Intelligent operation and maintenance system and method for fracturing plug valve

Abstract

The invention discloses an intelligent operation and maintenance system and method for a fracturing plug valve, and the system comprises a plurality of monitoring devices, a control unit, and a plurality of execution devices. The multiple monitoring devices are used for monitoring the working pressure of the plug valve, the torque value of the valve rod when the plug valve is opened and closed, the rotating angle of the valve rod, the temperature of the liquid inlet end and the liquid outlet end of a fluid channel of the plug valve and the sound at the connecting positions of the two ends of the fluid channel and external equipment. The multiple execution devices are used for conducting grease injection, cleaning and sand discharging operation on the plug valve. The control unit is in communication connection with the monitoring devices and the execution devices and used for judging whether the running state of the plug valve needs to be maintained or not according to data monitored by the monitoring devices and controlling the corresponding execution devices to conduct grease injection, cleaning and sand discharging operation on the plug valve or stop fracturing operation. And corresponding prompt information is sent. According to the invention, the maintenance opportunity of the plug valve can be accurately judged, and the corresponding maintenance operation is executed.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of operating and maintaining plug valves. More particularly, the present application relates to an intelligent operating and maintaining system and method for fracturing plug valves. BACKGROUND

[0002] In the working conditions of ultra-fine sand fracturing, testing, etc., in order to ensure that the plug valve does not leak and maintain normal working state, reduce operation interruption and downtime and improve operation efficiency, it is necessary to frequently maintain the plug valve. In the prior art, Chinese patent CN202210589246.1 discloses a lubricating method and lubricating equipment, the lubricating method is suitable for a lubricating system for controlling the lubricating equipment to lubricate the plug valve; the lubricating method comprises: accessing locking data of the plug valve, and marking the plug valve as a valve to be lubricated if the locking data indicates that the plug valve is not locked; accessing opening and closing data of the valve to be lubricated; if the valve to be lubricated is in an open state, issuing a lubricating instruction; if the valve to be lubricated is in a closed state, issuing a first prompt information; and when a first instruction for opening the valve to be lubricated is received, to solve the problem of low efficiency of manually lubricating the plug valve in the prior art. Chinese patent CN202211293600.2 discloses a lubricating system for plug valves and fracturing equipment, the lubricating system is used for injecting lubricating grease into the plug valve, and the lubricating system comprises a power mechanism and a flow control valve group; the power mechanism comprises a driving motor, a hydraulic pump and a hydraulic oil tank, the driving motor is connected with the hydraulic pump, to solve the problem of high difficulty in lubricating the plug valve. The prior art mainly solves the problems of difficulty and low efficiency in lubricating the plug valve through the automation of the lubricating system, but there is no better equipment and method to accurately determine the maintenance time of the plug valve according to the online operating state of the plug valve to perform intelligent maintenance operations such as lubrication, cleaning and sand removal. SUMMARY

[0003] An object of the present application is to solve at least the above problems and to provide at least the advantages to be described later.

[0004] In order to achieve the purposes and other advantages according to the present application, a fracturing plug valve intelligent operation and maintenance system is provided, comprising: a plurality of monitoring devices, a control unit and a plurality of execution devices, the plurality of monitoring devices are respectively used to monitor the working pressure of the plug valve, the torque value of the valve rod when the plug valve is switched, the rotation angle of the valve rod, the temperature of the liquid inlet and outlet of the fluid passage of the plug valve, and the sound at the connection between the two ends of the fluid passage and the external equipment; the plurality of execution devices are respectively used to perform grease injection, cleaning and sand removal operations on the plug valve; the control unit is respectively connected with each monitoring device and each execution device, judges whether the running state of the plug valve needs to be maintained according to the data monitored by each monitoring device, controls the corresponding execution device to perform grease injection, cleaning, sand removal operation or stop fracturing operation on the plug valve, and sends the corresponding prompt information.

[0005] Preferably, the plurality of monitoring devices are respectively a pressure sensor, a torque sensor, an image sensor, an infrared thermal imager and an acoustic emission sensor; the pressure sensor is arranged in the fluid passage of the plug valve to monitor the working pressure of the plug valve; the torque sensor is arranged on the valve rod of the plug valve to monitor the torque value of the valve rod when the plug valve is switched; the image sensor is arranged above the plug valve to monitor the rotation angle of the valve rod; the infrared thermal imager is arranged above the plug valve to monitor the temperature of the two ends of the fluid passage; the acoustic emission sensor is arranged at the connection between the two ends of the fluid passage and the external equipment to monitor whether there is a leakage sound at the corresponding position.

[0006] Preferably, the control unit comprises a processor, a memory, a field bus, an input / output interface and a communication interface; the memory is used to store the monitoring data of each monitoring device; the processor retrieves the monitoring data from the memory for calculation, judges the working state of the plug valve, and generates execution instructions and prompt information; the communication interface is used for data transmission between the processor and each monitoring device and each execution device; the input / output interface is used to obtain monitoring data from each monitoring device or output execution instructions to each execution device; the field bus is used for data exchange between the processor, the memory, each monitoring device and each execution device.

