Turbine-driven fracturing system on semi-trailer
The present disclosure is directed to a system for fracturing operation in oil/gas fields. The disclosed fracturing system is integrated onto a semitrailer that can be conveniently transported to any oil field. The disclosed fracturing system further includes major components needed for delivering high-pressure fracturing fluid into a wellhead, including but not limited to at least one power generation source and at least one plunger pump driven by the at least one power generation source via simple transmission mechanisms utilizing reduction gearbox and/or transmission shafts. The power generation source, in particular, includes a turbine engine capable of being powered by 100% natural gasified liquid fuel. The fracturing system further includes hydraulic and cooling component for serving the various needs for the turbine engine, the reduction gearbox, and the plunger pump, such as lubrication of various moving parts.
1. A turbine fracturing semi-trailer system, comprising:
a semi-trailer body;
a turbine engine comprising a rotational output end associated with a first rotational axis;
a first reduction gearbox assembly comprising a first planetary gearset engaging a parallel gearset engaging a second planetary gearset, the first planetary gearset and the second planetary gearset being associated with a second rotational axis and a third rotational axis, respectively; and
a plunger pump comprising a crankcase associated a fourth rotational axis;
wherein:
the turbine engine, the first reduction gearbox assembly and the plunger pump are sequentially disposed on the semi-trailer body;
the first rotational axis is collinearly aligned and coupled to the second rotational axis;
the third rotational axis is collinearly aligned and coupled to the fourth rotational axis; and
the first rotational axis and the fourth rotational axis are offset from one another more horizontally than vertically when the turbine fracturing semi-trailer system is in an operational state.
2. The turbine fracturing semi-trailer system according to claim 1 , wherein the first reduction gearbox assembly is integrated with the plunger pump.
3. The turbine fracturing semi-trailer system according to claim 2 , further comprising a transmission device disposed between the turbine engine and the first reduction gearbox assembly.
4. The turbine fracturing semi-trailer system according to claim 2 , further comprising a second reduction gearbox assembly disposed between the turbine engine and the first reduction gearbox assembly.
5. The turbine fracturing semi-trailer system according to claim 4 , further comprising a transmission device disposed between the first reduction gearbox assembly and the second reduction gearbox assembly.
6. The turbine fracturing semi-trailer system according to claim 5 , wherein the transmission device comprises a single rotational shaft.
7. The turbine fracturing semi-trailer system according to claim 1 , wherein:
the turbine engine further comprises an exhaust system disposed on an opposite end of the turbine engine from the first reduction gearbox assembly; and
the exhaust system comprises an exhaust silencer and an exhaust piping, the exhaust silencer is communicated with an exhaust port of the turbine engine through the exhaust piping.
8. The turbine fracturing semi-trailer system according to claim 7 , wherein the exhaust system, the turbine engine, the first reduction gearbox assembly, and the plunger pump are sequentially disposed in a straight line along a transmission direction of rotational power.
9. The turbine fracturing semi-trailer system according to claim 1 , wherein:
an air intake system is disposed on the semi-trailer body above the turbine engine;
the air intake system comprises a plurality of air intake filters, an air intake silencer, and an air intake duct;
one end of the air intake silencer is connected to the plurality of air intake filters;
the other end of the air intake silencer is connected to one end of the air intake duct; and
the other end of the air intake duct is connected to an air intake port of the turbine engine.
10. The turbine fracturing semi-trailer system according to claim 9 , wherein the plurality of air intake filters are disposed on two sides of the air intake system along a direction of power transmission of the turbine fracturing semi-trailer system and extend at least an entire length of the turbine engine.
11. The turbine fracturing semi-trailer system according to claim 10 , further comprising a plurality of inertia separators coupled to the plurality of air intake filters for separating solid particles and liquid droplets from air inflow into the air intake system.
12. The turbine fracturing semi-trailer system according to claim 1 , wherein output power of the plunger pump is 5000 hp or above.
13. The turbine fracturing semi-trailer system according to claim 1 , further comprising 3 or more axles installed beneath the semi-trailer body, wherein each axel is installed with at least a pair of wheels.
14. The turbine fracturing semi-trailer system according to claim 1 , further comprising a hydraulic power unit disposed on a gooseneck portion at one end of the semi-trailer body, the hydraulic power unit is configured to drive a hydraulic system in the turbine fracturing semi-trailer system.
15. The turbine fracturing semi-trailer system according to claim 14 , wherein the hydraulic power unit is driven by a diesel engine or driven by an electric motor.
16. The turbine fracturing semi-trailer system according to claim 14 , wherein a cooling system is collocated with the hydraulic power unit on the gooseneck portion of the semi-trailer body, the cooling system being configured to cool engine oil or lubrication oil displaced by the hydraulic power unit for an operation of the turbine engine, the first reduction gearbox assembly, or the plunger pump.
17. The turbine fracturing semi-trailer system according to claim 1 , wherein the crankcase of the plunger pump comprises at least 6 axle journals and at least 5 bellcranks.
18. The turbine fracturing semi-trailer system according to claim 17 , wherein a distance between a first center of rotation of the at least 5 bellcranks and a second center of rotation of a crankshaft of the crankcase is between 120 and 160 mm.
19. The turbine fracturing semi-trailer system according to claim 18 , wherein a plunging stroke of the plunger pump is between 10 and 12 inches when being in operation.
20. The turbine fracturing semi-trailer system according to claim 1 , wherein the plunger pump is disposed on a lapping section of the semi-trailer body and wherein the lapping section is configured with a traction pin for attachment to a towing equipment for the turbine fracturing semi-trailer system.