Intelligent and automatic control high-pressure manifold system

Abstract

The invention discloses an intelligent and automatic control high-pressure manifold system, and relates to the field of oil and gas equipment. The invention discloses an intelligent and automatic control high-pressure manifold system. The high-pressure manifold system comprises a control system, an intelligent control center, a grease injection system, a manifold system and a wellhead module, the manifold system is connected with the wellhead module and used for conveying pressure liquid to the wellhead module; the grease injection system is used for injecting grease to valves which are respectively arranged on the manifold system and the wellhead module; the control system is in signal connection with the grease injection system, the manifold system and the wellhead module. And the intelligent control center is in signal connection with the control system. The problem that the oil and gas system cannot be monitored can be solved at least.

Description

Technical Field

[0001] The present application belongs to the technical field of oil and gas equipment, and specifically relates to an intelligent and automated high-pressure manifold system. Background Art

[0002] In the related art, some oil and gas systems are mainly operated manually when operating in a well site, and the operation of the oil and gas systems cannot be monitored, which makes the oil and gas systems prone to failure. Summary of the invention The purpose of the embodiments of the present application is to provide an intelligent and automatically controlled high-pressure manifold system, which can at least solve the problem of being unable to monitor the oil and gas system.

[0003] In order to solve the above technical problems, this application is implemented as follows: The embodiment of the present application provides a high-pressure manifold system with intelligent and automatic control, the high-pressure manifold system comprising: a control system, an intelligent control center, a grease injection system, a manifold system and a wellhead module; The manifold system is connected to the wellhead module and is used to deliver pressure liquid to the wellhead module; The grease injection system is used to inject grease into the valves provided in the manifold system and the wellhead module respectively; The control system is signal-connected to the grease injection system, the manifold system and the wellhead module respectively; The intelligent control center is connected with the control system by signal.

[0004] Optionally, the grease injection system includes a power module, a pumping module, a distribution module and a control module; The power module is in driving connection with the pumping module, and the pumping module is connected with the distribution module, and the power module drives the pumping module to pump sealing grease to the distribution module; The control module is signal-connected with the power module, the pumping module and the distribution module respectively.

[0005] Optionally, the power module includes an air compressor, an air tank and a pneumatic booster pump, the distribution module includes a power cylinder, and the pumping module includes a grease injection pump; The air outlet of the air compressor is connected to the air tank, the air outlet of the air tank is connected to the pneumatic booster pump, the air outlet of the pneumatic booster pump is connected to the air inlet of the power cylinder, and the air outlet of the power cylinder is connected to the grease injection pump; Under the action of the air compressor, the gas in the gas tank enters the booster pump and is transported to the power cylinder by the pump pressure pump. The gas is pressed into the grease injection pump through the power cylinder to inject grease into the valve through the grease injection pump.

[0006] Optionally, the control system is used to monitor the respective operating conditions of the manifold system and the wellhead module through at least one of pressure, displacement, flow and displacement monitoring.

[0007] Optionally, the manifold system and the wellhead module both include a driving device, which is connected to the corresponding valve transmission to drive the valve to move and adjust the opening of the valve, wherein the driving device includes one of an electric driving component, a hydraulic driving component, and a pneumatic driving component.

[0008] Optionally, the manifold system includes a pipeline and a leakage detection device; The interface area of ​​the pipeline is provided with a leakage channel; The leakage detection device includes a pressure transmitter, an instrument and a power supply. The pressure transmitter is arranged at the leakage channel and is connected to the instrument signal. The power supply is respectively connected to the pressure transmitter and the instrument to supply power to the pressure transmitter and the instrument respectively.

[0009] Optionally, a valve position monitoring element is provided at the valve, and the valve position monitoring element is used to monitor the position of the valve, wherein the valve position monitoring element monitors the position of the valve by at least one of ranging, displacement monitoring, and electromagnetic proximity sensing.

[0010] Optionally, a sealing grease detection element is further provided at the valve, and the sealing grease detection element is used to detect at least one of the grease injection pressure and the grease injection amount at the valve.

[0011] Optionally, the manifold system includes a pipeline, a quick-change joint body, a flange, a split retaining ring and a spring retaining ring; One end of the quick-change connector body is detachably connected to the pipeline; The split retaining ring is connected between the other end of the quick-change connector body and the flange, and the spring retaining ring is connected to the split retaining ring for closing the split retaining ring.

