Efficient long-life low-noise mobile skid house intelligent control reciprocating plunger pump system

Abstract

This invention relates to the field of oilfield water injection equipment technology, and discloses a high-efficiency, long-life, low-noise mobile skid-mounted intelligent reciprocating plunger pump system. The skid-mounted unit adopts a van-type structure, divided into a power room and a control room by partition walls, achieving reasonable zoning of equipment and control areas. All six sides (surroundings, top, and bottom) are equipped with three layers of noise-reducing and sound-insulating panels. From the outside to the inside, these are corrugated panels, sound-insulating panel A with built-in sound-absorbing fibers, sound-insulating panel B, and a porous sound-absorbing decorative panel with built-in sound-absorbing cotton. An air mixing layer is provided between sound-insulating panels A and B, and between sound-insulating panel B and the porous sound-absorbing decorative panel, effectively blocking noise transmission. The control system supports remote intelligent operation, enabling data uploading, functional protection, and fault diagnosis, meeting the needs of unattended operation. This improves the equipment's mobility, noise reduction effect, and intelligence level. The distance sensor at the power end of the reciprocating plunger pump monitors the gap according to a formula, further ensuring stable equipment operation.

Description

Technical Field

[0001] This invention belongs to the technical field of oilfield water injection equipment, specifically relating to a high-efficiency, long-life, low-noise mobile skid-mounted intelligent control reciprocating plunger pump system. Background Technology

[0002] In oilfield development and industrial injection processes, injecting media into oil reservoirs or industrial systems to replenish pressure is a crucial step in ensuring production efficiency. Traditional injection methods rely on fixed injection stations, requiring land acquisition, civil construction, and equipment installation, with construction periods ranging from several months to over a year. This is not only inefficient but also involves high upfront costs. Furthermore, as the water cut of oil wells increases or industrial demands change, some injection stations may become unusable and be shut down or abandoned, resulting in resource waste.

[0003] In recent years, mobile injection equipment has gradually become an important alternative to fixed water injection stations, but it still has significant technical shortcomings in practical applications: Severe noise pollution: Existing noise control measures for mobile equipment are insufficient, and the noise level during equipment operation often exceeds 100 dB(A). This not only fails to meet the standard requirement of GB / T29529 that "the noise level at 1m during equipment operation shall not exceed 85 dB(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 unattended operation. It requires manual on-site operation and maintenance, which increases labor costs and results in insufficient responsiveness.

[0005] Unreasonable structural design: The equipment has low integration, and the core components such as pumps, motors, and manifolds are scattered. There is a lack of a unified sound insulation and protection structure, which not only affects the stability of equipment operation, but also exacerbates noise diffusion and maintenance difficulties.

[0006] Therefore, developing a mobile injection device with low noise characteristics, high intelligence level and high integration to solve the problems of high cost and long cycle of traditional fixed water injection stations, while overcoming the defects of existing mobile equipment such as noise pollution and insufficient intelligence, has become an urgent need in the oilfield and industrial injection fields. Summary of the Invention

[0007] The present invention aims to solve the technical problems of existing water injection stations, which require land acquisition and long-term civil construction, have long deployment cycles and high costs, and are easily abandoned due to changes in well locations. In addition, existing mobile equipment has insufficient noise control, low level of intelligence, and relies on manual operation, making it difficult to achieve unmanned operation.

[0008] To achieve the above objectives, the present invention provides the following technical solution: A high-efficiency, long-life, low-noise mobile skid-mounted house intelligent reciprocating piston pump system includes: The skid-mounted cabin is a car body structure, divided into a power room and a control room by a partition wall. The power room is used to install a reciprocating plunger pump, and the control room is equipped with a frequency converter cabinet. All six sides of the skid-mounted cabin, including the four sides, the top and the bottom, are made of three layers of noise reduction and sound insulation panels. The three layers of noise reduction and sound insulation panels, from the outside to the inside, include a corrugated board, a sound insulation panel A with built-in sound-absorbing fibers, a sound insulation panel B with built-in sound-absorbing fibers, and a porous sound-absorbing decorative panel with built-in sound-absorbing cotton. An air mixing layer A is set between the sound insulation panel A and the sound insulation panel B, and an air mixing layer B is set between the sound insulation panel B and the porous sound-absorbing decorative panel. The reciprocating piston pump is installed in a skid-mounted compartment. The power end of the reciprocating piston pump includes the machine body and a reciprocating moving part consisting of a crankshaft, connecting rod, crosshead A, intermediate rod, and piston. A detection plate is provided on the piston or intermediate rod or at the connection between the two. A distance sensor is provided in the machine body to monitor the position change of the detection plate. The distance sensor calculates the initial set safety clearance reference value L according to the formula. When the actual clearance detected exceeds the reference value, a warning signal is triggered. The control system enables intelligent operation and remote control of the reciprocating piston pump, completes data uploading, functional protection and fault diagnosis, and supports remote control via computer and mobile APP through network platform to achieve unattended operation.

[0009] This high-efficiency, long-life, low-noise mobile intelligent reciprocating piston pump skid-mounted house adopts a truck-type structure and is divided into a power room and a control room by a partition wall. It not only achieves a reasonable zoning of equipment and control areas, but also effectively blocks noise transmission by using three layers of noise reduction and sound insulation panels (including corrugated board, double-layer sound insulation board and porous sound-absorbing decorative board, combined with two air mixing layers) on all six sides. At the same time, the control system supports remote intelligent operation, can complete data uploading, functional protection and fault diagnosis, meet the needs of unattended operation, and greatly improve the mobility, noise reduction effect and intelligence level of the equipment.

