High-efficiency long-service-life low-noise intelligent control reciprocating plunger pump system for mobile skid-mounted house

Abstract

The invention relates to the technical field of oilfield water injection equipment, and discloses an efficient long-service-life low-noise intelligent control reciprocating plunger pump system for a mobile skid-mounted room, the skid-mounted room adopts a carriage type structure and is divided into a power room and a control room through a partition wall, and reasonable partition of equipment and a control area is realized. Three layers of noise reduction and sound insulation boards are arranged on the six faces of the periphery, the top and the bottom of the sound insulation board respectively and sequentially comprise a corrugated board, a sound insulation board A internally provided with sound absorption fibers, a sound insulation board B internally provided with sound absorption cotton and a porous sound absorption decorative board internally provided with sound absorption cotton from outside to inside, and air sound mixing layers are arranged between the sound insulation board A and the sound insulation board B and between the sound insulation board B and the porous sound absorption decorative board, so that noise transmission is effectively blocked, and the noise reduction effect is good. The control system supports remote intelligent control, data uploading, function protection and fault diagnosis can be completed, the unattended requirement is met, the movement flexibility, the noise reduction effect and the intelligent level of the equipment are improved, the distance measuring sensor at the power end of the reciprocating plunger pump monitors the gap according to a formula, and stable operation of the equipment is further guaranteed.

Description

Technical Field

[0001] The present invention belongs to the technical field of oilfield water injection equipment, and in particular relates to a high-efficiency, long-life, low-noise, mobile skid-mounted intelligently controlled reciprocating plunger pump system. Background Art

[0002] In oilfield development and industrial injection processes, injecting media into reservoirs or industrial systems to replenish pressure is a critical step in ensuring production efficiency. Traditional injection methods rely on fixed water injection stations, which require infrastructure projects such as land acquisition, civil construction, and equipment installation. Construction periods can range from several months to over a year, resulting in low efficiency and high initial investment costs. Furthermore, as the water content of oil wells increases or industrial demand changes, some water injection stations lose their usefulness and are decommissioned or abandoned, resulting in a waste of resources.

[0003] In recent years, mobile injection equipment has gradually become an important alternative to fixed water injection stations, but it still has significant technical defects in practical applications: Serious noise pollution: Existing noise control measures for mobile equipment are insufficient. The noise level during equipment operation often exceeds 100dB(A). This not only fails to meet the standard requirement of GB / T29529 that "the noise level at 1m away from the equipment during operation shall not exceed 85dB(A)", but also has a serious impact on the surrounding environment and operators.

[0004] Low level of intelligence: Most equipment lacks a complete intelligent control system, making it impossible to achieve remote monitoring, automatic adjustment, and unmanned operation. It needs to rely on manual on-site operation and maintenance, which increases labor costs and lacks timely response.

[0005] Unreasonable structural design: The equipment has low integration, and the core components such as the pump body, motor, and manifold are arranged in a scattered manner. There is a lack of a unified sound insulation and protection structure, which not only affects the stability of equipment operation, but also aggravates noise diffusion and maintenance difficulty.

[0006] Therefore, it is an urgent need in the oil field and industrial injection field to develop a mobile injection equipment with low noise characteristics, high intelligence level and high degree of integration to solve the high cost and long cycle problems of traditional fixed water injection stations, and at the same time overcome the defects of existing mobile equipment such as noise pollution and lack of intelligence. Summary of the Invention

[0007] The present invention aims to solve the technical problems that the water injection stations in the above-mentioned existing technologies require land expropriation and long-term civil construction, have a long deployment cycle and high costs, and are easily abandoned due to changes in well locations; and the existing mobile equipment has insufficient noise control, low intelligence, reliance on manual operation, and is difficult to achieve unmanned operation.

[0008] To achieve the above object, the present invention provides the following technical solutions: A high-efficiency, long-life, low-noise mobile skid-mounted intelligently controlled reciprocating piston pump system, including: The skid-mounted room has a carriage structure and is divided into a power room and a control room by a partition wall. The power room is used to install a reciprocating piston pump, and the control room is equipped with a frequency converter cabinet. The skid-mounted room is equipped with three layers of noise-reducing sound insulation panels on all six sides, including the four sides, top, and bottom. The three layers of noise-reducing sound insulation panels, from the outside to the inside, include corrugated board, sound insulation panel A with built-in sound-absorbing fiber, sound insulation panel B with built-in sound-absorbing fiber, and porous sound-absorbing decorative panel with built-in sound-absorbing cotton. An air mixing layer A is installed between sound insulation panels A and B, and an air mixing layer B is installed between sound insulation panel B and the porous sound-absorbing decorative panel. The reciprocating piston pump is installed in a skid-mounted room. The power end of the reciprocating piston pump includes the body and reciprocating parts consisting of a crankshaft, connecting rod, crosshead A, intermediate rod, and plunger. A detection plate is installed on the plunger or intermediate rod, or at the connection between the two. A distance sensor is installed in the body to monitor the position changes of the detection plate. The distance sensor calculates the initial safety clearance reference value L based on a formula. When the actual clearance detected exceeds this reference value, an early warning signal is triggered. The control system can realize the intelligent operation and intelligent control and remote transmission functions of the reciprocating piston pump, complete data upload, function protection and fault diagnosis, and support remote control via a computer and mobile phone APP through a network platform to achieve unmanned operation.

[0009] The skid-mounted room for this high-efficiency, long-life, low-noise mobile intelligent-controlled reciprocating piston pump adopts a carriage-type structure and is separated into a power room and a control room by partition walls. This not only achieves a reasonable division of the equipment and control areas, but also uses three layers of noise-reducing sound insulation panels on all six sides (including corrugated panels, double-layer sound insulation panels and porous sound-absorbing decorative panels, with two air mixing layers) to effectively block noise propagation. At the same time, the control system supports remote intelligent control, can complete data upload, function protection and fault diagnosis, meet unmanned operation needs, and greatly improve the equipment's mobility, noise reduction effect and intelligence level.

[0010] As a preference, the formula for initially setting the safety clearance reference value L is as follows: in, L To initially set the safety gap reference value; S The stroke of the plunger pump is the basic distance parameter of the plunger's reciprocating motion; A is the crankshaft bearing wear clearance; B The loose clearance after the friction is removed for the connecting rod bolt and connecting rod half fixation; C The wear clearance between the crankshaft throw and the connecting rod big end bearing; D The wear clearance between the connecting rod small end bushing and the cross head pin; E Remove the loose gap between the cross head and the intermediate rod thread connection after end face friction; F Remove the loose clearance between the intermediate rod and the plunger thread connection after end face friction; D1 is the inner diameter of the connecting rod big end bearing; D2 is the inner diameter of the connecting rod small end sleeve; is the thermal expansion coefficient of aluminum alloy; S50 It is the average amplitude when the vibration frequency reaches 50Hz.