[0012] Optionally, the valve comprises a flat valve, a plug valve, a check valve or a safety valve. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 A schematic diagram of a high-pressure manifold system disclosed in an embodiment of the present application; Figure 2 This is a first structural schematic diagram of the manifold system disclosed in an embodiment of the present application; Figure 3 A second structural schematic diagram of the manifold system disclosed in an embodiment of the present application; Figure 4A third structural schematic diagram of the manifold system disclosed in the embodiment of the present application; Figure 5 A schematic diagram of a partial structure of a manifold system disclosed in an embodiment of the present application; Figure 6 A schematic diagram of a driving device disclosed in an embodiment of the present application; Figure 7 A schematic diagram of a valve disclosed in an embodiment of the present application; Figure 8 This is a first schematic diagram of a pipeline disclosed in an embodiment of the present application; Fig. 9 A second schematic diagram of a pipeline disclosed in an embodiment of the present application; Fig.10 A schematic diagram of an automatic control module disclosed in an embodiment of the present application; Fig.11 This is a schematic diagram of a first form of control system disclosed in an embodiment of the present application; Fig.12 A schematic diagram of a second form of control system disclosed in an embodiment of the present application; Fig.13 A control schematic diagram of a valve disclosed in an embodiment of the present application; Fig.14 A pipeline detection and early warning flow chart disclosed in the embodiment of this application; Fig.15 A schematic diagram of a grease injection system disclosed in an embodiment of the present application; Fig.16 A schematic diagram of the intelligent manifold system disclosed in the embodiment of the present application; Fig.17 A schematic diagram of leakage detection disclosed in an embodiment of the present application; Fig.18 A first control flow chart of the control system disclosed in the embodiment of the present application; Fig.19 A second control flow chart of the control system disclosed in the embodiment of the present application; Fig. 20 A third control flow chart of the control system disclosed in the embodiment of the present application; Fig.21 This is the fourth control flow chart of the control system disclosed in the embodiment of the present application. DETAILED DESCRIPTION

[0014] The following will be combined with the drawings in the embodiments of the present application to clearly and completely describe the technical solutions in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, not all of the embodiments. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of this application.

[0015] The terms "first", "second", etc. in the specification and claims of the present application are used to distinguish similar objects, and are not used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable under appropriate circumstances, so that the embodiments of the present application can be implemented in an order other than those illustrated or described here, and the objects distinguished by "first", "second", etc. are generally of one type, and the number of objects is not limited. For example, the first object can be one or more. In addition, "and / or" in the specification and claims represents at least one of the connected objects, and the character " / " generally indicates that the objects associated with each other are in an "or" relationship.

[0016] The embodiments of the present application are described in detail below through specific embodiments and their application scenarios in conjunction with the accompanying drawings.

[0017] refer to Figures 1 to 21 The embodiment of the present application discloses an intelligent and automatically controlled high-pressure manifold system. The disclosed high-pressure manifold system includes a control system, an intelligent control center, a grease injection system, a manifold system, and a wellhead module. Each system can be adjusted and laid out according to the actual operating conditions of the well site.

[0018] Among them, reference Figures 2 to 5 , the manifold system may include a high- and low-pressure manifold skid device, which includes a bottom skid, a low-pressure manifold assembly, a high-pressure manifold assembly, a control module assembly, etc., which are arranged from bottom to top, and each part is independent of each other in structure, and the disassembly and maintenance do not affect each other. The control module assembly can realize the mutual connection between the various parts, so that a modular layout can be realized, which is convenient for maintenance. Among them, the high-pressure manifold assembly is connected to the pump outlet, and the input high-pressure fluid flows back into the main channel; the low-pressure manifold assembly transports the operating low-pressure fluid to each pump truck, so as to realize the high- and low-pressure conversion through the pump truck. Optionally, the pump truck can adopt electric drive, liquid drive, diesel drive and other drive forms. Of course, other drive forms are also possible, which are not specifically limited here.

[0019] In addition, the control module assembly can be built into each control box as a whole, and the control module assembly includes a hydraulic assembly and an electric control assembly. Among them, the hydraulic assembly can include a motor, various hydraulic components, a hydraulic oil tank, and hydraulic branch pipelines, etc.; the electric control assembly can include a control component, a control cabinet, and an electric control branch pipeline. Based on this, through the reasonable arrangement of each control part, it can be ensured that the overall height of the control box does not exceed the upper limit requirements of transportation regulations. When local operation is required, ensure that the operator can operate each part normally while standing on the bottom skid to meet ergonomic requirements.

[0020] Each control box can be integrated on the upper surface of the four-way in the high-pressure manifold assembly, making rational use of the upper space of the high- and low-pressure manifold skid device, and at the same time, the four-way can be used as a support for the control module assembly to reduce the use of unnecessary support brackets. The weight and dimensions of the entire high- and low-pressure manifold skid device are controlled without additional increase to reduce the difficulty of transportation.

[0021] A shock-absorbing component can be added between the control box and the cross-way. The shock-absorbing component can be in the form of spring shock absorption, rubber shock absorption, mechanical shock absorber, etc., which can reduce the vibration of the bottom skid, each manifold, and each control box caused by high-speed fluid during operation, which is beneficial to extend the service life of each component in the control module assembly. Of course, the control box can also be used as an independent control box and dispersed in the space of the skid frame.

[0022] refer to Figure 5 and Fig.15 The grease injection system mainly includes a power module, a pumping module, a distribution module and a control module. The power module includes an electric, gas, and liquid drive unit and a sealing grease pumping unit; the pumping module mainly includes a high-pressure grease injection pump and a sealing grease switching device; the distribution module mainly includes branch valves, connecting pipes, power cylinders and other execution and control components, and the sealing grease is injected into each valve according to the preset program under the control of the control system. The power module is connected to the 380 / 220V power supply at the construction site to drive the electric drive air compressor. The high-pressure gas is stored in the gas tank, and the hydraulic oil is pumped and pressurized by the pneumatic booster pump at the back end. The kinetic energy supply of the entire grease injection system is realized. Pumping module, distribution module: Customized high-pressure grease injection pumps are used to pump the sealing grease to each distribution module for standby. After receiving the grease injection command, the distribution module realizes secondary boosting and efficient grease injection through the power cylinder. Control module: Controls the grease injection action and monitors and controls the pressure and flow of the grease injection circuit in real time. Communicates with the well site intelligent control platform, receives instructions from the control personnel, and can sense the well site operation status, perform self-diagnosis and alarm, and prevent personnel from misoperation.