[0010] As a preferred option, the formula for initially setting the safety clearance reference value L is as follows: in, L To initially set the reference value for the safety clearance; S The stroke of a piston pump is the fundamental distance parameter for the reciprocating motion of the piston. A This refers to the wear clearance of the crankshaft bearing. B To remove the loosening clearance after friction is removed from the connecting rod bolt and connecting rod half-fixing; C For the wear clearance of the crankshaft bearing and connecting rod big end bearing; D This is the wear clearance between the small end bushing and the crosshead pin of the connecting rod; E Remove any loose gaps caused by end-face friction in the threaded connection between the crosshead and the center rod; F To remove any loosening clearance caused by end-face friction in the threaded connection between the intermediate rod and the plunger; D1 The inner diameter of the connecting rod big end bearing; D2 The inner diameter of the connecting rod small end bushing; The coefficient of thermal expansion of aluminum alloy; S50 The average amplitude is the vibration frequency when it reaches 50 Hz.

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

[0012] Preferably, a loosening and wear sensor is installed on the end face of the plunger at the end of the power end that connects to the intermediate rod, to monitor the loosening of the plunger and the wear gap of the moving parts, and to transmit the monitoring data to the control system.

[0013] The loosening and wear sensors installed at the end of the power unit can monitor the loosening of the plunger and the wear gap of the moving parts in real time, and transmit the data to the control system to facilitate the timely detection of potential faults and the taking of measures.

[0014] Preferably, the hydraulic end of the reciprocating plunger pump is equipped with a lubrication and oil-water separation system. This system includes an oil tank A, an oil supply valve, an inlet pipeline, a centrifugal pump, a replenishing valve, a level gauge, and an oil level indicator. The oil tank A supplies lubricating oil to the hydraulic end through the oil supply valve and the inlet pipeline under the drive of the centrifugal pump. The level gauge and 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 replenishing valve to replenish lubricating oil to the oil tank A.

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

[0016] Preferably, the lubrication and oil-water separation system also includes a water tank, an oil-water exchange pipe, a level exchange pipe, a level gauge, and a solenoid valve B. Cooling water or media mixed in during the operation of the hydraulic end flows into the water tank through the oil-water exchange pipe. After stratification due to density differences, the lubricating oil flows back through the level exchange pipe, while the water remains at the bottom of the water tank. The level exchange pipe is equipped with an upper limit drain protection monitoring position and a lower limit drain protection monitoring position. When the water level in the tank reaches the upper limit, the level gauge triggers a signal, and the control system opens the solenoid valve B to drain water. When the water level is lower than the lower limit, the draining stops.

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

[0018] As a preferred option, both sound insulation board A and sound insulation board B in the three-layer noise reduction and sound insulation board are fireproof sound insulation boards, and the average noise of the unit measured at 1m in the skid-mounted house with the door closed does not exceed 85dB(A). The base of the skid-mounted house measures 10m×2.8m to 10m×3.2m. Custom-made channel steel is installed on the base to support the reciprocating plunger pump, and three layers of noise reduction and sound insulation panels (115) are installed at the bottom of the base.

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

[0020] Preferably, the reciprocating piston pump is equipped with a motor vibration sensor. The motor vibration sensor is installed on the top of the front and rear bearing housings of the motor, at a distance of no more than 2mm 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 electric motor can accurately collect radial vibration data and transmit it to the control system, which can promptly monitor problems such as motor bearing failure and rotor misalignment, ensuring the safe operation of the motor.

[0022] Preferably, a pulley loosening sensor is installed at pulley A of the reciprocating plunger pump. The pulley loosening sensor is fixed inside the protective cover at the position corresponding to the edge of pulley A. Its detection end maintains a gap of 3-5mm with the detection protrusion on the side of pulley A, and two detection points are evenly arranged along the circumference.

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

[0024] Preferably, the reciprocating plunger pump is equipped with a forced lubrication filter and a power-end level transmitter at the power end. The power-end level transmitter is vertically inserted into the oil tank at the power end, with the bottom of the detection rod 50mm away from the bottom wall of the oil tank, for monitoring the lubricating oil level. The forced lubrication filter at the power end purifies the lubricating oil, and together with the level transmitter, accurately monitors the oil level, ensuring sufficient lubrication and good oil quality for key components at the power end, thus extending the equipment's lifespan.

[0025] Preferably, the hydraulic end of the reciprocating piston pump is equipped with a synchronous exchange device corresponding to the piston's movement trajectory. This synchronous exchange device integrates a synchronous exchange device level transmitter, solenoid valve A, and a synchronous exchange device pressure transmitter, all three connected in parallel to the control system. This system monitors the hydraulic end's level and pressure and controls oil replenishment. Through the integrated level transmitter, pressure transmitter, and solenoid valve, the synchronous exchange device at the hydraulic end can monitor the level and pressure in real time and automatically control oil replenishment, ensuring stable operation of the hydraulic end.

[0026] Compared with the prior art, the technical effects and advantages of the present invention are: This invention adopts a trailer-mounted skid-mounted structure, which can directly realize on-site mobile water injection and flexibly change the well position. Unlike traditional water injection stations, it does not require land acquisition, long-term civil construction and other basic engineering, which greatly shortens the cycle from deployment to production. At the same time, it avoids the problem of site abandonment caused by changes in the water content of oil wells, and significantly improves the utilization rate and economy of the equipment.

[0027] This invention utilizes a three-layer noise-reducing and sound-insulating panel installed on all six sides of the skid-mounted equipment, combined with an air mixing layer and fire-resistant sound-insulating materials, to form a comprehensive sound insulation and noise reduction system, effectively reducing noise transmission during equipment operation. Compared to the severe noise pollution problems of traditional equipment, this invention can control noise within standard ranges when the doors are closed, improving the working environment and meeting environmental protection and safe production requirements.

