箱总成3的输入角度可以根据输入要求进行调整，可以满足压裂设备中五缸柱塞泵传动所需的多角度调整。所述减速箱总成3采用斜齿啮合，所述行星级减速箱17包括一个太阳轮22、四个行星齿轮20和一个齿轮圈21，四个行星齿轮20组成行星齿轮机构，行星齿轮机构设在齿轮圈21的内部，太阳轮22位于行星齿轮机构中心；所述平行级减速箱16包括大齿轮18和小齿轮19，小齿轮19与输入法兰4相连，大齿轮18与行星级减速箱17的太阳轮22同轴连接；输入法兰4输入转速，经小齿轮19传递给大齿轮18实现一级减速，通过大齿轮18传递给太阳轮22，太阳轮22传递到行星齿轮20实现二级减速，从而获得大传动比。所述液力端总成2包括阀箱12和柱塞11，柱塞11设置在阀箱12内部。
所述减速箱总成3的减速比为12.2-12.5。所述平行级减速箱16减速比为2.1-2.5，所述行星级减速箱17减速比为5-5.8。所述减速箱总成3的减速比适用于以电动机为动力源的压裂作业，即电驱压裂。所述减速箱总成3的减速比为9.4-9.6。所述平行级减速箱16减速比为1.6-1.8，所述行星级减速箱17减速比为5.3-6.3，所述减速箱总成3的减速比适用于涡轮发动机为动力源的压裂作业，即涡轮压裂。两种传动比，解决了电驱压裂与涡轮压裂中没有大功率柱塞泵与现有大功率动力源匹配的问题，同时根据不同传动比适应不同压裂作业形式，还可以更好地匹配涡轮发动机和选型电动机。
通过不同减速比的设置，使得该5000HP的大功率五缸柱塞泵的适用性增加，即可适用于电驱压裂作业，也可适用于涡轮压裂作业。增大了单台电驱压裂设备和单台涡轮压裂设备的排量输出，很好的解决了当下“小井场”难以大作业的技术难题。
所述减速箱总成3根据实际使用需求安装在动力端总成1的左端或右端。与现有五缸柱塞泵相比，增加了右端的连接方式，即减速箱总成3与动力端总成1中曲轴7的右端连接。
当大功率五缸柱塞泵使用在以电动机为动力源的压裂作业时，所述减速箱总成3安装在动力端总成1的左端或右端，因电动机的输出转动方向可调，故无论减速箱总成3安装在动力端总成1的左端还是右端，只需根据曲轴7的输入转动方向要求调整电动机的输出转动方向即可。当大功率五缸柱塞泵使用在以涡轮发动机为动力源的压裂作业时，所述减速箱总成3安装在动力端总成1的右端。在不增加换向机构的前提下，仅以最小的代价解决最大的问题，即减速箱总成3的右端安装，使涡轮发动机的输出转动方向与曲轴7的输入转动方向匹配，从而使涡轮压裂设备在不增加重量，不增加故障风险，不增加维护成本的情况下，实现五缸柱塞泵的驱动。
所述动力端总成1根据实际使用需求，采用整体式动力端总成1或分体式动力端总成1。整体式动力端总成1因其刚度高，承载能力强，结构稳定，适用于井场压裂的高压力连续性工况作业，适用于整橇安装布置。分体式动力端总成1较整体式动力端总成1重量轻，适用于井场压裂的间歇性作业，且可以为压裂设备提供更多的载体形式，如车载、半挂、橇装等形式。两种动力端总成1可以更好更多的满足现场不同作业需求及运载需求。
所述动力端总成1包括动力端壳体5，十字头支撑箱体13和保持架14，所述动力端壳体5，十字头支撑箱体13和保持架14依次设置，当为整体式动力端总成1时，动力端壳体5和十字头支撑箱体13为整体式，当为分体式动力端总成1时，动力端壳体5和十字头支撑箱体13均为独立结构，动力端壳体5和十字头支撑箱体13通过螺栓固定。在动力端壳体5内设曲轴总成，十字头支撑箱体13内设连杆十字头总成8，曲轴总成与连杆十字头总成8的一端连接，连杆十字头总成8的另一端通过拉杆的传动驱动柱塞11在阀箱12内做往复运动，实现低压液体的吸入和高压液体的排出。所述曲轴总成包括曲轴7和轴承6，所述曲轴7通过轴承6与动力端壳体5连接，所述曲轴7包括六个曲颈9和五个曲拐10，相邻两个曲颈9之间设一个曲拐10，所述曲拐10与曲轴7的旋转中心距离为5in，所述轴承6为圆柱滚子轴承。
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 (12)
1.大功率五缸柱塞泵，其特征在于：所述大功率五缸柱塞泵的冲程为10in，缸间距为11.5in，制动功率为5000HP。
2.根据权利要求1所述的大功率五缸柱塞泵，其特征在于：所述大功率五缸柱塞泵包括动力端总成、液力端总成和减速箱总成，所述液力端总成和减速箱总成分别与动力端总成连接，所述减速箱总成包括平行级减速箱和行星级减速箱，所述行星级减速箱一端与平行级减速箱连接，所述行星级减速箱另一端与动力端总成连接。
3.根据权利要求2所述的大功率五缸柱塞泵，其特征在于：所述减速箱总成的减速比为12.2-12.5。
4.根据权利要求3所述的大功率五缸柱塞泵，其特征在于：所述平行级减速箱减速比为2.1-2.5，所述行星级减速箱减速比为5-5.8。
5.根据权利要求3或4所述的大功率五缸柱塞泵，其特征在于：所述减速箱总成的减速比适用于以电动机为动力源的压裂作业。
6.根据权利要求2所述的大功率五缸柱塞泵，其特征在于：所述减速箱总成的减速比为9.4-9.6。
7.根据权利要求6所述的大功率五缸柱塞泵，其特征在于：所述平行级减速箱减速比为1.6-1.8，所述行星级减速箱减速比为5.3-6.3。
8.根据权利要求2或6所述的大功率五缸柱塞泵，其特征在于：所述减速箱总成的减速比适用于以涡轮发动机为动力源的压裂作业。
9.根据权利要求1所述的大功率五缸柱塞泵，其特征在于：所述减速箱总成根据实际使用需求安装在动力端总成的左端或右端。
10.根据权利要求9所述的大功率五缸柱塞泵，其特征在于：当大功率五缸柱塞泵使用在以电动机为动力源的压裂作业时，所述减速箱总成安装在动力端总成的左端或右端，当大功率五缸柱塞泵使用在以涡轮发动机为动力源的压裂作业时，所述减速箱总成安装在动力端总成的右端。
11.根据权利要求1所述的大功率五缸柱塞泵，其特征在于：所述动力端总成根据实际使用需求，采用整体式动力端总成或分体式动力端总成。
12.根据权利要求11所述的大功率五缸柱塞泵，其特征在于：所述动力端总成包括动力端壳体，十字头支撑箱体和保持架，所述动力端壳体，十字头支撑箱体和保持架依次设置，当为整体式动力端总成时，动力端壳体和十字头支撑箱体为整体式，当为分体式动力端总成时，动力端壳体和十字头支撑箱体均为独立结构，动力端壳体和十字头支撑箱体通过螺栓固定。
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