[0023] Continue to refer Figure 5 In some embodiments, the grease injection system may mainly include a hydraulic power source, a grease injection booster cylinder, a grease injection booster cylinder control valve, a high-pressure sealing grease distribution solenoid valve, valves and related delivery pipelines, transition joints, etc.

[0024] Among them, the hydraulic power source can provide power for the grease injection booster cylinder. The hydraulic power source includes a power source (such as an electric motor, an internal combustion engine, a hydraulic motor, a pneumatic motor, etc.), a hydraulic pump, a hydraulic oil tank, a one-way valve, a unloading valve, a relief valve, an oil suction filter, an oil return filter, etc. Its characteristic is that when the speed of the power source is constant, two or more different flow rates can be output according to different load pressures, that is, under high-pressure loads, a small flow rate is output, and under low-pressure loads, a large flow rate is output.

[0025] The grease injection booster cylinder is used to pressurize the sealing grease and inject it into the valve grease injection point. Its structure is divided into a low-pressure part and a high-pressure part. Among them, the low-pressure part is connected to the oil port of the control valve, and the control valve can control the reciprocating movement of the plunger inside the cylinder; the high-pressure part is filled with sealing grease, which is injected into the valve after the piston inside the cylinder increases the pressure at a fixed ratio. The maximum pressure of the pressurized sealing grease can reach 15000psi.

[0026] The control box may include an intelligent control part for monitoring the valve pressure, grease injection amount, and setting maintenance cycles. A sealing grease monitoring element may be provided in the grease injection booster cylinder, and the sealing grease monitoring element may be one or more sensors selected from electromagnetic induction monitoring, ultrasonic monitoring, laser monitoring, and visual monitoring. Exemplarily, the sealing grease detection element may be a magnetostrictive sensor, and a scale visual display may be configured externally, so that the grease injection status may be clearly seen through a remote control system or local observation.

[0027] The principle of hydraulic grease injection is as follows: a hydraulic control circuit for grease injection of multiple (e.g., eight, etc.) valves. Before starting the hydraulic power, the high-pressure part of the grease injection booster cylinder is filled with sealing grease. After the hydraulic power source is started, one of the solenoid valves of the grease injection booster cylinder control valve is energized. The hydraulic oil output by the solenoid valve pushes the plunger inside the grease injection booster cylinder to move and squeeze the sealing grease. After the sealing grease is pressurized, it enters the grease injection point on one side of the valve through the high-pressure sealing grease distribution solenoid valve. After this grease injection point is fully greased, the high-pressure sealing grease distribution solenoid valve is reversed to inject the high-pressure sealing grease into the grease injection point on the other side of the valve. After the grease injection point on the other side is fully greased, this valve completes a grease injection process, and so on, grease is injected to other valves.

[0028] The control module assembly can intelligently topology the manifold process according to the layout of the manifold system, and send instructions as needed to form one-key process switching and real-time status feedback indication. At the same time, the process forms linkage instructions and sends them to related equipment to form linkage interlocking, providing safety for equipment operation. In addition, the system can also form life cycle management, real-time viewing of manifold-related data and usage time, effectively reducing the risk of manifold overload, and realizing statistical analysis and life management of the manifold.

[0029] The control software of the control module assembly is integrated with the control software of the fracturing pump truck on the instrument vehicle, forming a program control logic relationship of opening the valve first and then running the fracturing pump truck; stopping the fracturing pump truck first and then closing the valve, avoiding misoperation and ensuring equipment safety and smooth construction.

[0030] After receiving the switch command, the local control system controls the valve action. When the valve is switched to the specified position, the sensor sends a signal to the local control box. The control element in the local control box sends a command and the operation interface shows that the valve is in place. The computer operation interface in the instrument car and the local control box operation interface both display the valve switch status, which can control the switch of a single valve or multiple valves at the same time. The local control system can be operated on the touch screen operation interface of the main control box, or directly operated by buttons to form control redundancy.

[0031] The remote control system can be used during the fracturing construction process and when the manifold is not under pressure. The operator issues operating instructions at the operation terminal in the control center. The signal can form a link with the local control system through bus form (modbus, profinet, canOpen, etc.) or wireless form (wifi, lora, zigbee, etc.) to realize remote control of valve opening or closing. At the same time, the valve switch status signal is fed back to the remote terminal and displayed on the remote terminal.

[0032] As an alternative to the manifold, multiple functional skids can be set up to integrate operation functions, such as ball dropping operation, pressure relief operation, fluid one-way control (e.g., configuration of one-way valve), and main channel closing (e.g., configuration of main control valve) to form a skid-mounted unit for easy on-site disassembly and assembly.

[0033] In the embodiment of the present application, the wellhead module includes a wellhead tree, a manifold skid, connecting pipelines between skids, etc. Among them, the manifold skid has two combinations: horizontal and vertical. The valve is equipped with a remote control driver, which can adopt electric, hydraulic, pneumatic and other working modes, and a manual emergency operation mechanism is designed for emergency conditions.