[0028] This invention utilizes a control system to achieve intelligent remote control of components such as reciprocating plunger pumps, motors, and manifolds. It monitors the equipment's operating status in real time through various sensors, including clearances of moving parts on the power end, liquid level and pressure on the hydraulic end, and motor vibration. The system also enables data uploading, fault diagnosis, and automatic protection. Compared to existing technologies that rely on manual operation and inspection, this invention allows for unattended operation, improving stability and reliability while reducing labor costs.

[0029] This invention reduces component wear and media leakage, and improves volumetric efficiency and operating efficiency by employing a plunger self-aligning structure, a packing seal lubrication device, and a high-efficiency valve group design. Simultaneously, the forced lubrication system on the power end and the oil-water separation and automatic oil replenishment mechanism on the hydraulic end further ensure the stable operation of key components and extend the service life of vulnerable parts. Compared with traditional equipment, it offers significant improvements in operating efficiency, reliability, and maintenance cycle, better meeting the long-term needs of oilfield and industrial injection processes. Attached Figure Description

[0030] Figure 1 This is a top sectional view of the present invention; Figure 2 This is the front view of the present invention; Figure 3 This is the left view of the present invention; Figure 4 This is a partial sectional view in the main view direction of the present invention; Figure 5 For the present invention Figure 4 Schematic diagram of a reciprocating piston pump; Figure 6 For the present invention Figure 1 Enlarged structural diagram at point A; Figure 7 For the present invention Figure 3 Enlarged structural diagram at point B; Figure 8 This is a schematic diagram of the internal structure of the power end of the present invention; Figure 9 This is a diagram showing the state changes of the detection board on the power end of the present invention; Figure 10 This is a schematic diagram of the key clearance parameters of the power end of the present invention; Figure 11 This is a schematic diagram of the hydraulic end lubrication and liquid level control system of the present invention.

[0031] In the diagram: 100. Skid-mounted house; 101. Partition wall; 102. Power room; 103. Control room; 104. Air conditioner; 105. Variable frequency drive cabinet; 106. Outdoor unit; 107. Surveillance camera; 108. Intelligent exhaust fan; 109. Straight elevator; 110. Double door; 111. Single door; 112. Removable skylight; 113. Square tube column; 114. Inner hole; 115. Three-layer noise reduction insulation. Soundboard; 1151, Corrugated board; 1152, Sound insulation board A; 1153, Perforated sound-absorbing decorative board; 1154, Air mixing layer A; 1155, Air mixing layer B; 1156, Sound insulation board B; 116, Window frame; 117, Door post; 118, Base; 119, Top frame; 120, Drainage channel; 121, Cable routing frame; 122, Channel steel; 123, Wire interface; 200. Reciprocating plunger pump; 201. Power end; 202. Hydraulic end; 203. Oil tank; 204. Electric motor; 205. Static water tank; 206. Common seat A; 207. Pipeline passage; 208. Loosening and wear sensor; 209. Pulley A; 210. Belt A; 211. Protective cover; 212. Forced lubrication filter; 213. Power end level transmitter; 214. Synchronous exchange device level transmitter; 215. Solenoid valve A; 216. Synchronous exchange device pressure transmitter; 217. Motor vibration sensor; 218. Pulley loosening sensor; 219. Pump speed sensor; 210. Machine body; 211. Crankshaft; 212. Connecting rod; 213. Crosshead A; 214. Crosshead pin; 215. Intermediate rod; 216. Pulley; 217. Detection plate; 218. Distance sensor; 301. Inlet manifold; 302. Drain 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. Oil tank A; 402. Liquid inlet line; 403. Oil supply valve; 404. Oil-water exchange pipe; 405. Liquid level exchange pipe; 406. Oil 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 Implementation

[0032] Before detailing any embodiment of the invention, it should be understood that the invention, in its application, is not limited to the details of the construction and arrangement of the components set forth in the following description or illustrated in the following figures. The invention can have other embodiments and can be practiced or carried out in various ways. Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered limiting. The use of “comprising” or “having” and variations thereof is intended to cover the items set forth below and their equivalents, as well as any additional items. Unless otherwise specified or limited, the terms “installation,” “connection,” “support,” and “linkage,” and variations thereof are used broadly and cover both direct and indirect installation, connection, support, and linking. Moreover, “connection” and “linkage” are not limited to physical or mechanical connections or links.

[0033] Furthermore, firstly, in the disclosure of this invention, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the mechanism or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the above terms should not be construed as limiting this invention. Secondly, the term "a" should be understood as "at least one" or "one or more," that is, in one embodiment, the number of an element can be one, while in another embodiment, the number of the element can be multiple. The term "a" should not be construed as a limitation on the quantity.

[0034] Those skilled in the art should understand that the embodiments of the present invention described above and shown in the accompanying drawings are merely examples and do not limit the present invention. The objectives of the present invention have been fully and effectively achieved. The functions and structural principles of the present invention have been demonstrated and explained in the embodiments, and any variations or modifications may be made to the implementation of the present invention without departing from the stated principles.