[0011] The formula for initially setting the safety clearance reference value L comprehensively considers factors such as plunger stroke, wear and loose clearance of various components, thermal expansion coefficient and vibration amplitude. It can accurately determine the safe operation threshold and provide a scientific basis for power end fault diagnosis.

[0012] Preferably, a looseness and wear sensor is installed on the end surface where the plunger at the end of the power end is connected to the intermediate rod, which is used to monitor the looseness of the plunger and the wear clearance of the moving parts, and transmit the monitoring data to the control system.

[0013] The looseness and wear sensor installed at the end of the power end can monitor the looseness of the plunger and the wear clearance of the moving parts in real time, and transmit the data to the control system, so that potential faults can be discovered in time and measures can be taken.

[0014] Preferably, the hydraulic end of the reciprocating plunger pump is equipped with a lubrication and oil-water separation system, which includes an oil tank A, an oil supply valve, a liquid inlet pipeline, a centrifugal pump, an oil replenishing valve, a liquid level gauge and an oil level indicator; the oil tank A transports lubricating oil to the hydraulic end through the oil supply valve and the liquid inlet pipeline driven by the centrifugal pump, and the liquid level gauge and the oil level indicator are used to monitor the oil level in the oil tank A. When the oil level is lower than the set value, the control system opens the oil replenishing valve to replenish the lubricating oil to the oil tank A.

[0015] The lubrication and oil-water separation system of the hydraulic end delivers lubricating oil to the hydraulic end through the oil tank, oil supply valve and other components. Combined with the liquid level monitoring and automatic oil replenishment functions, it ensures that the plunger and packing are always in a good lubrication state, reducing wear.

[0016] Preferably, the lubrication and oil-water separation system also includes a water tank, an oil-water exchange tube, a liquid level exchange tube, a liquid level meter and a solenoid valve B; the cooling water or medium mixed in during the operation of the hydraulic end flows into the water tank through the oil-water exchange tube, and after stratification by density difference, the lubricating oil flows back through the liquid level exchange tube, and the water remains at the bottom of the water tank; the liquid level exchange tube is provided with an upper limit water discharge protection monitoring position and a lower limit water discharge protection monitoring position. When the water level in the water tank reaches the upper limit, the liquid level meter triggers a signal, and the control system opens the solenoid valve B to drain water, and stops draining when the water level is lower than the lower limit.

[0017] The newly added water tank, liquid level exchange tube and other components of the lubrication and oil-water separation system can achieve natural stratification and automatic drainage of oil and water, preventing water from mixing into the lubricating oil and affecting the life of the equipment, and ensuring the stable operation of the lubrication system.

[0018] Preferably, both sound insulation board A and sound insulation board B in the three-layer noise reduction sound insulation board are fireproof sound insulation boards, and the average noise level of the unit measured at 1m with the door closed in the skid-mounted room does not exceed 85dB(A); The base size of the skid-mounted room is 10m×2.8m~10m×3.2m. Customized channel steel is provided on the base corresponding to the installation position of the reciprocating piston pump to support the equipment, and three layers of noise reduction and sound insulation panels (115) are provided at the bottom of the base.

[0019] The three-layer noise reduction and sound insulation panels are made of fireproof materials and ensure that the noise level at 1m after the door of the skid-mounted room is closed does not exceed 85dB(A). At the same time, the base size is adapted and custom channel steel and bottom sound insulation panels are set, which not only meets the fire prevention and noise reduction requirements, but also improves the stability of equipment installation.

[0020] Preferably, the motor of the reciprocating piston pump is equipped with a motor vibration sensor, which is installed on the top of the front and rear bearing seats of the motor, with a distance of no more than 2 mm from the outer ring of the bearing, and is used to collect radial vibration data and transmit it to the control system.

[0021] The motor vibration sensor equipped with the motor can accurately collect radial vibration data and transmit it to the control system. It can timely monitor motor bearing failures, rotor alignment and other problems to ensure the safe operation of the motor.

[0022] Preferably, a pulley looseness sensor is installed at the pulley A of the reciprocating piston pump. The pulley looseness sensor is fixed on the inner side of the protective cover at a position corresponding to the edge of the pulley A. A gap of 3 to 5 mm is maintained between the detection end and the detection convex point on the side of the pulley A, and two detection points are evenly arranged along the circumferential direction.

[0023] The pulley looseness sensor installed at pulley A can effectively detect pulley looseness and belt wear through reasonable installation position and gap setting, and provide early warning of transmission system failure.

[0024] As a preferred option, the reciprocating piston pump's power end is equipped with a forced lubrication filter and a power end level transmitter. The power end level transmitter is inserted vertically into the power end's oil tank, with the bottom of the detection rod maintained 50mm from the tank bottom wall to monitor the lubricant level. The forced lubrication filter installed on the power end purifies the lubricant, and the level transmitter accurately monitors the oil level, ensuring that key power end components are adequately lubricated and of good quality, extending the life of the equipment.

[0025] Preferably, the hydraulic end of the reciprocating plunger pump is equipped with a synchronous exchange device corresponding to the plunger's motion trajectory. This synchronous exchange device integrates a synchronous exchange device liquid level transmitter, solenoid valve A, and a synchronous exchange device pressure transmitter. These three are connected in parallel to the control system to monitor the hydraulic end liquid level and pressure and control oil replenishment. The hydraulic end synchronous exchange device, through the integrated liquid level transmitter, pressure transmitter, and solenoid valve, can monitor the liquid level and pressure in real time and automatically control oil replenishment, ensuring the stable operation of the hydraulic end.

[0026] Compared with the prior art, the technical effects and advantages of the present invention are: The present invention adopts a carriage-type skid-mounted house structure, which can directly realize on-site mobile water injection and flexibly change well locations. It does not require basic projects such as land expropriation and long-term civil construction like traditional water injection stations. It greatly shortens the period from deployment to production, and avoids the problem of site abandonment caused by changes in the water content of oil wells, significantly improving the utilization rate and economy of the equipment.

[0027] This skid-mounted room utilizes three layers of noise-reducing panels on all six sides, combined with an air mixing layer and fire-resistant sound-insulating materials, to create a comprehensive sound-insulating system, effectively reducing noise transmission during equipment operation. Compared to traditional equipment, which suffers from severe noise pollution, this new system can control noise within a standard range even when the door is closed, improving the working environment and meeting environmental and production safety requirements.

[0028] This invention leverages a control system to achieve intelligent remote control and transmission of components such as reciprocating piston pumps, motors, and manifolds. Various sensors monitor the equipment's operating status in real time, including clearances between moving parts at the power end, fluid level pressure at the hydraulic end, and motor vibration. The system also enables data upload, fault diagnosis, and automatic protection. Compared to existing technologies that rely on manual operation and inspections, this system can operate unattended, improving operational stability and reliability while reducing labor costs.