[0034] The control system can serve as the power unit and data transmission part of the wellhead module. It can provide a power source for the valve to realize the drive of the valve, and realize automatic control of the drive through sensors for pipeline pressure monitoring and valve position monitoring. Combined with the process flow rate, the electrical control unit can realize the operation of the valve according to the process flow.

[0035] refer to Figure 6, the valves in the manifold skid and the wellhead tree can adopt a drive device for realizing remote control, and the drive device can adopt a combination of one or more drive modes of electric drive, hydraulic drive, pneumatic drive, and manual drive. For example, a hand-hydraulic integrated valve driver is adopted, and the structure mainly includes a hydraulic cylinder, a control valve block, a manual oil pump, etc. The hydraulic cylinder directly drives the valve stem or other forms of driving rod of the valve through the contraction and extension of the piston rod, so as to control the opening of the valve; the control valve block can switch the path of the hydraulic oil flowing into the hydraulic cylinder and prevent the pressure of the manual oil pump from being transmitted to the pump station or the pressure of the pump station from being transmitted to the manual oil pump; the manual oil pump is used to manually transfer the hydraulic oil in the oil cylinder from the rodless chamber to the rod chamber or reversely to drive the contraction or extension of the hydraulic cylinder.

[0036] Control and close the outlets at both ends of the manual oil pump, open the oil circuit from the pump station to the oil cylinder, and the hydraulic oil can drive the hydraulic cylinder through the passage from the pump station to the oil cylinder. After closing the outlets at both ends of the hydraulic station, open the inlet and outlet of the manual oil pump, and drive the manual oil pump to control the hydraulic oil from the rod chamber of the hydraulic cylinder through the manual oil pump to the rodless chamber to achieve the contraction of the hydraulic cylinder, or control the hydraulic oil from the rodless chamber of the hydraulic cylinder through the manual oil pump to the rod chamber to achieve the extension of the hydraulic cylinder and the driving of the hydraulic cylinder.

[0037] refer to Figure 7 , valve driving mode: the structural form of power end + connecting device + valve, can be manual + electric, can also be hydraulic cylinder + manual, can also be a hydraulic motor drive + manual integrated structure, to achieve remote control mode, and can monitor the pressure, flow, torque, etc., to achieve control of valve status and abnormal problems.

[0038] The valve position monitoring method adopted by the valve can be distance measurement, displacement monitoring, electromagnetic proximity sensing and other forms or a combination thereof, such as ultrasonic distance measurement and proximity switch. The valve position can be monitored through the principles of ultrasonic distance measurement and electromagnetic induction.

[0039] The angular travel valve position indicator (limit switch) is mainly composed of a stainless steel standard shaft, a cam, a micro switch, a wiring port, a die-cast aluminum housing, an indicator cover, a mounting bracket, etc. The stainless steel standard shaft is connected to the plug valve hydraulic actuator to ensure that the standard shaft and the plug valve rotate coaxially; when the cam touches the micro switch, the micro switch is closed or disconnected, and the switch signal is transmitted to the outside, which is displayed locally through the indicator; the standard shaft drives the indicator cover to rotate, and the valve position switch status is indicated by a striking visual color change.

[0040] refer to Figure 8 and Fig. 9The pipeline connection adopts connection forms that can be realized by clamps, flanges, unions or threads. The connection between skids can be realized by two structures: hard pipe and hose, and can be used in conjunction with one or more structural forms of quick connection devices and pipe bodies.

[0041] Among them, the rotating flange can be rotated and quickly connected with other flange structures. The retaining ring is a split structure, including at least two petals. When used with the rotating flange, the flange can be quickly connected. The clamping ring is used to close the split retaining ring together to achieve installation consistency. The quick-change connector body and the pipe body can be connected and locked by threads, and high-pressure sealing can be achieved by a sealing ring. The sealing structure can be designed according to actual conditions, using a radial sealing structure or an axial sealing structure, and the material can be non-metallic or metal.

[0042] refer to Fig.10 The automatic control module is the key part to realize the automatic control of the manifold system, including valve remote control device, power unit, pipeline system sensor (including pressure sensor, valve position sensor, leakage detection sensor, flow sensor, etc.), video monitoring device, etc. The valve control mode can be remote operation, local automatic control, local manual control, etc. The automatic control module can realize the main body and remote control and integrated control of hydraulic plug valve and valve plate valve switch by controlling the valve control system. Through the detection and feedback of valve position, pressure, video, etc., the process is confirmed and abnormal alarm is issued, and the single valve action or multiple valve actions are realized through the pre-set commands, and matched with the system operation process to reduce the risk and intensity of human operation.

[0043] The control system, power unit and pipeline unit are configured separately and independently as skids. In this way, a total power unit can be set up to distribute power to all control systems in the well site to achieve unified power management. Alternatively, the control system can be integrated with the power unit and pipeline unit to control a single or multiple wellheads with one set of control systems.

[0044] The control system includes hydraulic components, electrical components, control panels, video displays, etc., and is connected to a remote data center. The data transmission of the remote data center can be wireless or wired. The local and remote control panel status is displayed and controlled, and the valve status can be viewed by controlling the camera.