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

[0036] The following combination Figures 1 to 11 This application will be described in further detail. Example 1 like Figure 1-10 As shown in the figure, this application discloses a high-efficiency, long-life, low-noise mobile skid-mounted house intelligent reciprocating piston pump system, including: The skid-mounted building 100 has a carriage structure and is divided into a power room 102 and a control room 103 by a partition wall 101. The control room 103 is equipped with an air conditioner 104 and a frequency converter cabinet 105. The outdoor unit 106 of the air conditioner 104 is installed on the outer wall of the skid-mounted building 100. Surveillance cameras 107 are installed in the power room 102 and the control room 103 respectively. Two sets of intelligent exhaust fans 108 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 straight ladder 109 is installed on the outer wall of the power room 102 for people to climb to the top of the skid-mounted building 100. Surveillance cameras 107 are also installed on the outer wall of the skid-mounted building 100. The skid-mounted building 100 is equipped with two double doors 110 and two single doors 111. One double door 110 and one single door 111 are located on the front side of the skid-mounted building 100. The double door 110 is used to open and close the control room 103, and the single door 111 is used to open and close the power room 102. Another double door 110 is located on the right side of the skid-mounted building 100, and another single door 111 is located on the rear side of the skid-mounted building 100. Both are used to open and close the power room 102. The top of the skid-mounted building 100 is equipped with a removable skylight 112 for easy lifting during equipment maintenance, corresponding to the position of the reciprocating plunger pump 200. The walls of the skid-mounted house 100 are constructed by welding together four square tube columns 113, three layers of noise-reducing and sound-insulating panels 115, window frames 116, doorposts 117, bases 118, and a roof frame 119. Water is guided out through drainage channels 120 on both sides of the top of the skid-mounted house 100, and the water in the drainage channels 120 flows through the inner holes 114 of the four square tube columns 113, passes through the base 118, and then exits to the ground. The walls of the skid-mounted house 100, consisting of six sides (surroundings, top, and bottom), are all constructed with three layers of noise-reducing and sound-insulating panels 115. The sound insulation panel 115 includes, from the outside to the inside, a corrugated board 1151, a sound insulation panel A1152 with built-in sound-absorbing fibers, a sound insulation panel B1156 with built-in sound-absorbing fibers, and a porous sound-absorbing decorative panel 1153 with built-in sound-absorbing cotton. An air mixing layer A1154 is provided between the sound insulation panel A1152 and the sound insulation panel B1156, and an air mixing layer B1155 is provided between the sound insulation panel B1156 and the porous sound-absorbing decorative panel 1153. Both the sound insulation panel A1152 and the sound insulation panel B1156 are fireproof sound insulation panels. With the door closed, the average noise level of the skid-mounted unit measured at 1m did not exceed 85dB(A).

[0037] The skid-mounted house 100 has a cable tray 121 for electrical control circuits at its bottom. The base 118 of the skid-mounted house 100 has a wire interface 123 leading out from it according to the installation position of the electrical control valves and instruments in the manifold. The dimensions of the base 118 of the skid-mounted house 100 are between 10m×2.8m and 10m×3.2m. On the base 118, at the position where the reciprocating plunger pump 200 is installed, a channel steel 122 is custom-installed according to the external dimensions of the reciprocating plunger pump 216 to support the installation of the reciprocating plunger pump 216. Three layers of noise reduction and sound insulation panels 115 are installed at the bottom of the base 118 to prevent noise from being transmitted from the bottom.

[0038] The base 118 of the skid-mounted house 100 is difficult to machine with metal cutting to form a vertical, parallel and straight reference surface for assembly. The inverted reference method is used to fix and weld the positioning. Specifically, the assembly operation can be carried out using a double-support reciprocating pump with the pump body as the reference, as described in patent number 202210931746.9. The reciprocating piston pump 200 is mounted on the mounting bracket of the power compartment 102. The reciprocating piston pump 200 can be operated intelligently through the control system when unattended. The control system has intelligent remote control function for the reciprocating piston pump 200, and can complete data uploading, function protection and fault diagnosis. The reciprocating piston pump 200 includes a power end 201, a hydraulic end 202, a replenishing tank 203, an electric motor 204, and a stilling water tank 205, all integrated and mounted on a common base 118. The core components of the reciprocating piston pump 200 are all integrated and mounted on a common base A206, forming a modular overall structure. The common base A206 is welded from main rib channel steel 122 and mounted on the base 118, providing a stable mounting reference for each component. Its bottom is provided with connection holes for fixing to the ground, and a pipeline passage 207 is reserved.

[0039] like Figure 8 and 9 As shown, the power end 201 includes a body 210, inside which a reciprocating motion component consisting of a crankshaft 211, a connecting rod 212, a crosshead A213, an intermediate rod 215, and a plunger 216 is arranged. Bearings are installed at both ends of the crankshaft 211 to match the body 210. The crankshaft 211 is connected to the output end of the large pulley A209 for transmission. One end of the connecting rod 212 is connected to the crankshaft 211 via a bearing bush, and the other end is connected to the crosshead A213 via a crosshead pin 214, wherein the crosshead A213 is connected to the intermediate rod; the end of the intermediate rod is connected to the 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, and a distance sensor 218 for monitoring the position change of the detection plate 217 is provided inside the body 210; The power end 201 converts the rotational motion of the motor 204 into the reciprocating linear motion of the plunger 216 through the reciprocating motion component, providing power to the hydraulic end 202; a loosening and wear sensor 208 is installed on the end face of the connection between the plunger 216 at the end of the power end 201 and the intermediate rod 215, which is used to monitor the loosening of the plunger 216 and the wear gap 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, in conjunction with the suction valve and discharge valve, enables the intake and discharge of the medium. The motor 204 is connected to the power end 201 via pulley A209 and belt A210. The pulley A209 and belt A210 are covered with protective covers 211. The power end 201 is equipped with a forced lubrication filter 212 and a power end 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 driven by 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. A synchronous exchange device is set up on the hydraulic end 202 corresponding to the movement trajectory of the plunger 216. The main body of the synchronous exchange device is integrated on the side of the housing of the hydraulic end 202. The synchronous exchange device integrates the synchronous exchange device level transmitter 214, the solenoid valve A215 and the synchronous exchange device pressure transmitter 216. Among them, the synchronous exchange device level transmitter 214 is installed on the top of the oil tank 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 by thread, and the solenoid valve A215 is connected in series in the oil replenishment pipeline of the oil replenishment tank 203 and the hydraulic end 202. The three are connected in parallel to the control system through 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; all sensors and transmitters are electrically connected to the control system to realize real-time monitoring and intelligent control of the pump's operating status.