[0007] Preferably, each execution device is respectively a grease injection device, a cleaning device and a sand removal device; a lubricating passage, a flushing passage and a sand removal passage are respectively arranged on the plug valve and communicated with the valve cavity; the grease injection device controls the valve to be communicated with the lubricating passage through the lubricating passage control valve; the cleaning device controls the valve to be communicated with the flushing passage through the flushing passage control valve; the sand removal device controls the valve to be communicated with the sand removal passage through the sand removal passage control valve; the lubricating passage control valve, the flushing passage control valve and the sand removal passage control valve are respectively connected with the control unit.

[0008] Preferably, the grease injection device comprises a grease injection hydraulic cylinder, a hydraulic control device, a grease injection pressure sensor; the liquid outlet of the grease injection hydraulic cylinder is connected with the lubrication channel control valve through a grease injection pipeline; the hydraulic control device is connected with the grease injection hydraulic cylinder through a hydraulic pipeline to control the grease injection amount of the grease injection hydraulic cylinder; the grease injection pressure sensor is arranged at the oil outlet of the hydraulic control device to monitor the pressure of the hydraulic oil output by the hydraulic control device.

[0009] Preferably, the cleaning device comprises a stainless steel crankshaft pump, a reversing valve, a cleaning pressure sensor, an acid liquid tank and an alkali liquid tank; the output ends of the stainless steel crankshaft pump and the reversing valve are connected, the input ends of the reversing valve are connected with the acid liquid tank and the alkali liquid tank respectively; the cleaning pressure sensor is arranged at the liquid outlet of the stainless steel crankshaft pump; the liquid outlet of the stainless steel crankshaft pump is connected with the flushing channel control valve through a flushing pipeline, and a first pressure regulating valve is arranged on the flushing pipeline.

[0010] Preferably, the sand discharging device comprises a stainless steel high-temperature plunger pump, a sand discharging pressure sensor, a stop valve and a sand discharging liquid tank; the stainless steel high-temperature plunger pump and the stop valve are connected, and the stop valve is connected with the sand discharging liquid tank; the sand discharging pressure sensor is arranged at the liquid outlet of the stainless steel high-temperature plunger pump; the liquid outlet of the stainless steel high-temperature plunger pump is connected with the sand discharging channel control valve through a sand discharging pipeline, and a second pressure regulating valve is arranged on the sand discharging pipeline.

[0011] The present application also has the purpose of providing a fracturing plug valve intelligent operation and maintenance method, using the fracturing plug valve intelligent operation and maintenance system, comprising the following steps: S1, collect the historical data of the working pressure of the plug valve when it works normally and the torque of the valve rod when it is opened, obtain the real-time working pressure of the plug valve and the current torque of the valve rod when it is opened, compare the current torque value and the historical torque value under the corresponding working pressure; if 1.1 times the historical torque value < current torque value ≤ 1.3 times the historical torque value, send a prompt information of grease injection operation, and open the execution device to inject grease to the plug valve; if the current torque value > 1.3 times the historical torque value, go to step S2; S2, set the valve stem at 0° position when the cock valve is fully opened, the valve stem is at 90° position when the cock valve is fully closed; the rotation angle of the cock valve stem is obtained, if 0° < the rotation angle of the valve stem < 15° or 75° < the rotation angle of the valve stem < 90°, and 1.3 times of the historical torque value < the current torque value ≤ 1.5 times of the historical torque value, the prompt information of grease injection and cleaning operation is sent, the execution device is opened to clean the valve cavity of the cock valve first, and then the cock valve is injected with grease; if 15° ≤ the rotation angle of the valve stem ≤ 75°, and 1.3 times of the historical torque value < the current torque value ≤ 1.5 times of the historical torque value, the sand sticking alarm prompt information is sent; the fracturing operation is stopped, and the execution device is opened to clean and desand the valve cavity of the cock valve in turn, and then the cock valve is injected with grease; S3, the temperature of the liquid inlet end and the liquid outlet end of the cock valve fluid passage is obtained, if the temperature difference of the two ends is ≥ 10℃, the erosion throttling alarm prompt information is sent; the fracturing operation is stopped, and the valve core of the cock valve is replaced; S4, the sound of the two ends of the cock valve fluid passage and the external equipment connection is obtained, if the sound of fluid leakage appears, the leakage alarm prompt information is sent; the fracturing operation is stopped, and the sealing element of the cock valve is replaced.

[0012] The present application at least includes the following beneficial effects: The intelligent operation and maintenance system and method of the fracturing cock valve provided by the present application realize accurate judgment of the maintenance time of the cock valve through monitoring and analysis of multiple parameters in the operation process of the cock valve, and corresponding maintenance operation is performed. The problem of low operation efficiency caused by operation interruption or shutdown due to the fact that the cock valve cannot maintain normal working state because of untimely sand cleaning or untimely grease injection under the working conditions of superfine sand fracturing, testing and the like is solved.