[0045] refer to Fig.11 and Fig.12, the hydraulic operating handle can be visually confirmed to be consistent with the system process switch state through various structural forms such as pneumatic lock, mechanical lock, hydraulic lock, etc. System safety setting: the valve position status can be detected by the valve position sensor, and the valve status can be checked by controlling the camera for secondary confirmation. Set the operation authority and enter the password to operate. The priority is local operation. The remote control is specified and the switching command can be executed locally. The pipeline pressure value needs to be detected before the valve is actuated. If the management pressure value is greater than the required set value, the operation is not allowed. The program must be confirmed before any instruction is issued to meet the process requirements.

[0046] refer to Fig.13 , the valve can be monitored by wire or wirelessly, and different sensor methods are used for structures such as flat valves and plug valves. The plug valve adopts a 90° development method, and a cam mechanism is used inside. When the rotation touches the fiber switch, the ring is moved through the mechanical limit switch, and the power is supplied by a high-performance battery. The built-in Lora antenna realizes wireless signal transmission and connects to the control system. The flat valve can be moved in parallel in the form of ranging, displacement monitoring, electromagnetic proximity sensing, etc. or a combination, such as ultrasonic ranging, proximity switch, through ultrasonic ranging and electromagnetic induction principles, triggering the switch action to realize the awakening of the switch action, through high-performance batteries and ultra-low power wireless status monitoring modules, to realize signal conversion, and through the built-in antenna, to realize signal transmission. At the same time, the wireless signal transmission method can also be transmitted through wired transmission, and the power supply can also be wired.

[0047] refer to Fig.14 , pipeline monitoring and early warning: valve position monitoring, pressure monitoring, visual confirmation, vibration monitoring, and data integration and transmission, real-time monitoring of operation data records, through automation and digital management, to provide users with confirmation and guarantee of pipeline status and abnormal problems, to prevent accidents and ensure the safety of operations and personnel.

[0048] refer to Fig.16 The intelligent control center is an independent software system that provides an interface with the intelligent decision-making system (customer). The interface includes the operation process instructions issued by the intelligent decision-making system, the status feedback of the manifold control operation process, the status feedback of the valve or pressure value, the status feedback of abnormal processing, etc. The binding of the hydraulic station and the valve position, the automatic grease injection and maintenance of the valve, the control arrangement of the operation process, the abnormal valve status processing, the abnormal pressure processing, etc. are all completed in the manifold control center.

[0049] This control system edits the distribution diagram of equipment, manifolds, valves, and wellhead connections; edits the communication parameters, hydraulic control, and grease injection control parameters of each valve. Configuration items include: ① Bind the hydraulic station to which it belongs and its IP address; ② Bind the hydraulic control port connected to the hydraulic valve; ③ Bind the grease injection port connected to the hydraulic valve; ④ Bind the LoRa identification ID that monitors the switch status of the hydraulic valve; Configurable manifold types include: hydraulic plug valves, hydraulic flat valves, large-diameter high and low pressure manifold skids, wellhead trees, diversion skids, and all equipment information during oil and gas field operations.

[0050] Functions implemented: configure parameters such as hydraulic station name, IP address, communication protocol, etc.; configure PLC valve status, switch control channel address; grease injection related channels; pressure monitoring related channels.

[0051] Configuration function: Configure the valve opening sequence and status corresponding to the fracturing operation process; including pressure testing, back pressure, wellhead opening, pumping, wellhead closing and other process-related valve operations. Support process setting preview. In manual mode, you can choose to execute the preset process; in automatic mode, only receive the operation process issued by the decision-making command center; the valve switch status is dynamically displayed during the process execution, and the status will be reported to the decision-making command center in automatic mode; the valve can be manually double-clicked for emergency control of a single valve. The system records the number of operating layers and operation time of each wellhead in the platform; saves and queries the operation data of instruments, sand mixing, fracturing and other equipment; associates operation data with maintenance; maintenance plans and reminders, and displays the injection history information and operation information of a certain module unit for operators to judge whether injection is needed. Maintenance records of manifolds, wellheads, etc.

[0052] The intelligent manifold control system software is based on the Windows system, which conforms to the operating habits of most users; it is developed using Microsoft C# programming language, and the program reliability and stability are guaranteed; the software interface is developed using Winform UI framework and DevExpress controls, and the interface is beautiful; data storage uses the Sqlite database widely used in the industry to ensure data security and reliability; database access uses the SqlSugar open source ORM framework, and data access efficiency is high; communication with PLC uses the S7.NetPlus communication library based on the Siemens S7 protocol, which supports batch reading and writing of data, and the communication is stable and reliable; the MQTT protocol widely used in the Internet of Things field is used for message communication with Jerry's self-developed intelligent fracturing system, which can be integrated and expanded.

[0053] refer to Fig.17, Pipeline leakage detection: The seal of high-pressure fluid pipeline transportation is between pipeline connections, such as flange and flange connection, flange and cross connection, union connection, clamp connection, etc. During the operation process, the general leakage is first micro-leakage, and then this micro-leakage is not easy to observe. The fluid will continue to flow along the leakage channel. After a period of time, the high-pressure fluid will cause erosion to increase the crack. As the sealing crack increases, the fluid will form turbulence at the crack due to pressure difference. The medium in the turbulent flow impacts and rubs against the medium sealing surface, causing large flow leakage. Once a leak occurs during the operation, it will directly affect the operation process, causing economic losses to the on-site construction, and there are also safety risks.