[0040] The motor vibration sensor 217 is installed on the top of the front and rear bearing housings of the motor 204, at a distance of no more than 2mm from the outer ring of the bearing, and is used to collect radial vibration data.

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

[0042] Pump speed sensor 219 is fixed inside the protective cover 211 to detect the rotational speed of the large pulley A209 on the input shaft of the power end 201, thereby determining the pump speed of the power end 201.

[0043] The oil 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 level transmitter 213 is vertically inserted into the oil tank of the power end 201, with the bottom of its detection rod 50mm away from the bottom wall of the oil tank, and is connected to the top of the oil tank through a flange; The still water tank 205 is located on one side of the common base 118 and is connected to the cooling system of the hydraulic end 202 through pipelines, providing a cooling medium foundation for equipment operation; The manifold includes an inlet manifold 301, a outlet manifold 302, and a return manifold 303. The inlet manifold 301, outlet manifold 302, and return manifold 303 are fixed to the precast steel plate and channel steel 122 of the base 118 and secured with special clips. The inlet manifold 301 and outlet manifold 302 are respectively connected to the inlet and outlet chambers of the hydraulic end 202 of the reciprocating plunger 216 pump body. The inlet manifold 301 and outlet manifold 302 are respectively fixed to the power end 201 with flange bolts. The inlet manifold is equipped with an inlet A304 that penetrates the skid-mounted housing 100; the outlet manifold is equipped with an outlet A305 that penetrates the skid-mounted housing 100. The return manifold 303, which connects the inlet and outlet manifolds, is also equipped with an electric throttle valve 306. Through intelligent control of the control system, the flow rate and pressure of the medium in the pipeline are adjusted, achieving precise control of the operating status of the reciprocating plunger 216 pump. The inlet manifold 301 is sequentially equipped 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 equipped 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 part connecting the inlet and outlet manifolds). This valve, in conjunction with the control system, adjusts the 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, preventing equipment damage due to overpressure operation. Simultaneously, during equipment startup, shutdown, or operating condition switching, the electric throttle valve 306 can slowly adjust the flow rate, reducing the impact of pressure fluctuations on the pump body and manifold, ensuring system stability. Furthermore, combined with monitoring equipment such as mass flow meters and pressure transmitters, the electric throttle valve 306 can automatically adjust based on real-time data, achieving intelligent operation in unattended mode, further enhancing equipment safety and efficiency.

[0045] The control system enables intelligent operation and remote control of the reciprocating piston pump 200, completes data uploading, function protection and fault diagnosis, and can be remotely controlled via a network platform using a computer and mobile APP.

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

[0047] The reciprocating piston pump 200 is equipped with lubrication conditions to increase the piston packing, ensuring that the piston packing forms an operating oil film and exchanges oil and water with the medium, reducing leakage and improving the service life of the piston packing. For details, please refer to the reciprocating pump piston packing sealing and lubrication device in patent number ZL201710059558.0. In the valve group design of the reciprocating plunger pump 200, a rotatable double-guided non-metallic sealed cone valve with patent number ZL201220574699.9 and a new type of double-flow cone valve with patent number ZL201610124225.7 can be used to effectively improve the sealing, opening and closing of the valve group in a timely and correct manner, without lag or backflow, thereby improving the volumetric efficiency and unit efficiency.

[0048] The application of the aforementioned patents improves the reliability, lifespan, and efficiency of the reciprocating piston pump 200 inside the skid-mounted house 100, ensuring unattended operation.

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

[0050] The loosening 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 fault of the power end 201: Equation (1) in, L Set the initial safety clearance reference value (mm); S The plunger pump stroke (mm) is the basic distance parameter for the reciprocating motion of plunger 216; A The wear clearance of crankshaft 211 bearing (mm); B The loosening clearance (0.02~0.05mm) after removing friction for connecting rod 212 bolt and connecting rod 212 half fixation. C The wear clearance between the crankshaft 211 bearing and the connecting rod 212 big end bearing is 0.06 to 0.24 mm. D The wear clearance between the small end bushing of connecting rod 212 and crosshead pin 214 is 0.02 to 0.12 mm. ERemove any loose gaps (0.02–0.05 mm) caused by end-face friction in the threaded connection between the crosshead and the center rod. F Remove the loose gap (0.02~0.05mm) after end face friction from the threaded connection between the intermediate rod 215 and the plunger 216. D1 The inner diameter of the connecting rod 212 big end bearing bush (mm); D2 , where is the inner diameter of the small end bushing of connecting rod 212 (mm), and is the temperature difference (°C) between the oil temperature at the ambient temperature and the warning oil temperature. The coefficient of thermal expansion of aluminum alloy (within the temperature range of 20-100℃, the thermal expansion is 22-24×10⁻⁴ for every 1℃ increase in temperature). 6 mm); S 50 The average amplitude (0.02~0.0315mm) is when the vibration frequency reaches 50Hz. The influence of equipment vibration on the clearance is taken into account. The vibration intensity of motorized reciprocating pumps is generally required to be ≤7.1mm / s, and this parameter corresponds to this.