[0029] By utilizing a plunger-aligning structure, a packing seal and lubrication system, and a high-efficiency valve block design, this invention reduces component wear and media leakage, improving both the volumetric coefficient and operational efficiency. Furthermore, the forced lubrication system on the power end and the oil-water separation and automatic oil replenishment mechanisms on the hydraulic end further ensure the stable operation of key components and extend the service life of vulnerable parts. Compared to traditional equipment, this device offers significant improvements in operational efficiency, reliability, and maintenance cycles, better meeting the long-term needs of oilfield and industrial injection processes. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A top cross-sectional view of the present invention; Figure 2 It is the front view of the present invention; Figure 3 It is a left side view of the present invention; Figure 4 It is a partial cross-sectional view of the main viewing direction of the present invention; Figure 5 For the present invention Figure 4 Schematic diagram of the structure of a reciprocating plunger pump; Figure 6 For the present invention Figure 1 A schematic diagram of the structure enlarged in the middle; Figure 7 For the present invention Figure 3 The enlarged structural diagram at B in the middle; Figure 8 Schematic diagram of the internal structure of the power end of the present invention; Figure 9 This is a state change diagram of the detection plate on the power end of the present invention; Figure 10 This is a schematic diagram of key gap parameters of the power end of the present invention; Figure 11 Schematic diagram of the hydraulic end lubrication and liquid level control system of the present invention.

[0031] In the figure: 100, skid-mounted room; 101, partition wall; 102, power room; 103, control room; 104, air conditioner; 105, frequency converter cabinet; 106, outdoor unit; 107, surveillance camera; 108, intelligent exhaust fan; 109, vertical ladder; 110, double door; 111, single door; 112, removable skylight; 113, square tube column; 114, inner hole; 115, three-layer noise reduction insulation Sound board; 1151. Corrugated board; 1152. Sound insulation board A; 1153. Porous sound-absorbing decorative board; 1154. Air mixing layer A; 1155. Air mixing layer B; 1156. Sound insulation board B; 116. Window frame; 117. Doorpost; 118. Base; 119. Top frame; 120. Drainage trough; 121. Wire and cable running frame; 122. Channel steel; 123. Wire interface; 200, reciprocating piston pump; 201, power end; 202, hydraulic end; 203, oil supply tank; 204, electric motor; 205, stilling tank; 206, utility base A; 207, pipeline passage; 208, looseness and wear sensor; 209, pulley A; 210, belt A; 211, protective cover; 212, forced lubrication filter; 213, power end level transmitter; 214, synchronous exchange unit level transmitter; 215, solenoid valve A; 216, synchronous exchange unit pressure transmitter; 217, motor vibration sensor; 218, pulley looseness sensor; 219, pump speed sensor; 210, machine body; 211, crankshaft; 212, connecting rod; 213, crosshead A; 214, crosshead pin; 215, intermediate rod; 216, plunger; 217, detection plate; 218, distance sensor; 301. Liquid inlet manifold; 302. Liquid discharge manifold; 303. Return manifold; 304. Inlet A; 305. Outlet A; 306. Electric throttle valve; 307. Inlet accumulator; 308. Inlet digital pressure transmitter; 309. Inlet pressure gauge; 310. Inlet flow meter; 311. Inlet electric gate valve; 312. Outlet accumulator; 313. Outlet safety valve; 314. Outlet digital pressure transmitter; 315. Outlet pressure gauge; 316. Outlet flow meter; 317. Outlet check valve; 318. Outlet electric gate valve; 401. Fuel tank A; 402. Liquid inlet pipeline; 403. Fuel supply valve; 404. Oil-water exchange pipe; 405. Liquid level exchange pipe; 406. Fuel replenishment valve; 407. Water tank; 408. Liquid level gauge; 409. Liquid level indicator; 410. Oil level indicator; 411. Upper limit water discharge protection monitoring position; 412. Lower limit water discharge protection monitoring position; 413. Solenoid valve B; 414. Centrifugal pump. DETAILED DESCRIPTION

[0032] Before describing in detail any embodiment of the present invention, it should be understood that the present invention is not limited in its application to the construction and arrangement details of the components set forth in the following description or illustrated in the following figures. The present invention is capable of other embodiments and can be practiced or carried out in various ways. In addition, it should be understood that the words and terms used herein are for descriptive purposes and should not be considered restrictive. The use of "including" or "having" and their variations herein is intended to cover the items and their equivalents set forth below and additional items. Unless otherwise specified or limited, the terms "mounted", "connected", "supported" and "coupled" and their variations are used broadly and cover direct mounting and indirect mounting, connection, support and coupling. In addition, "connected" and "coupled" are not limited to physical or mechanical connections or couplings.

[0033] Furthermore, on the first hand, in the disclosure of the present invention, the terms "longitudinal", "transverse", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like to indicate orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings, which are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the mechanism or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore the above terms cannot be understood as limitations on the present invention; on the second hand, the term "one" should be understood as "at least one" or "one or more", that is, in one embodiment, the number of an element may be one, while in another embodiment, the number of the element may be multiple, and the term "one" cannot be understood as a limitation on the quantity.

[0034] Those skilled in the art will appreciate that the embodiments of the present invention described above and shown in the accompanying drawings are intended to be illustrative only and are not intended to limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functional and structural principles of the present invention have been demonstrated and illustrated in the embodiments. Any variations or modifications may be made to the embodiments of the present invention without departing from the principles described.

[0035] The present invention will be described in detail below with reference to the accompanying drawings and in combination with embodiments.

[0036] The following combination Figures 1 to 11 To further explain this application, Example 1 like Figure 1-10 As shown, the embodiment of the present application discloses a high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system, comprising: The skid-mounted room 100 is a carriage-type structure, and is divided into a power room 102 and a control room 103 by a partition wall 101. An air conditioner 104 and a frequency converter cabinet 105 are installed in the control room 103. The external unit 106 of the air conditioner 104 is mounted on the outer wall of the skid-mounted room 100. Surveillance cameras 107 are installed in the power room 102 and the control room 103 respectively. Two sets of intelligent exhaust fans 108 arranged diagonally are embedded in the wall of the power room 102, and one set of intelligent exhaust fans 108 is embedded in the wall of the control room 103. A ladder 109 is installed on the outer wall of the power room 102 for manual climbing to the top of the skid-mounted room 100. Surveillance cameras 107 are also installed on the outer wall of the skid-mounted room 100. The skid-mounted room 100 is provided with two double doors 110 and two single doors 111. One double door 110 and one single door 111 are located at the front side of the skid-mounted room 100. The double door 110 is used for opening and closing the control room 103, and the single door 111 is used for opening and closing the power room 102. Another double door 110 is located on the right side of the skid-mounted room 100, and another single door 111 is located at the rear side of the skid-mounted room 100. Both are used for opening and closing the power room 102. A removable skylight 112 is provided at the top of the skid-mounted room 100, corresponding to the position of the reciprocating piston pump 200, to facilitate lifting during equipment maintenance. The walls of the skid-mounted house 100 are welded together by four-sided square tube columns 113, three-layer noise reduction and sound insulation boards 115, window frames 116, door pillars 117, bases 118, and top frames 119; the drainage grooves 120 on both sides of the top of the skid-mounted house 100 guide the water flow to be discharged, and the water in the drainage grooves 120 flows through the inner holes 114 of the four-sided square tube columns 113, flows through the base 118, and then flows out to the ground. Among them, the three-layer noise reduction and sound insulation boards 115 are used on the walls of the skid-mounted house 100 on all sides, including the top and bottom. The sound insulation board 115 includes, arranged from outside to inside, a corrugated board 1151, a sound insulation board A1152 with built-in sound-absorbing fibers, a sound insulation board B1156 with built-in sound-absorbing fibers, and a porous sound-absorbing decorative board 1153 with built-in sound-absorbing cotton. An air mixing layer A1154 is provided between the sound insulation board A1152 and the sound insulation board B1156, and an air mixing layer B1155 is provided between the sound insulation board B1156 and the porous sound-absorbing decorative board 1153. Both the sound insulation board A1152 and the sound insulation board B1156 are fireproof sound insulation boards. The average noise level of the unit measured at 1m in the skid-mounted room 100 with the door closed shall not exceed 85dB(A).