[0054] Working principle of pipeline leakage device: open the end face sealing groove on the standard flange, open the leakage channel on the outer diameter of the flange, and install the pressure transmitter for detection. Once the fluid inside the channel leaks or leaks, the leakage seal will seal the leakage pressure in the leakage channel, and report the abnormal pressure data of the channel leakage to the control system through the pressure transmitter, so as to avoid further expansion of losses and improve safety performance. This patented device can transmit the leakage point signal to the instrument through the data line. The instrument can display the leakage on the screen of the intelligent control system and issue an early warning in time to remind customers to check for leaks and troubleshoot problems. This patented device can be set at all connection points in the high-pressure manifold system, and the junction box can be configured for data transmission according to the on-site layout.

[0055] refer to Figures 18 to 21 Based on the added sensors, data collectors, edge calculators, 4G gateways, fault mechanisms and machine learning algorithms, the high-pressure manifold system can be used to monitor the operation time, fatigue damage and leakage. High-pressure manifold failure monitoring can accurately count and record the use time of the pipeline, reduce man-hours, improve work efficiency, and identify and warn of pipeline loosening, fatigue cracks and leakage in advance. Signal monitoring and early warning are combined with the intelligent manifold control system to identify abnormal signals beyond the range, thereby warning and intervening in abnormal manifold failure to avoid major accidents.

[0056] In summary, the intelligent and automated high-pressure manifold system in the embodiment of the present application integrates an intelligent control system, automated and digital management, a modular platform design of the manifold system, intelligent decision-making and a standard data model.

[0057] Among them, the intelligent control system: integrates sensors, safety operations and data centers, expands information transmission and data integration between local and remote locations, and the data panel provides a flexible data display to display real-time data at the well site, control center or any location, and can remotely control valves through the HDC control unit. It can remotely operate, monitor operations and confirm processes, thereby improving the safety and efficiency of the entire well site operation.

[0058] Automation and digital management: Valve positioning monitoring, pressure monitoring, hydraulic locking, remote control and video monitoring system integration, real-time monitoring and operation data recording, provide users with confirmation and guarantee of the actual valve position and abnormal problems. Avoid manual data and solve the problem of field operation data model storage and manual entry. No need to enter the red zone for verification, ensuring the safety of operations and personnel.

[0059] Modular platform design of manifold system: The system is divided into several modules, including high and low pressure skids, diversion skids, multi-function skids and wellheads. Flexible pipes and quick connection devices are used to quickly install each module. The valve is remotely controlled and driven. Automatic grease injection system, valve position sensors and pressure sensors are installed to achieve automatic control and monitoring. The system can be quickly deployed, NPT can be reduced, and the labor intensity of personnel can be reduced. Convenient and efficient maintenance can reduce loss costs and increase product service life.

[0060] Intelligent decision-making and standard data model: data sharing between operation data and intelligent decision-making systems ensures seamless integration of data transmission and intelligent decision-making between various systems, improves data accuracy, and thus achieves data-driven analysis and decision-making. Control and lock based on the customer's SOP data-driven logic to reduce the risk of human error, thereby improving on-site operation efficiency and reducing operating costs.

[0061] In the embodiment of the present application, the control system can remotely operate, monitor operations and confirm processes, thereby improving the safety and efficiency of the entire well site operation; the high- and low-pressure manifold skid is provided with high-pressure, low-pressure and control system parts, which can realize independent control or combined control, and the grease injection unit integrated in the skid frame can realize local automatic grease injection of the valve; the diversion manifold skid module can adopt a variety of vertical or horizontal structural forms, and realize pipeline integration on the skid frame; the control system can realize independent control of the wellhead or control system operation by connecting multiple control modules in series for the platform well; the wellhead valve adopts automatic grease injection, which can realize remote, quantitative and automatic grease injection maintenance function, and transmit data with the data center to realize maintenance reminders; the control system can monitor the high-pressure manifold operation process through various models such as pressure, displacement, flow, video monitoring, etc., and provide real-time feedback on whether the pipeline has pressure, whether the pipeline is leaking, and the switch status of the valve during operation, so as to realize the confirmation and reminder function before the process operation; the control system monitors and feedbacks the valve position and pressure signal, and displays it locally and on the remote control panel screen; the pressure and displacement monitoring method can be wired or wireless transmission, and the signal conversion is realized through high-performance batteries and ultra-low-power wireless status monitoring modules, and the signal transmission is realized through the built-in antenna. At the same time, the wireless signal transmission method can also be transmitted through wires, and the power supply can also be wired; the valve switch stroke can be realized through mechanical locks, including color distinction to realize remote video monitoring, as an auxiliary inspection method for valve position detection.