[0051] A, B, C, D, E, F These parameters comprehensively reflect the excessive wear clearance and loose connection clearance of the reciprocating and rotating components 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 for the effect of component thermal expansion caused by temperature changes on the gap; After calculating the L value using this formula, when the actual clearance detected by the distance sensor 218 exceeds this reference value, a warning signal will be issued, prompting an inspection of the corresponding cylinder's fault point, thereby timely adjustment to eliminate hidden dangers and prevent accidents such as cylinder scoring, cylinder knocking, cracked engine block 210, broken crankshaft 211, and burnt crosshead caused by excessive operating clearance and loose connection of the power end 201.

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

[0054] The relevant judgments regarding the volume ratio are as follows: According to GB / T9234-2018 "Motorized Reciprocating Pumps", the volumetric coefficients differ for different discharge pressure ranges. By setting an initial normal operating volumetric coefficient ηv, a 1% decrease in the measured volumetric coefficient ηv triggers a chain alarm. If the value continues to decrease for more than 2% over 2 hours and falls below the lower limit of the total volume, a chain alarm and shutdown are implemented to determine various faults within the hydraulic end (202) (internal leakage from seals within the pump body, leakage from the 216 plunger packing, backflow losses from valve group sealing surfaces, etc.). The formula for calculating the volumetric 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 diagram shows the key hardware layout for fault monitoring of the power unit 201, which is the foundation for achieving real-time gap monitoring. Specific 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 moves back and forth with the parts. It serves as a reference carrier for gap measurement. The distance sensor 218 is installed inside the body 210 of the power end 201 and is set opposite to the detection plate 217. It is used to collect the distance change between the two in real time and indirectly reflect the wear or loosening gap of the moving parts.

[0056] The ranging sensor 218 continuously monitors the distance between itself and the detection plate 217, transmits the data to the control system, and combines it with... Figure 10 The clearance parameters and Formula 1 are used to determine whether there is an out-of-tolerance clearance in the power end 201 and to trigger an early warning in a timely manner. This can replace the traditional fault diagnosis method that relies on manual hearing or temperature monitoring, realize the quantitative and automated monitoring of the clearance of the power end 201, and improve the reliability of unattended operation.

[0057] Example 2 Based on Example 1, the lubrication and oil-water separation system of the reciprocating plunger pump 200 will be further described in detail. Figure 11This demonstration showcases the lubrication, level control, and oil-water separation system of the hydraulic end 202 of the reciprocating piston pump 200. Its core function is to intelligently regulate the circulation of lubricating oil and cooling water to ensure stable operation of key components such as the piston 216 and packing in the hydraulic end 202 within an oil film, while simultaneously preventing oil-water mixing from affecting the equipment's lifespan. Detailed descriptions of each component are as follows: Oil tank A401, as the core container for storing lubricating oil, provides lubricating medium to hydraulic end 202 through inlet pipeline 402 and oil supply valve 403. Oil supply valve 403 is installed on the pipeline between oil tank A401 and hydraulic end 202 to control the flow rate of lubricating oil from oil tank A401 to hydraulic end 202. Hydraulic end 202, as the core working area of ​​reciprocating plunger pump 200, includes plunger 216, packing and other components. It receives lubricating oil from oil tank A401 through pipeline and is connected to oil-water exchange pipe 404 and liquid level exchange pipe 405 to achieve oil-water separation. Oil replenishment valve 406 connects oil tank A401 to an external oil replenishment source. When the oil level in oil tank A401 is too low, lubricating oil is replenished to oil tank A401 through oil replenishment valve 406.

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

[0059] The liquid level exchange pipe 405 is equipped with an upper limit discharge protection monitoring position 411 and a lower limit discharge protection monitoring position 412, which are linked with the solenoid valve B413 to control the drainage action. The solenoid valve B413, under the command of the control system, opens or closes the passage to the sewage drain pipe to realize automatic drainage. The centrifugal pump 414 provides power to the entire system, driving the lubricating oil and cooling water to circulate in the pipeline.

[0060] The lubricating oil in the oil tank A401 is delivered to the hydraulic end 202 by the power of the centrifugal pump 414 through the oil supply valve 403 and the inlet pipeline 402. An oil film is formed in the annular gap between the plunger 216 and the packing, which reduces friction and isolates media such as sewage and crude oil.

[0061] When the level gauge 408 / oil level indicator 410 detects that the oil level in oil tank A401 is lower than the set value, the control system opens the oil replenishment valve 406 to replenish lubricating oil to oil tank A401, ensuring a continuous lubrication supply. During the operation of hydraulic end 202, a small amount of cooling water or medium may mix into the lubricating oil and flow into water tank 407 through oil-water exchange pipe 404. Due to the different densities of oil and water, they naturally separate in water tank 407 (oil on top, water on the bottom). The separated lubricating oil flows back to hydraulic end 202 or oil tank A401 through level exchange pipe 405 for recycling; the water remains at the bottom of 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 level sensor 409 triggers a signal, and the control system opens the solenoid valve B413 to discharge excess water through the sewage drain pipe, preventing water from entering the lubricating oil system and causing emulsification.

[0063] When the water level in 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 to prevent excessive drainage from causing air to enter the pipeline.