[0037] A wire and cable runner 121 for the electric control circuit is provided at the bottom of the skid-mounted room 100, and a wire interface 123 is led out from the top of the base 118 of the skid-mounted room 100 according to the installation position of the electric control valve instrument in the manifold; the size of the base 118 of the skid-mounted room 100 is between 10m×2.8m and 10m×3.2m; on the base 118, at the position where the reciprocating piston pump 200 is installed, a channel steel 122 is customized according to the external dimensions of the compound piston pump 216 pump to support the installation of the compound piston pump 216; three layers of noise reduction and sound insulation panels 115 are provided at the bottom of the base 118 to prevent noise from being transmitted from the bottom.

[0038] The base 118 of the skid-mounted room 100 is difficult to cut and machine, so a vertical, parallel, and flat reference surface is formed for assembly, and the inverted reference method is used to fix the assembly and welding. Specifically, the double-supported reciprocating pump and assembly process based on the pump body according to Patent No. 202210931746.9 can be used for assembly. A reciprocating piston pump 200 is installed on a mounting frame in the power room 102. The reciprocating piston pump 200 can be operated intelligently through a control system when unattended. The control system has an intelligent remote control function for the reciprocating piston pump 200, capable of completing data upload, function protection, and fault diagnosis. The reciprocating piston pump 200 includes a power end 201, a hydraulic end 202, an oil replenishing tank 203, an electric motor 204 and a still water tank 205 which are integrated and installed on a common base 118; the core components of the reciprocating piston pump 200 are all integrated and installed on a common base A206 to form a modular overall structure; the common base A206 is welded with main reinforcement channel steel 122 and installed on the base 118, providing a stable installation reference for each component, and a connection hole fixed to the ground is provided at the bottom thereof, and a pipeline passage 207 is reserved.

[0039] like Figure 8 and 9 As shown, the power end 201 includes a body 210, in which a reciprocating member is provided, which is composed of a crankshaft 211, a connecting rod 212, a crosshead A213, an intermediate rod 215, and a plunger 216. Bearings are installed at both ends of the crankshaft 211 to match the body 210. The crankshaft 211 is in transmission connection with the output end of the large pulley A209. One end of a connecting rod 212 is connected to the crankshaft 211 via a bearing, and the other end is connected to a crosshead A213 via a crosshead pin 214. Crosshead A213 is connected to an intermediate rod; the end of the intermediate rod is connected to a plunger 216. A detection plate 217 is provided on the plunger 216 or the intermediate rod, or at the connection between the plunger 216 and the intermediate rod. A distance sensor 218 is provided within the body 210 to monitor changes in the position of the detection plate 217. The power end 201 converts the rotary motion of the motor 204 into reciprocating linear motion of the plunger 216 through a reciprocating motion member, providing power to the hydraulic end 202. A looseness and wear sensor 208 is installed at the connecting end surface of the plunger 216 at the end of the power end 201 and the intermediate rod 215 to monitor the looseness of the plunger 216 and the wear clearance of the moving parts. The hydraulic end 202 is connected to the plunger 216 of the power end 201. The reciprocating motion of the plunger 216 cooperates with the suction valve and the discharge valve to realize the suction and discharge of the medium. The motor 204 is connected to the power end 201 through the pulley A209 and the belt A210. The outer cover of the pulley A209 and the belt A210 is provided with a protective cover 211. The power end 201 is equipped with a forced lubrication filter 212 and a power end liquid level transmitter 213. The pulley A209 includes a large pulley A209 and a small pulley A209. The large pulley A209 and the small pulley A209 are connected by the belt A210. The small pulley A209 is installed at the output end of the motor 204, and the large pulley A209 is installed at the input end of the power end 201. The hydraulic end 202 is provided with a synchronous exchange device corresponding to the motion trajectory of the plunger 216. The main body of the synchronous exchange device is integrated into the side of the housing of the hydraulic end 202. The synchronous exchange device integrates the synchronous exchange device liquid level transmitter 214, the solenoid valve A215 and the synchronous exchange device pressure transmitter 216. Among them, the synchronous exchange device liquid level transmitter 214 is installed on the top of the oil tank body of the hydraulic end 202, the synchronous exchange device pressure transmitter 216 is connected to the side wall of the discharge chamber of the hydraulic end 202 via a thread, and the solenoid valve A215 is connected in series in the oil supply pipeline between the oil supply tank 203 and the hydraulic end 202. The three are connected in parallel to the control system via cables. The motor 204 is equipped with a motor vibration sensor 217, a pulley looseness sensor 218 is installed at the pulley, and a pump speed sensor 219 is provided at the input shaft end of the power end 201; each sensor and transmitter is electrically connected to the control system to realize real-time monitoring and intelligent regulation of the pump body's operating status.

[0040] The motor vibration sensor 217 is installed on the top of the front and rear bearing seats of the motor 204, with a distance from the outer ring of the bearing not exceeding 2 mm, and is used to collect radial vibration data.

[0041] The pulley looseness sensor 218 is fixed on the inner side of the protective cover 211 at a position corresponding to the edge of the pulley A209. Its detection end maintains a gap of 3 to 5 mm with the detection convex point on the side of the pulley A209, and two detection points are evenly arranged along the circumference of the pulley A209.

[0042] The pump speed sensor 219 is fixed on the inner side of the protective cover 211 to detect the rotation speed of the large pulley A209 on the input shaft of the power end 201, and then determine the pump speed of the power end 201.

[0043] The oil replenishing tank 203 is fixed on the support at the top of the power end 201 and is connected to the input end of the forced lubrication filter 212 through a stainless steel pipeline. The forced lubrication filter 212 is installed on the oil distribution block on the side of the power end 201, and its output port is connected to the lubrication points such as the crankshaft 211 bearing and the connecting rod 212 bearing through branch oil pipes.