[0062] In addition, the embodiments of the present application provide a flexible data display to display real-time data of the well site, control center or any location; it is configured with data storage and recording functions, and digital conversion is realized at the same time, manual data is avoided, and the problem of field operation data model storage and manual entry is solved; the layout of the well site is modularized and platformized, and the system is divided into several modules such as high and low pressure skids, diversion skids, multi-function skids and wellheads, and each module is quickly installed through flexible pipes and quick connection devices; the valve adopts a remote control system, and can have various combinations of control methods such as electric, hydraulic, and pneumatic to achieve remote control and monitoring; the valve position sensor can adopt the form or combination of ranging, displacement monitoring, electromagnetic proximity sensing, such as ultrasonic ranging, proximity switch form, through ultrasonic ranging and electromagnetic induction principles, triggering the switch action; the high-pressure process can perform safety locking, unlocking operations and emergency operations (emergency unlocking of a single valve). The hydraulic control unit in this patent is provided with a hydraulic locking function, mechanical locking or electric, pneumatic, hydraulic locking, to achieve the locking of the valve status and confirmation before the process; the flat panel is set with a hydraulic operating handle to enable visual confirmation that it is consistent with the system process switch status; explosion-proof motor pump group: 2 sets of electric hydraulic pumps are used for boosting, one for use and one for backup, equipped with UPS (4 hours) and manual pumps, and the hydraulic control system needs to ensure that there is no pressure leakage in the event of power failure; pre-made instructions - according to the operation process, multiple instructions of the fracturing plan are implemented, the sequential opening and closing of multiple valves for fracturing, and instructions such as ball dropping and pressure release during the process are issued; the pipeline pressure value needs to be detected before the valve is actuated. If the management pressure value is greater than the required set value, no operation is allowed; the program must be confirmed before any instruction is issued to meet the process requirements; the screen display interface is optimized to display the valve status and operation process of the fracturing operation; modularization of electrical control. It can be transplanted to the valves, pressure monitoring and control means of high-pressure and low-pressure manifolds; the control logic and methods of the software can be flexibly configured and edited for the interface, the pipeline display of the operation process, and the display of the operation status and data, as well as the automatic storage and recording of data; the process locking function logic controls the locking and manual unlocking functions according to the priority of the on-site operation; the PLC address corresponding to the control valve switch reads the PLC address of the current valve status; the valve opening sequence and status corresponding to the fracturing operation process are configured, including pressure testing, back pressure, wellhead opening, pumping, wellhead closing and other process-related valve operations, and supports process setting preview.

[0063] In the embodiment of the present application, the wellhead Christmas tree part: by configuring automatic control flat valves in different forms such as manual-hydraulic integrated, electric-driven, hydraulic-driven, etc., automatic control and data feedback of the operation process are realized, which solves the problem of manual operation and confirmation of the well site; the wellhead Christmas tree is connected to the well control or the delivery manifold by a quick connection device, which realizes rapid connection during the disassembly and assembly process, improves efficiency and reduces waste of manual work hours; the wellhead Christmas tree part is provided with a valve position sensor on the valve, and pressure sensors are provided on the main pipeline, return pipeline and connection position, etc., to realize monitoring and early warning of the operation process through real-time data feedback; a flexible manifold or a large-diameter manifold is used to connect the diversion manifold skid and the wellhead tree to realize rapid connection between the wellhead and the diversion skid; the diversion manifold skid can adopt a vertical or horizontal structure, through the module The shunt manifold skid adopts the driving mode of dual automatic control valves, and one valve is also equipped with a manual operating mechanism to realize automatic control under the premise of ensuring operation safety; the shunt manifold skid is connected with the pumping and blowdown manifolds to realize the modularization of the operation process, and is equipped with valve position monitoring and pressure monitoring to realize the centralized management of data transmission and control; the high and low pressure manifold skid integrates high pressure manifold, low pressure manifold, control module, grease injection module, etc., and adopts modular centralized management to realize the rapid layout of the well site; the module design of the high and low pressure manifold skid can realize multiple layout modes of high pressure on the top, high pressure on the bottom, two low pressure manifolds or one low pressure manifold to meet the different operation requirements of the well site; the high and low pressure manifold skid device adopts multiple high pressure interface modes, and the low pressure interface is 1.5-2 times, to meet different operational requirements; the high and low pressure manifold skid integrates pressure monitoring, valve position monitoring, grease injection monitoring and other monitoring and data transmission methods to achieve automatic control, data monitoring and early warning of high pressure manifold skid control; the multifunctional skid can be optionally configured, which integrates the pumping, return, pressure relief, pipeline cutting and other functions in the operation process, realizes functional modularization, and is convenient for on-site installation; the multifunctional skid is equipped with a remote ball delivery device, which can realize remote detection and control to meet the requirements of temporary plugging agent / ball delivery during the operation process; the main pipeline can be equipped with large-diameter flat valves and plug valves and other flow valves to achieve pipeline cutting; the flat valve structure has hand-hydraulic, hydraulic, electric There are many control valve structures such as manual and pneumatic, with diversified choices; the valve switch status can integrate remote indication of valve position and local display of valve position, among which the display form of valve position can be proximity switch, magnetostriction, ultrasonic, laser and other possible implementation forms; the status of the connection device, including the clamp connection form-(metal + non-metallic sealing design), quick tightening mechanism; flexible pipe quick connector design, union flange + rotating flange structure, etc.; the layout structure of the automatic grease injection system includes grease injection unit, power unit and control unit and other accessories; the working principle and logic of the automatic grease injection system can realize local + remote control, real-time monitoring function of gas circuit, display of grease injection amount and cumulative quantitative Display, one-button operation of control panel and PAD or other display devices; automatic grease injection system realizes early warning function, including reminder of maintenance cycle, low liquid level alarm and electric heating function; for high-pressure sealing grease, high-pressure grease injection unit can be used to cover storage unit or grease supply unit; hydraulic control system, integrated sensor device, hydraulic control system, control part and display of control interface and other functions; pipeline leakage monitoring method, manual inspection and hardware detection and software monitoring and other methods, combined with on-site convenience materials, according to the flange leakage principle, real-time leakage detection is carried out through sensor early warning; position sensor monitors flange position, including valve position monitoring method, control handle operation The hydraulic and electrical components include relays, transformers, circuit breakers, and corresponding input and output lines and communication parts; the hydraulic part includes accumulators, reversing valves, safety valves, backup power supplies, manual pumps, etc. At the same time, the hydraulic pipelines are uniquely identified by color and differentiation, digital markings, differences in quick-change connectors, and physical address binding functions combined with electrical components; the control logic and methods of the software can be flexibly configured and edited in the interface, the pipeline display of the operation process, and the display of the operation status and data, and also include automatic data storage and recording; the process locking function logic controls the locking and manual unlocking functions according to the priority of the on-site operation.