[0064] Throughout the process, the centrifugal pump 414 continuously provides power to ensure that the lubricating oil and cooling water circulate in the inlet line 402, the oil-water exchange line 404, and the level exchange line 405, maintaining 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 by the centrifugal pump 414 through the oil supply valve 403 and the inlet pipeline 402, forming an oil film in the annular gap between the plunger 216 and the packing, reducing friction and isolating the medium; when the oil level in the oil tank A401 is lower than the set value, the 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 the operation of the hydraulic end 202 is discharged through the oil-water exchange pipe 4 04 The lubricating oil flows into the water tank 407 and naturally separates due to density differences. The separated lubricating oil flows back to the hydraulic end 202 or the oil tank A401 for recycling through the liquid level exchange pipe 405, while the water remains at the bottom of the water tank 407. When the water level in the water tank 407 reaches the upper limit discharge protection monitoring position 411, the liquid level sensor 409 triggers a signal, and the control system opens the solenoid valve B413 to discharge water into the sewage pipe. When the water level is lower than the lower limit discharge protection monitoring position 412, the drainage stops to prevent air from entering the pipeline. The centrifugal pump 414 continuously provides 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 remote control module's control terminal and platform enable remote operation via computer and mobile APP through a network platform. Core functions include equipment start / stop, setting and adjusting operating parameters (such as pressure, flow, and frequency); real-time data query (such as inlet and outlet pressure, flow, motor temperature, and lubricating oil level) and generation of historical data reports; and maintenance reminders (based on running time and the lifespan threshold of vulnerable parts).

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

[0068] The deployment of sensors and monitoring points for the fault diagnosis module is shown in Table 1. Table 1. Sensor and Monitoring Point Deployment Table The PLC analog input / output module in the data acquisition and analysis component acquires real-time data (such as vibration value, pressure value, liquid level value) from sensors and transmitters. The intelligent module in the data acquisition and analysis component analyzes data and determines the equipment status based on preset algorithms (such as the volume coefficient formula ηv=Qr / QT and the power end safety clearance formula L).

[0069] Remote control and local protection working together: Remote commands have lower priority than local safety protection: When remote start-up, shutdown, or parameter adjustment may cause equipment overpressure or overtemperature, local sensors trigger protection mechanisms (such as automatic pressure relief by outlet safety valve 313 or motor overload shutdown), and simultaneously report fault information to the remote platform. Example: When remotely adjusting the opening of electric throttle valve 306, if the outlet pressure transmitter 314 detects that the pressure exceeds the threshold, the system automatically closes the valve and pushes a warning to the APP.

[0070] Fault diagnosis and response linkage Power-end fault: Distance sensor 218 detected that the actual clearance exceeded the safety reference value L (according to the formula). Upon calculation, an audible and visual alarm is immediately triggered, and a "power end clearance out of tolerance" warning is pushed to the remote platform, prompting the corresponding cylinder block to be checked; if the clearance continues to widen, the system will automatically shut down.

[0071] Hydraulic end fault: When the inlet flow meter 310 and outlet flow meter 316 detect a 1% decrease in the volume coefficient ηv compared to the initial value, a chain warning is issued; if the decrease exceeds 2% for 2 consecutive hours and falls below the lower limit, the system will shut down and push out the fault location and repair plan for "hydraulic end internal leakage / valve group leakage".

[0072] Lubrication system malfunction: The power end 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 is still not up to standard after replenishment, it triggers a shutdown and alarm.

[0073] Motor fault: 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 a warning; if the fault is not eliminated, the system will automatically stop and push the diagnostic result of "motor bearing wear / winding short circuit".

[0074] Information push mechanism Warning information (such as a 1% decrease in volume factor or low oil level) is pushed in real time via APP / WeChat; Alarm information (such as overpressure shutdown, clearance exceeding tolerance) will trigger simultaneous telephone and SMS notifications, along with the location of the fault (such as "wear on the power end of cylinder 3") and solutions (such as "check connecting rod bearing clearance").

[0075] The core logic closed-loop process is as follows: real-time monitoring by sensors → data acquisition by PLC module → status analysis by intelligent algorithm → determination of normal / early warning / alarm → execution of corresponding operations (remote adjustment / local protection) → information push to terminal → maintenance response record, forming a fully unattended closed loop.

[0076] This high-efficiency, long-life, low-noise mobile intelligent reciprocating plunger pump skid-mounted house features a modular integrated design. The vehicle-type skid-mounted house 100 enables overall equipment mobility. The power room 102 and control room 103, separated by partition walls 101, respectively house the reciprocating plunger pump 200 and control components. Multiple doors, a removable skylight 112, and a straight ladder 109 optimize operation and maintenance convenience. Noise control relies on a six-sided, three-layer noise-reducing and sound-insulating panel 115 and an air mixing layer structure, combined with a sound-insulating design at the bottom of the base 118, forming a comprehensive sound insulation system. For power transmission, the electric motor 204 drives the reciprocating motion of the power end 201 via a pulley assembly, converting rotational motion into linear motion of the plunger 216, providing power for the medium transport at the hydraulic end 202. Compared to traditional fixed water injection stations, it eliminates the need for land acquisition and long-term civil engineering, significantly shortening the deployment cycle. Its flexible mobility allows for relocation with the well site, solving the problem of idle and wasteful traditional sites.

[0077] The power end 201 monitors the status of moving parts in real time through a detection plate 217, a distance sensor 218, and a loosening / wear sensor 208, combined with a safety clearance calculation formula. The hydraulic end 202 relies on a synchronous exchange device, a flow meter, and a pressure transmitter to achieve media delivery and status feedback. The electric throttle valve 306 of the manifold system, in conjunction with sensors, completes precise control of pressure and flow. The lubrication and oil-water separation system, through the linkage of oil tank A401, water tank 407, and solenoid valves, ensures that the plunger 216 operates in the oil film and automatically separates water. Compared with existing mobile equipment, it overcomes the limitations of relying on manual inspection, and achieves remote monitoring, fault early warning, and automatic protection through the control system. Moreover, the volume coefficient monitoring mechanism can detect potential problems such as internal leakage in advance, significantly improving the reliability of unattended operation.