[0044] The power end liquid level transmitter 213 is vertically inserted into the oil tank of the power end 201, with the bottom of its detection rod kept 50mm away from the bottom wall of the oil tank and connected to the top of the oil tank through a flange; The still water tank 205 is provided on one side of the common base 118 and is connected to the cooling system of the hydraulic end 202 through a pipeline, providing a cooling medium basis for the operation of the equipment; The manifold includes a liquid inlet manifold 301, a liquid discharge manifold 302 and a return manifold 303; the liquid inlet manifold 301, the liquid discharge manifold 302 and the return manifold 303 are fixed to the prefabricated steel plate and the channel steel 122 of the base 118 and fixed with special clips. The liquid inlet manifold 301 and the liquid discharge manifold 302 are respectively connected to the liquid inlet cavity and the liquid discharge cavity of the hydraulic end 202 of the reciprocating piston pump 216, and the liquid inlet manifold 301 and the liquid discharge manifold 302 are respectively fixed to the power end 201 with flange bolts. The liquid inlet manifold is provided with an inlet A304 provided through the skid-mounted room 100; the outlet manifold is provided with an outlet A305 provided through the skid-mounted room 100; the return manifold 303 connected to the liquid inlet manifold and the outlet manifold is also provided with an electric throttle valve 306, which adjusts the flow rate and pressure of the medium in the pipeline through intelligent control of the control system to achieve precise regulation of the operating state of the reciprocating piston pump 216; The inlet manifold 301 is sequentially installed with an imported accumulator 307, an imported digital pressure transmitter 308, an imported pressure gauge 309, an imported flow meter 310 and an imported electric gate valve 311; The outlet manifold is sequentially installed with an outlet accumulator 312, an outlet safety valve 313, an outlet digital pressure transmitter 314, an outlet pressure gauge 315, an outlet flow meter 316, an outlet check valve 317 and an outlet electric gate valve 318; Specifically, an electric throttle valve 306 is installed in the return manifold 303 (the portion connecting the inlet and outlet manifolds). This valve cooperates with the control system to adjust the medium return flow rate in real time. When the system pressure is too high, the electric throttle valve 306 is opened to increase the return flow rate and reduce the discharge pressure, thus preventing equipment damage due to overpressure operation. At the same time, during equipment startup, shutdown, or operating mode switching, the electric throttle valve 306 can slowly adjust the flow rate, reducing the impact of pressure fluctuations on the pump body and manifold, thereby ensuring the stability of system operation. In addition, when combined with monitoring equipment such as mass flow meters and pressure transmitters, the electric throttle valve 306 can automatically adjust according to real-time data, achieving intelligent operation in an unmanned state, further improving the safety and efficiency of the equipment.

[0045] The control system realizes the intelligent operation and intelligent control and remote transmission functions of the reciprocating plunger pump 200, completes data upload, function protection and fault diagnosis, and can be remotely controlled by computer and mobile phone APP through the network platform.

[0046] The centering knot of the plunger 216 of the reciprocating plunger pump 200 can adopt a plunger pump plunger centering structure with patent number ZL201620985139.0, so that the plunger 216 automatically aligns and moves in a straight line without uneven wear, ensuring that the plunger 216 remains parallel to the power end 201 to reduce friction power consumption.

[0047] The reciprocating plunger pump 200 is provided with a lubrication condition for the plunger packing to ensure that the plunger packing forms an operating oil film, exchanges oil and water with the medium, reduces leakage and increases the operating life of the plunger packing. For details, please refer to Patent No. ZL201710059558.0, a reciprocating pump plunger packing sealing and lubrication device; In the valve group design of the reciprocating plunger pump 200, a rotatable double-guide non-metallic sealing conical valve with patent number ZL201220574699.9 and a new double-channel conical valve with patent number ZL201610124225.7 can be used. These can effectively improve the timely and correct sealing and opening and closing of the valve group, without lag or backflow, and improve the volumetric coefficient and unit efficiency.

[0048] The application of the above patent improves the reliability, lifespan and efficiency of the reciprocating piston pump 200 in the skid-mounted room 100, and ensures unmanned operation.

[0049] like Figure 10 As shown, the initial setting safety clearance reference value L of the distance measuring sensor 218 at the power end 201 of the reciprocating plunger pump 200 is calculated by formula (1). Its core function is to determine a reference clearance threshold for safe operation by quantifying the wear, loose clearance, temperature, vibration and other influencing factors of each moving part of the power end 201, thereby providing an accurate judgment basis for the fault diagnosis of the power end 201.

[0050] The looseness and wear sensor 208 of the power end 201 calculates the initial set safety clearance reference value according to the following formula to diagnose the power end 201 fault: Formula (1) in, L Initial setting of safety clearance reference value (mm); S is the plunger pump stroke (mm), which is the basic distance parameter of the reciprocating motion of the plunger 216; A is the crankshaft 211 bearing wear clearance (mm); B The loose clearance (0.02-0.05mm) after the friction force is removed for the connecting rod 212 bolt connecting rod 212 Haff fixation; C The wear clearance between the crankshaft 211 and the connecting rod 212 big end bearing is 0.06-0.24mm. D The wear clearance between the small end sleeve of the connecting rod 212 and the cross pin 214 is 0.02 to 0.12 mm. ERemove the loose clearance (0.02-0.05mm) after end face friction in the threaded connection between the crosshead and the intermediate rod; F A loose clearance (0.02-0.05 mm) is provided for the threaded connection between the intermediate rod 215 and the plunger 216 after removing the end surface friction; D1 is the inner diameter of the connecting rod 212 big end bearing (mm); D2 is the inner diameter of the connecting rod 212 small end sleeve (mm), is the temperature difference between the oil temperature at the equipment ambient temperature and the warning oil temperature (°C); The thermal expansion coefficient of aluminum alloy (in the temperature range of 20-100℃, the thermal expansion is 22-24×10~ for every 1℃ increase in temperature) 6 mm); S 50 It is the average amplitude (0.02~0.0315mm) when the vibration frequency reaches 50Hz; considering the influence of equipment vibration on the gap, the vibration intensity of the motorized reciprocating pump is generally required to be ≤7.1mm / s, and this parameter corresponds to it.

[0051] A, B, C, D, E, F These parameters comprehensively reflect the excessive wear clearance and loose connection clearance of the reciprocating and rotating parts of the power end 201, and are the two main sources of fault diagnosis.

[0052] The (D1×△T×α1+D2×△T×α1) part is used to correct the effect of thermal expansion of components caused by temperature changes on the gap; After the L value is calculated using this formula, when the actual gap monitored by the distance sensor 218 exceeds this reference value, a warning signal will be issued, prompting you to check the fault point of the corresponding cylinder, so as to make timely adjustments to eliminate hidden dangers and prevent the power end 201 from causing accidents such as cylinder pulling, cylinder pushing, cracking of the fuselage 210, breaking of the crankshaft 211, and burning of the crosshead due to excessive operating clearance and loose connections.