[0064] Therefore, in the embodiments of the present application, the intelligent and automated high-pressure manifold system can integrate data into a unified instrument, provide valuable suggestions for operations, system connection services, digital workflows, and increase operation process control. Through intelligent decision-making systems and data-driven logic control, standard data models for field control and hydraulic interlocking are implemented, thereby reducing the operation and labor intensity of operators, improving the operating efficiency of the well site, reducing operating costs, and ensuring the safety and sustainability of well site operations.

[0065] The embodiments of the present application are described above in conjunction with the accompanying drawings, but the present application is not limited to the above-mentioned specific implementation methods. The above-mentioned specific implementation methods are merely illustrative and not restrictive. Under the guidance of the present application, ordinary technicians in this field can also make many forms without departing from the purpose of the present application and the scope of protection of the claims, all of which are within the protection of the present application.

Claims

1. An intelligent and automated high-pressure manifold system, characterized in that: The high-pressure manifold system includes: a control system, an intelligent control center, a grease injection system, a manifold system and a wellhead module; The manifold system is connected to the wellhead module and is used to deliver pressure liquid to the wellhead module; The grease injection system is used to inject grease into the valves provided in the manifold system and the wellhead module respectively; The control system is signal-connected to the grease injection system, the manifold system and the wellhead module respectively; The intelligent control center is connected with the control system by signal.

2. The high pressure manifold system according to claim 1, characterized in that: The grease injection system comprises a power module, a pumping module, a distribution module and a control module; The power module is in driving connection with the pumping module, and the pumping module is connected with the distribution module, and the power module drives the pumping module to pump sealing grease to the distribution module; The control module is signal-connected with the power module, the pumping module and the distribution module respectively.

3. The high pressure manifold system according to claim 2, characterized in that: The power module includes an air compressor, an air tank and a pneumatic booster pump, the distribution module includes a power cylinder, and the pumping module includes a grease injection pump; The air outlet of the air compressor is connected to the air tank, the air outlet of the air tank is connected to the pneumatic booster pump, the air outlet of the pneumatic booster pump is connected to the air inlet of the power cylinder, and the air outlet of the power cylinder is connected to the grease injection pump; Under the action of the air compressor, the gas in the gas tank enters the booster pump and is transported to the power cylinder by the pump pressure pump. The gas is pressed into the grease injection pump through the power cylinder to inject grease into the valve through the grease injection pump.

4. The high pressure manifold system according to claim 1, characterized in that: The control system is used to monitor the operation status of the manifold system and the wellhead module respectively through at least one of pressure, displacement, flow and displacement monitoring.

5. The high pressure manifold system according to claim 1, characterized in that: The manifold system and the wellhead module both include a driving device, which is connected to the corresponding valve transmission to drive the valve to move and adjust the opening of the valve, wherein the driving device includes one of an electric driving component, a hydraulic driving component, and a pneumatic driving component.

6. The high pressure manifold system according to claim 1, characterized in that: The manifold system includes pipelines and leakage detection devices; The interface area of ​​the pipeline is provided with a leakage channel; The leakage detection device includes a pressure transmitter, an instrument and a power supply. The pressure transmitter is arranged at the leakage channel and is connected to the instrument signal. The power supply is respectively connected to the pressure transmitter and the instrument to supply power to the pressure transmitter and the instrument respectively.

7. The high pressure manifold system according to claim 1, characterized in that: A valve position monitoring element is provided at the valve, and the valve position monitoring element is used to monitor the position of the valve, wherein the valve position monitoring element monitors the position of the valve by at least one of distance measurement, displacement monitoring, and electromagnetic proximity sensing.

8. The high pressure manifold system according to claim 1, characterized in that: A sealing grease detection element is also provided at the valve, and the sealing grease detection element is used to detect at least one of the grease injection pressure and the grease injection amount at the valve.

9. The high pressure manifold system according to claim 1, characterized in that: The manifold system includes a pipeline, a quick-change joint body, a flange, a split retaining ring and a spring retaining ring; One end of the quick-change connector body is detachably connected to the pipeline; The split retaining ring is connected between the other end of the quick-change connector body and the flange, and the spring retaining ring is connected to the split retaining ring for closing the split retaining ring.

10. The high pressure manifold system according to claim 1, characterized in that: The valve includes a flat valve, a plug valve, a check valve or a safety valve.

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