[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 improves the alignment of the valve group seal and plunger (216), extending the life of vulnerable parts. A three-layer noise reduction structure and fireproof sound insulation panels (1152, 1156) ensure noise control meets standards, improving the working environment. Compared to traditional equipment, its efficiency is significantly improved through intelligent control and low-loss design, noise pollution is greatly reduced, and the modular common seat (A206) ​​and customized channel steel (122) installation structure enhance equipment stability. This solves the problems of low integration, excessive noise, and short lifespan of existing mobile equipment, making it more suitable for the high-efficiency and intelligent needs of oilfield and industrial injection scenarios.

[0079] The above description only illustrates the preferred embodiments of the present invention and should not be construed as limiting the scope of the claims. The present invention is not limited to the above embodiments, and variations in its specific structure are permitted. All modifications made within the scope of the independent claims of this invention are also within the scope of protection of this invention.

Claims

1. A high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system, characterized in that, include: The skid-mounted cabin (100) is a car body structure, 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 plunger pump (200), and the control room (103) is equipped with a frequency converter cabinet (105). All six sides of the skid-mounted cabin (100), including the four sides, top and bottom, are covered with three layers of noise reduction and sound insulation panels (115). The three layers of noise reduction and sound insulation panels (115) are arranged from the outside to the inside. The system comprises, in sequence, 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. 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 piston pump (200) is installed in a skid-mounted house (100). The power end (201) of the reciprocating piston pump (200) includes a body (210) and a reciprocating motion component consisting of a crankshaft (211), a connecting rod (212), a crosshead A (213), an intermediate rod (215), and a piston (216). A detection plate (217) is provided on the piston (216) or the intermediate rod (215) or at the connection between the two. A distance sensor (218) for monitoring the position change of the detection plate (217) is provided in the body (210). The distance sensor (218) calculates the initial set safety clearance reference value L according to the formula. When the actual clearance detected exceeds the reference value, a warning signal is triggered. The control system enables intelligent operation and remote control of the reciprocating piston pump (200), completes data uploading, function protection and fault diagnosis, and supports remote control via computer and mobile APP through network platform to achieve unattended operation. The formula for initially setting the reference value L of the safety clearance 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 reciprocating motion of the plunger (216); A For the bearing wear clearance of the crankshaft (211); B To remove the loose clearance of the half fixed bolt of the connecting rod (212) after the friction. C For the crankshaft (211) journal and connecting rod (212) big head bush wear clearance; D To connect the rod (212) small head bushing and crosshead pin (214) wear clearance; E To remove the loose clearance after the end face friction of the crosshead and middle rod thread connection; F The intermediate rod (215) and the plunger (216) are connected by screw thread to remove the loose clearance after end face friction. D1 For the big end bearing of the connecting rod (212); D2 For the small end of the connecting rod (212) inner diameter; Cte is the coefficient of thermal expansion for the aluminum alloy; S 50 The average amplitude is for a vibration frequency of 50 Hz.

2. The high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system according to claim 1, characterized in that: A loosening and wear sensor (208) is installed on the end face of the plunger (216) at the end of the power end (201) and the intermediate rod (215) to monitor the loosening of the plunger (216) and the wear gap of the moving parts, and transmit the monitoring data to the control system.

3. The high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system according to claim 1, characterized in that: 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), an inlet pipeline (402), a centrifugal pump (414), a replenishing valve (406), a level gauge (408), and an oil level sensor (410). The oil tank A (401) supplies lubricating oil to the hydraulic end (202) under the drive of the centrifugal pump (414) through the oil supply valve (403) and the inlet pipeline (402). The level gauge (408) and the oil level sensor (410) are used to monitor the oil level of the oil tank A (401). When the oil level is lower than the set value, the control system opens the replenishing valve (406) to replenish the lubricating oil to the oil tank A (401).

4. The high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system according to claim 3, characterized in that: The lubrication and oil-water separation system also includes a water tank (407), an oil-water exchange pipe (404), a level exchange pipe (405), a level gauge (409), and a solenoid valve B (413). Cooling water or medium mixed in during the operation of the hydraulic end (202) flows into the water tank (407) through the oil-water exchange pipe (404). After stratification due to density differences, the lubricating oil flows back through the level exchange pipe (405), and the water remains at the bottom of the water tank (407). The level exchange pipe (405) is equipped with an upper limit water discharge protection monitoring position (411) and a lower limit water discharge protection monitoring position (412). When the water level in the water tank (407) reaches the upper limit, the 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 stops.

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

6. The high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system according to claim 1, characterized in that: The motor (204) of the reciprocating piston pump (200) is equipped with a motor vibration sensor. The motor vibration sensor is installed on the top of the front and rear bearing housings of the motor (204), at 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.

7. The high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system according to claim 1, characterized in that: A pulley loosening sensor is installed at the pulley A (209) of the reciprocating plunger pump (200). The pulley loosening sensor is fixed inside the protective cover at the position corresponding to the edge of the pulley A (209). Its detection end maintains a gap of 3-5mm with the detection protrusion on the side of the pulley A (209), and two detection points are evenly arranged along the circumference.

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

9. The high-efficiency long-life low-noise mobile skid house intelligent control reciprocating plunger pump system according to claim 1, characterized in that: The hydraulic end (202) of the reciprocating plunger pump (200) is equipped with a synchronous exchange device corresponding to the plunger movement trajectory. The synchronous exchange device integrates the synchronous exchange device level transmitter, solenoid valve A and synchronous exchange device pressure transmitter. The three are connected in parallel to the control system to monitor the liquid level and pressure of the hydraulic end (202) and control the oil replenishment.

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