[0053] At the hydraulic end 202, the lubricating oil pressed into the space between the plunger 216 and the packing by the oil tank forms a working oil film. The flow of the lubricating oil in the annular gap between the plunger 216 and the packing is a gap flow, which is usually laminar flow. The relevant formula is as follows: Annular gap flow: Formula (2) Annular gap pressure difference: Formula (3) In formula (2) and formula (3), Q is the flow rate (m³ / s); d is the hole diameter (m); δ is the gap amount (m); ; d0 is the shaft diameter (m); Δp is the pressure difference (Pa); ; μ is the dynamic viscosity (Pa·s); L is the gap length (m).

[0054] The relevant judgment of volume coefficient is as follows: According to GB / T9234-2018 "Motorized Reciprocating Pump", the volume coefficients for different discharge pressure ranges are different. By setting the volume coefficient ηv for initial normal operation, a chain alarm is triggered when the measured volume coefficient ηv decreases by 1%. When the value decreases by more than 2% for two consecutive hours and is lower than the lower limit volume, a chain alarm shutdown is implemented to determine various faults in the hydraulic end (202) (failure of various seals in the pump body, internal leakage of the plunger 216 packing, leakage and backflow loss of the valve group sealing surface, etc.). The calculation formula of the volume coefficient ηv is: ηv=Qr / QT, where Qr is the actual discharge flow rate and QT is the inlet feed flow rate.

[0055] like Figure 9 The figure shows the key hardware layout of the power end 201 fault monitoring, which is the basis for achieving real-time monitoring of the gap. The details are as follows: The detection plate 217 is fixed to the moving parts of the power end 201, such as the plunger 216 or the intermediate rod, and reciprocates with the parts, serving as a reference carrier for gap measurement. The distance sensor 218 is installed in the fuselage 210 of the power end 201 and is arranged opposite to the detection plate 217, and is used to collect the distance changes between the two in real time, indirectly reflecting the wear or loose gap of the moving parts.

[0056] The distance sensor 218 continuously monitors the distance between the sensor and the detection plate 217 and transmits the data to the control system. Figure 10 Using the gap parameters and formula 1, the system determines whether the power terminal 201 has an out-of-tolerance gap and triggers a timely warning. This replaces traditional fault diagnosis methods that rely on manual hearing or temperature monitoring, enabling quantitative and automated monitoring of the power terminal 201 gap and improving unmanned operation reliability.

[0057] Example 2 Based on Example 1, the lubrication and oil-water separation system of the reciprocating plunger pump 200 is further described in detail. Figure 11The lubrication, liquid level control, and oil-water separation system of the reciprocating plunger pump 200's hydraulic end 202 is demonstrated. Its core function is to ensure stable operation of key components such as the hydraulic end 202's plunger 216 and packing within the oil film by intelligently regulating the circulation of lubricating oil and cooling water, while also preventing oil-water mixing that could affect the equipment's lifespan. The following is a detailed description of each component: The oil tank A401 serves as the core container for storing lubricating oil. It provides lubricating medium to the hydraulic end 202 through the liquid inlet pipeline 402 and the oil supply valve 403. The oil supply valve 403 is installed on the pipeline between the oil tank A401 and the hydraulic end 202 to control the flow of lubricating oil from the oil tank A401 into the hydraulic end 202. The hydraulic end 202 serves as the core working area of ​​the reciprocating plunger pump 200 and includes components such as the plunger 216 and filler. It receives lubricating oil from the oil tank A401 through the pipeline and is connected to the oil-water exchange pipe 404 and the liquid level exchange pipe 405 to achieve oil-water separation. The oil replenishment valve 406 connects the oil tank A401 with the external oil replenishment source. When the oil level in the oil tank A401 is too low, the lubricating oil is replenished to the oil tank A401 through the oil replenishment valve 406.

[0058] The water tank 407 serves as a container for storing cooling water and is connected to the hydraulic end 202 through the oil-water exchange tube 404. It is used to cool and separate the water in the lubricating oil. The liquid level meter 408 is installed on the oil tank A401. The liquid level meter 409 and the oil level meter 410 are respectively on the liquid level exchange tube 405 to monitor the oil level and water level in real time, and the data is transmitted to the control system.

[0059] Liquid level exchange tube 405 is equipped with upper and lower drain protection monitoring points 411 and 412, which work in conjunction with solenoid valve B413 to control drainage. Solenoid valve B413, in response to commands from the control system, opens or closes the passage to the sewage pipeline, achieving automatic drainage. Centrifugal pump 414 provides power for the entire system, circulating lubricating oil and cooling water through the pipelines.

[0060] The lubricating oil in the oil tank A401 is delivered to the hydraulic end 202 through the oil supply valve 403 and the liquid inlet pipeline 402 under the power of the centrifugal pump 414, forming an oil film in the annular gap between the plunger 216 and the packing, reducing friction and isolating media such as sewage and crude oil.

[0061] When the liquid level gauge 408 / oil level indicator 410 detects that the oil level in tank A401 falls below the set value, the control system opens the oil replenishment valve 406 to replenish lubricating oil in tank A401, ensuring a continuous lubrication supply. During operation of the hydraulic end 202, a small amount of cooling water or medium may mix with the lubricating oil and flow through the oil-water exchange tube 404 into the water tank 407. Due to the different densities of oil and water, they naturally separate in the water tank 407 (oil in the upper layer, water in the lower layer). The separated lubricating oil then flows back to the hydraulic end 202 or tank A401 through the liquid level exchange tube 405 for recycling, while the water remains at the bottom of the water tank 407, awaiting discharge.

[0062] When the water level in the water tank 407 reaches the upper limit water discharge protection monitoring position 411, the liquid level meter 409 triggers a signal, and the control system opens the solenoid valve B413 to discharge excess water through the sewage pipe to prevent water from entering the lubricating oil system and causing emulsification.

[0063] When the water level in the water tank 407 is lower than the lower limit water discharge protection monitoring position 412 or the amount of lubricating oil is insufficient, the system stops draining water to avoid excessive drainage causing air to enter the pipeline.

[0064] During the entire process, the centrifugal pump 414 continuously provides power to ensure that the lubricating oil and cooling water circulate in the liquid inlet line 402, the oil-water exchange pipe 404, and the liquid level exchange pipe 405, thereby maintaining a stable system pressure.

[0065] The operation process of the lubrication and oil-water separation system of the hydraulic end 202 is as follows: the lubricating oil in the oil tank A401 is delivered to the hydraulic end 202 through the oil supply valve 403 and the liquid inlet pipeline 402 under the drive of the centrifugal pump 414, and an oil film is formed in the annular gap between the plunger 216 and the packing to reduce friction and isolate the medium; when the oil level in the oil tank A401 is lower than the set value, the liquid level gauge 408 or the oil level indicator 410 transmits a signal to the control system, opening the oil replenishment valve 406 to replenish the lubricating oil; a small amount of cooling water or medium mixed in during operation of the hydraulic end 202 is discharged through the oil-water exchange pipe 414. 04 flows into the water tank 407 and is naturally stratified due to density differences. The separated lubricating oil flows back to the hydraulic end 202 or oil tank A401 through the liquid level exchange tube 405 for recycling, and the water is retained at the bottom of the water tank 407; when the water level in the water tank 407 reaches the upper limit water discharge protection monitoring position 411, the liquid level sensor 409 triggers a signal, and the control system opens the solenoid valve B413 to discharge the water into the sewage pipe. When the water level is lower than the lower limit water discharge protection monitoring position 412, the drainage is stopped to prevent air from entering the pipeline. The centrifugal pump 414 continues to provide power to ensure the circulation of the medium in the system.

