Pump system and method of starting pump
View Patent ↗A pump system positionable at a surface of a well site for downhole operations includes a pump assembly having a pump and a starting assist. The pump includes a crankshaft and is operable by a first motor. The starting assist includes a second motor and a gear system.
1. A pump system comprising:
a pump having a crankshaft;
a pump motor selectively engaged with an end of the crankshaft; and
a starting assist comprising a starting assist motor, a starting assist drive shaft coupled with the starting assist motor, and a gear set having an end coupled to the starting assist drive shaft and an opposing end coupled to and disposed adjacent an end of the crankshaft distal from the end of the crankshaft engaged with the pump motor, so that when the starting assist motor is energized, rotational power from the starting assist motor is transferred through the gear set and to the crankshaft.
2. The pump system of claim 1 , wherein the pump motor is energized and coupled to the crankshaft a period of time after commencing operation of the starting assist motor.
3. The pump system of claim 1 , wherein the crankshaft is disengaged from the pump motor when operation of the starting assist motor is initiated.
4. The pump system of claim 1 , wherein the pump motor and starting assist motors draw electrical power from a grid power system.
5. The pump system of claim 2 , wherein the starting assist motor has a smaller power rating than a power rating of the pump motor.
6. The pump system of claim 2 , further comprising a controller, wherein the controller receives rotational frequency data from the pump and activates the pump motor and deactivates the starting assist motor when the crankshaft rotates at a preset rotational frequency.
7. The pump system of claim 2 , further comprising a variable frequency drive connected to the pump motor.
8. The pump system of claim 2 , further comprising a transportable chassis, the pump assembly and pump motor positioned on the chassis.
9. The pump system of claim 1 , wherein the gear set has a gear ratio of X:Y, where X>Y.
10. The pump system of claim 9 , wherein the gear set is a planetary gear system.
11. The pump system of claim 10 , wherein the planetary gear system includes a sun gear, a plurality of planet gears that engage and are circumscribed by a ring gear, and a planet carrier coupled with each of the planet gears, a driveshaft of the starting assist motor connected to the sun gear and the crankshaft connected to the planet carrier.
12. The pump system of claim 9 , wherein the gear system is a fixed axis gear train.
13. The pump system of claim 1 , wherein a rotational torque at a connection between the gear set and the crankshaft is greater than that at a connection between the gear set and the starting assist motor.
14. The pump system of claim 1 , further comprising a shaft position encoder operatively engaged with the crankshaft for synchronization of a pump motor drive shaft that is connected to the pump motor, and a starting assist drive shaft that is connected to the starting assist drive shaft.
15. A method of operating a pump used in downhole operations comprising:
obtaining a pump system comprising,
a pump having a crankshaft,
a pump motor selectively engaged with an end of the crankshaft, and
a starting assist comprising,
a starting assist motor,
a starting assist drive shaft coupled with the starting assist motor,
and
a gear set having an end coupled to the starting assist drive shaft and an opposing end coupled to and disposed adjacent an end of the crankshaft distal from the end of the crankshaft engaged with the pump motor; and
rotating an end of the crankshaft opposite from where the crankshaft is engaged with the pump motor by energizing the starting assist motor.
16. The method of claim 15 , energizing the pump motor a period of time after commencing operation of the starting assist motor.
17. The method of claim 15 , wherein the gear system has a gear ratio of X:Y, where X>Y.
18. The method of claim 15 , wherein the pump motor is activated when the crankshaft rotates at a preset frequency.
19. The method of claim 15 , further comprising conducting a cementing operation prior to activating the pump motor.
20. The method of claim 15 , wherein activating the pump motor includes moving a drive shaft coupled with the pump motor to couple with the crankshaft.
21. The method of claim 15 , wherein the pump system is employed in a well operation including at least one of hydraulic fracturing, stimulation, tracer injection, cleaning, acidizing, steam injection, water flooding, and cementing.