Vibration-based oil and gas fracturing manifold fault alarm and diagnosis system

Abstract

The invention discloses a petroleum and natural gas fracturing manifold fault alarm and diagnosis system based on vibration, and the system comprises a sensor group which is disposed at a fracturing manifold measuring point and is used for collecting the vibration parameters of a fracturing manifold; the edge computer is used for receiving the vibration parameters collected by the sensor group; the field vibration monitoring system is used for receiving the vibration parameters transmitted by the edge computer and acquiring process parameters of the fracturing equipment; and the remote cooperative support center is used for receiving the vibration parameters and the process parameters and realizing time alignment of the vibration parameters and the process parameters. According to the invention, through the combination of the sensors, the requirements of different monitoring durations and network environments are met, and real-time acquisition and transmission of vibration data are ensured; through a field and remote two-stage monitoring mode, sound-light alarm and multi-stage information pushing are combined, it is ensured that alarm is not missed, and closed-loop management of faults from discovery to solution is achieved; and based on spectrum analysis and database matching, fault causes are quickly positioned, and field efficient rectification is assisted.

Claims

1. A vibration-based oil and gas fracturing manifold fault alarm and diagnostic system, characterized by: include: The sensor group is deployed at the fracturing manifold measuring point to collect the vibration parameters of the fracturing manifold along the X, Y, and Z axes. The vibration parameters include vibration acceleration, vibration velocity, and vibration displacement. an edge computer, configured to receive vibration parameters collected by the sensor group; On-site vibration monitoring system, used to receive vibration parameters transmitted by edge computers and obtain process parameters of fracturing equipment, including displacement, pressure and total displacement of a single fracturing truck / skid, and sand concentration; Remote collaborative support center, used to receive vibration parameters and process parameters, achieve time alignment of vibration parameters and process parameters, and analyze vibration parameters, issue alarms, and perform fault diagnosis; The client is used for users to access the remote collaborative support center or on-site vibration monitoring system to view real-time data, alarm information, spectrum data and historical data.

2. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 1, characterized in that: The sensor set includes: LoRa digital vibration sensor, used for short-term monitoring (≤20 construction sections per monitoring) and in scenarios with poor mobile networks. The vibration parameters collected by the sensor are transmitted to the edge computer via LoRa. 4G digital vibration sensors are used for short-term monitoring (≤ 20 construction sections per monitoring) in scenarios with good mobile networks. The collected vibration parameters are directly transmitted to the remote collaborative support center via the 4G network. Wired analog vibration sensors are used for long-term continuous monitoring (>20 construction sections each time). They output voltage signals, which are processed by the edge computer through fast Fourier transform to obtain vibration parameters.

3. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 1, characterized in that: Both the on-site vibration monitoring system and the remote collaborative support center include: The eigenvalue real-time monitoring module is used to collect and monitor the vibration acceleration, vibration velocity and vibration displacement of the X, Y and Z axes in real time; An alarm module is used to trigger an alarm when the vibration parameters exceed the threshold; Spectrum analysis module, used to acquire, store and analyze time domain spectrum and frequency domain spectrum; The historical data module is used to store vibration parameters, process parameters and spectrum data.

4. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 3, characterized in that: The alarm triggering conditions of the alarm module are: when it is in the construction state, it is judged by the pressure and displacement in the process parameters, the vibration speed or vibration displacement exceeds the preset threshold upper limit; when it is not in the construction state, the alarm is not triggered.

5. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 4, characterized in that: The alarm module's alarm modes include: the on-site vibration monitoring system triggers an audible and visual alarm; the remote collaborative support center sounds through a loudspeaker and pushes alarm information step by step according to a preset cycle.

6. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 5, characterized in that: The alarm module also includes an anti-false alarm unit, which eliminates false alarms caused by fluctuations in vibration parameter data by setting alarm trigger delay, recovery delay and dead zone.

7. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 6, characterized in that: The spectrum analysis module troubleshooting process includes: Step a: Obtain the vibration velocity and displacement data of the measuring point in real time. If the data is normal, store its spectrum as a reference spectrum in the normal data spectrum library; Step b: If the data triggers an alarm, obtain the fault spectrum and compare it with the fault spectrum samples in the fault library: If there are similar samples, determine the cause of the fault marked by the sample and notify the site; after the site feedbacks the final cause, mark the fault spectrum and store it in the fault database; If there are no similar samples, the fault spectrum is compared with the reference spectrum in the normal data spectrum library. If there are fault characteristics, the cause is marked in combination with on-site feedback and stored in the fault library; if there are no fault characteristics, the fault spectrum is obtained again.

8. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 1, characterized in that: The preset threshold is determined by the following method, which includes the following steps: Step c1: Set the upper and lower limits i and j of the effective data of vibration velocity or vibration displacement, and filter out invalid data during non-construction period; Step c2: Combine the vibration velocities or displacements that satisfy i < X < j under different pressure and displacement conditions of each fracturing truck, electric-driven fracturing skid, and diesel-driven fracturing skid into the data set X a ={X1, X2,..., X n}; Step c3: Sort Xa in ascending order and remove duplicates; Step c4: Calculate the position K of the data set by inputting the percentage P. The formula is as follows: Where n is the sample size of the dataset Xa; Step c5: If K is an integer, take the value at the Kth position as the upper alarm threshold Qp; if K is a decimal, calculate Qp by linear interpolation. The calculation formula is as follows: in, The following is the value of K rounded down to the integer position, is the value of K rounded up, K is rounded down; Step c6: Subdivide by fracturing equipment type, pressure level, and displacement level, and determine the upper limit alarm threshold for the corresponding working conditions.

9. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 8, characterized in that: Pressure levels range from ≤30MPa to 139.1-140MPa, and displacement levels range from ≤0.5m³ / min to 0.6-2.0m³ / min. Different equipment types, pressure levels, and displacement levels correspond to different upper limit alarm thresholds.

10. The vibration-based oil and gas fracturing manifold fault alarm and diagnosis system according to claim 1, characterized in that: Fracturing manifold measuring points include wellhead manifold measuring points, single vehicle / skid manifold measuring points and temporarily determined measuring points.

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