[0066] The control system includes a remote control module, a fault diagnosis module, and a data acquisition and analysis component; The control terminal and platform of the remote control module realize remote operation via computer and mobile phone APP through the network platform. The core functions include equipment start and stop, operating parameter (such as pressure, flow, frequency) setting and adjustment; real-time data query (such as inlet and outlet pressure, flow, motor temperature, lubricating oil level, etc.) and historical data report generation; maintenance time reminder (based on operating time and wearing parts life threshold).

[0067] The frequency converter cabinet 105 receives remote commands to adjust the motor frequency and control the operating speed of the reciprocating piston pump 200; the electric valve inlet electric gate valve 311, outlet electric gate valve 318, electric throttle valve 306, etc. are controlled by remote signals to switch and open, and adjust the manifold flow and pressure; the oil replenishment valve 406, solenoid valve A215, and solenoid valve B413 remotely control the lubricating oil supply, oil-water exchange, and drainage actions.

[0068] The sensors and monitoring points of the fault diagnosis module are deployed in Table 1. Table 1. Deployment of sensors and monitoring points The PLC analog input and output module in the data acquisition and analysis component collects real-time data from sensors and transmitters (such as vibration values, pressure values, and liquid level values); The intelligent module in the data acquisition and analysis component analyzes data based on preset algorithms (such as the volume coefficient formula ηv=Qr / QT and the power end safety clearance formula L) to determine the equipment status.

[0069] Remote control and local protection linkage: Remote commands have a lower priority than local safety protection: When remote start / stop or parameter adjustments could cause equipment overpressure or overtemperature, local sensors trigger protection mechanisms (such as automatic pressure relief from outlet safety valve 313 or motor overload shutdown) and simultaneously report fault information to the remote platform. For example, when remotely adjusting the opening of electric throttle valve 306, if outlet pressure transmitter 314 detects a pressure exceeding a threshold, the system automatically closes the valve and sends an alert to the app.

[0070] Fault diagnosis and response linkage Power end fault: Distance sensor 218 detects that the actual gap exceeds the safety reference value L (according to the formula Calculation), immediately triggering an audible and visual alarm, while the remote platform pushes a "power end gap out of tolerance" warning, prompting you to check the corresponding cylinder; if the gap continues to expand, the system automatically shuts down.

[0071] Hydraulic end failure: When the inlet flow meter 310 and the outlet flow meter 316 detect that the volume coefficient ηv drops by 1% compared with the initial value, a chain alarm is triggered; if the drop exceeds 2% for two consecutive hours and is lower than the lower limit, the system is shut down and the "hydraulic end internal leakage / valve group leakage" fault location and maintenance plan is pushed.

[0072] Lubrication system failure: The power end liquid level transmitter 213 detects that the oil level is too low and automatically opens the oil replenishment valve 406 to replenish oil; if the oil level still does not meet the standard after replenishment, it triggers a shutdown and an alarm.

[0073] Motor failure: If the vibration value collected by the motor vibration sensor 217 exceeds the standard, or the bearing temperature exceeds the set value, the system will first reduce the frequency and issue an early warning; if the fault is not eliminated, it will automatically shut down and push the "motor bearing wear / winding short circuit" diagnosis result.

[0074] Information push mechanism Early warning information (such as a 1% drop in volume coefficient or low oil level) is pushed in real time via APP / WeChat; Alarm information (such as overpressure shutdown and excessive clearance) will simultaneously trigger a text message notification, along with the fault location (such as "wear on the power end of cylinder No. 3") and solution (such as "check the connecting rod bearing clearance").

[0075] The core logic closed-loop process is as follows: real-time monitoring by sensors → data collection by PLC modules → status analysis by intelligent algorithms → determination of normal / warning / alarm → execution of corresponding operations (remote adjustment / local protection) → information push to the terminal → maintenance response records, forming an unmanned closed-loop process.

[0076] This high-efficiency, long-life, low-noise mobile intelligently controlled reciprocating piston pump skid-mounted house features a modular integrated design. The carriage-style skid-mounted house 100 enables overall equipment mobility. The power room 102 and control room 103, separated by a partition wall 101, respectively house the reciprocating piston pump 200 and control components. Multiple doors, a removable skylight 112, and a vertical elevator 109 optimize operation and maintenance convenience. Noise control utilizes six-sided, three-layered sound insulation panels 115 and an air mixing layer, combined with the sound insulation design at the bottom of the base 118, to create a comprehensive soundproofing system. For power transmission, an electric motor 204 drives the reciprocating element at the power end 201 through a pulley assembly, converting rotational motion into linear motion for the plunger 216, which powers the fluid delivery at the hydraulic end 202. Compared to traditional fixed water injection stations, this system eliminates the need for land acquisition and long-term construction, significantly shortening deployment cycles. Furthermore, its mobility allows for easy relocation with wells, eliminating the problem of idle and wasteful sites in traditional water injection stations.

[0077] The power end 201 uses a detection plate 217, a distance sensor 218, and a loose wear sensor 208, combined with a safety clearance calculation formula, to monitor the status of moving parts in real time. The hydraulic end 202 relies on a synchronous exchange device, a flow meter, and a pressure transmitter to achieve medium delivery and status feedback. The electric throttle valve 306 of the manifold system cooperates with the sensor to achieve precise pressure and flow control. The lubrication and oil-water separation system is linked through the oil tank A401, the water tank 407, and the solenoid valve to ensure that the plunger 216 operates in the oil film and automatically separates water. Compared with existing mobile equipment, it breaks through the limitations of relying on manual inspections and realizes remote monitoring, fault warning, and automatic protection through the control system. The volume coefficient monitoring mechanism can detect hidden dangers such as internal leaks in advance, significantly improving unmanned reliability.

[0078] The forced lubrication system on the power end (201) and the oil film lubrication design on the hydraulic end (202) reduce component wear. Patented technology utilizes the valve block seal and plunger (216) for neutral alignment, extending the life of vulnerable parts. A three-layer noise reduction structure and fireproof sound insulation panels (1152 and 1156) ensure noise control meets standards and improves the working environment. Compared with traditional equipment, its efficiency is significantly improved through intelligent control and low-loss design, significantly reducing noise pollution. The modular common base (A206) ​​and customized channel steel (122) mounting structure enhance equipment stability, addressing the low integration, excessive noise, and short lifespan of existing mobile equipment. It is more suitable for the efficient and intelligent needs of oilfield and industrial injection scenarios.

[0079] The above description is merely a description of the preferred embodiment of the present invention and is not to be construed as limiting the scope of the claims. The present invention is not limited to the above embodiment, and variations in the specific structure are permitted. Any variations within the scope of the independent claims of the present invention are also within the scope of protection of the present invention.

Claims

1. A high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system, characterized in that: include: The skid-mounted room (100) is a carriage structure, which is divided into a power room (102) and a control room (103) by a partition wall (101). The power room (102) is used to install a reciprocating piston pump (200), and a frequency conversion cabinet (105) is installed in the control room (103). The skid-mounted room (100) is made of three layers of noise reduction and sound insulation boards (115) from the outside to the inside. The invention sequentially comprises a corrugated board (1151), a sound insulation board A (1152) with built-in sound-absorbing fibers, a sound insulation board B (1156) with built-in sound-absorbing fibers, and a porous sound-absorbing decorative board (1153) with built-in sound-absorbing cotton, wherein an air mixing layer A (1154) is provided between the sound insulation board A (1152) and the sound insulation board B (1156), and an air mixing layer B (1155) is provided between the sound insulation board B (1156) and the porous sound-absorbing decorative board (1153); A reciprocating plunger pump (200) is installed in a skid-mounted room (100). The power end (201) of the reciprocating plunger pump (200) includes a body (210) and a reciprocating motion member consisting of a crankshaft (211), a connecting rod (212), a crosshead A (213), an intermediate rod (215), and a plunger (216). A detection plate (217) is provided on the plunger (216) or the intermediate rod (215) or at the connection between the two. A distance sensor (218) for monitoring position changes of the detection plate (217) is provided in the body (210). The distance sensor (218) calculates an initial set safety clearance reference value L according to a formula. When the actual clearance detected exceeds the reference value, an early warning signal is triggered. A control system can realize the intelligent operation and intelligent control remote transmission functions of the reciprocating plunger pump (200), complete data uploading, function protection and fault diagnosis, and support remote control using a computer and mobile phone APP through a network platform to achieve unmanned operation.

2. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: The formula for the initial setting of the safety clearance reference value L is as follows: in, L To initially set the safety gap reference value; S is the plunger pump stroke, which is the basic distance parameter of the reciprocating motion of the plunger (216); A is the crankshaft (211) bearing wear clearance; B The loose clearance after the friction force is removed by fixing the connecting rod (212) with the bolt connecting rod (212); C The wear clearance between the crankshaft (211) crankshaft and the connecting rod (212) big end bearing; D The wear clearance between the small end sleeve of the connecting rod (212) and the cross pin (214); E Remove the loose gap between the cross head and the intermediate rod thread connection after end face friction; F To remove the loose gap after end face friction between the threaded connection of the intermediate rod (215) and the plunger (216); D1 is the inner diameter of the big end bearing of the connecting rod (212); D2 is the inner diameter of the small end sleeve of the connecting rod (212); is the thermal expansion coefficient of aluminum alloy; S 50 It is the average amplitude when the vibration frequency reaches 50Hz.

3. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: The plunger (216) at the end of the power end (201) is connected to the intermediate rod (215) and is equipped with a looseness and wear sensor (208) on its end surface for monitoring the looseness of the plunger (216) and the wear clearance of the moving parts, and transmitting the monitoring data to the control system.

4. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: The hydraulic end (202) of the reciprocating plunger pump (200) is equipped with a lubrication and oil-water separation system, which includes an oil tank A (401), an oil supply valve (403), a liquid inlet pipeline (402), a centrifugal pump (414), an oil replenishing valve (406), a liquid level gauge (408) and an oil level indicator (410); the oil tank A (401) delivers lubricating oil to the hydraulic end (202) through the oil supply valve (403) and the liquid inlet pipeline (402) under the drive of the centrifugal pump (414); the liquid level gauge (408) and the oil level indicator (410) are used to monitor the oil level in the oil tank A (401); when the oil level is lower than a set value, the control system opens the oil replenishing valve (406) to replenish the lubricating oil to the oil tank A (401).

5. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 4 is characterized by: The lubrication and oil-water separation system further comprises a water tank (407), an oil-water exchange pipe (404), a liquid level exchange pipe (405), a liquid level gauge (409) and a solenoid valve B (413); cooling water or medium mixed in the hydraulic end (202) during operation flows into the water tank (407) through the oil-water exchange pipe (404); after being stratified by density difference, the lubricating oil flows back through the liquid level exchange pipe (405), and the water remains at the bottom of the water tank (407); an upper limit water discharge protection monitoring position (411) and a lower limit water discharge protection monitoring position (412) are provided on the liquid level exchange pipe (405); when the water level in the water tank (407) reaches the upper limit, the liquid level gauge (409) triggers a signal, and the control system opens the solenoid valve B (413) to drain water; when the water level is lower than the lower limit, the drainage is stopped.

6. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: The sound insulation board A (1152) and the sound insulation board B (1156) in the three-layer noise reduction sound insulation board (115) are both fireproof sound insulation boards, and the average noise of the unit measured at 1m in the skid-mounted room (100) with the door closed does not exceed 85dB(A); The base (118) of the skid-mounted room (100) has a size of 10m×2.8m to 10m×3.2m. A customized channel steel (122) is provided on the base (118) corresponding to the installation position of the reciprocating plunger pump (200) to support the equipment, and three layers of noise reduction sound insulation boards (115) are provided at the bottom of the base (118).

7. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: The motor (204) of the reciprocating plunger pump (200) is equipped with a motor vibration sensor (217). The motor vibration sensor (217) is installed on the top of the front and rear bearing seats of the motor (204) and is no more than 2 mm away from the outer ring of the bearing. The motor vibration sensor (217) is used to collect radial vibration data and transmit it to a control system.

8. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: A pulley loosening sensor (218) is installed at the pulley A (209) of the reciprocating piston pump (200). The pulley loosening sensor (218) is fixed at a position corresponding to the edge of the pulley A (209) on the inner side of the protective cover (211). A gap of 3 to 5 mm is maintained between the detection end and the detection convex point on the side of the pulley A (209), and two detection points are evenly arranged along the circumferential direction.

9. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: The power end (201) of the reciprocating plunger pump (200) is equipped with a forced lubrication filter (212) and a power end liquid level transmitter (213). The power end liquid level transmitter (213) is vertically inserted into the oil tank of the power end (201), and the bottom of the detection rod is kept at a distance of 50 mm from the bottom wall of the oil tank, for monitoring the lubricating oil level.

10. The high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating piston pump system according to claim 1 is characterized by: A synchronous exchange device is provided at the hydraulic end (202) of the reciprocating plunger pump (200) corresponding to the motion trajectory of the plunger (216). The synchronous exchange device integrates a synchronous exchange device liquid level transmitter (214), a solenoid valve A (215) and a synchronous exchange device pressure transmitter (216). The three are connected in parallel to a control system for monitoring the liquid level and pressure of the hydraulic end (202) and controlling oil replenishment.

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