[0013] Other advantages, objects and features of the present application will be partly embodied by the following description, and partly understood by those skilled in the art through research and practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 It is a schematic diagram of the installation position of the monitoring device in the intelligent operation and maintenance system of the fracturing cock valve described in the present application; Figure 2 It is a schematic diagram of the installation position of the monitoring device in the intelligent operation and maintenance system of the fracturing cock valve described in the present application; Figure 1 It is a schematic diagram of the installation position of the monitoring device in the intelligent operation and maintenance system of the fracturing cock valve described in the present application; Figure 3 It is a schematic diagram of the structure of the grease injection device described in the present application; Figure 4 It is a schematic diagram of the structure of the cleaning device described in the present application; Figure 5 It is a schematic diagram of the structure of the sand discharge device described in the present application; DETAILED DESCRIPTION

[0015] The application will be further described in detail below with reference to the drawings, so that those skilled in the art can implement the application according to the description.

[0016] It should be noted that the experimental methods in the following embodiments are conventional methods, and the reagents and materials are commercially available unless otherwise specified. In the description of the application, the terms "lateral", "longitudinal", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. indicate the orientation or positional relationship shown in the drawings, and are only used for the convenience of describing the application and simplifying the description, and do not indicate or imply that the devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the application.

[0017] As shown in Figures 1 to 5 The application provides a fracturing plug valve intelligent operation and maintenance system, which comprises a plurality of monitoring devices, a control unit and a plurality of execution devices. The plurality of monitoring devices are respectively used to monitor the working pressure of the plug valve 1, the torque value of the valve rod 2 when the plug valve 1 is switched, the rotation angle of the valve rod 2, the temperature of the liquid inlet end and the liquid outlet end of the fluid passage 7 of the plug valve, and the sound at the connection between the two ends of the fluid passage 7 and the external equipment. The plurality of execution devices are respectively used to perform grease injection, cleaning and sand removal operations on the plug valve 1. The control unit is in communication connection with each monitoring device and each execution device. According to the data monitored by each monitoring device, it is determined whether the running state of the plug valve needs to be maintained, and the corresponding execution device is controlled to perform grease injection, cleaning, sand removal operations or stop fracturing operation on the plug valve, and the corresponding prompt information is sent.

[0018] In this technical solution, the plug valve is a plug valve structure commonly used in fracturing operations in the prior art, as shown in Figure 1The valve body and the valve stem 2, the valve core and the fluid passage 7 arranged in the valve body are connected, and the connection relationship of the above components is the prior art, which will not be described here. The real-time running state of the plug valve 1 is monitored by a plurality of monitoring devices, and then the control unit determines whether the running state of the plug valve 1 needs to be maintained according to the monitored data. If it is needed, the corresponding execution device is started to perform one or more operations of lubricating, cleaning and sand removal in sequence. When the running state of the plug valve cannot meet the fracturing operation requirement, the control unit sends a prompt information to stop the fracturing operation, and the plug valve core or the sealing gasket is replaced. The control unit can send the prompt information to the mobile terminal or the fracturing operation control system. The intelligent operation and maintenance system of the plug valve solves the problem of low operation efficiency caused by the interruption or shutdown of the operation due to the failure of the plug valve to maintain the normal working state because of the untimely sand cleaning or lubricating under the working conditions of ultra-fine sand fracturing and testing.

[0019] In another technical solution, the plurality of monitoring devices are respectively a pressure sensor, a torque sensor 5, an image sensor 3, an infrared thermal imager 4 and an acoustic emission sensor 6; the pressure sensor is arranged in the fluid passage 7 of the plug valve 1 to monitor the working pressure of the plug valve 1; the torque sensor 5 is arranged on the valve stem 2 of the plug valve 1 to monitor the torque value of the valve stem 2 when the plug valve 1 is opened or closed; the image sensor 3 is arranged above the plug valve 1 to monitor the rotation angle of the valve stem 2, and a CMOS sensor can be specifically used; the infrared thermal imager 4 is arranged above the plug valve 1 to monitor the temperature at both ends of the fluid passage 7; and the acoustic emission sensor 6 is arranged at the connection position between the fluid passage 7 and the external equipment to monitor whether the corresponding position has a leakage sound.

[0020] The image sensor 3 is fixedly arranged above the plug valve 1 by a support and faces the valve stem 2; the distance between the image sensor 3 and the valve stem 2 needs to at least meet the requirement that the image range monitored by the image sensor 3 can cover the top surface of the valve stem 2; and the control unit judges the rotation angle of the valve stem 2 according to the image of the valve stem 2 captured by the image sensor 3. Similarly, referring to Figure 1 , the infrared thermal imager 4 is arranged above the plug valve 1 by a support and is fixed after the focal length of the infrared thermal imager 4 is adjusted. The distance between the infrared thermal imager 4 and the plug valve 1 needs to at least meet the requirement that the infrared thermal image of the plug valve 1 can be completely acquired, and specifically, the distance between the infrared thermal imager 4 and the plug valve 1 = total outer size of the plug valve 1 / angular resolution of the infrared thermal imager 4, and the optimal distance is generally set to 24 m to effectively control the temperature drift of the infrared thermal imager. The pressure sensor, the torque sensor 5 and the acoustic emission sensor 6 all monitor the corresponding data in a conventional manner.

[0021] In another technical solution, the control unit comprises a processor, a memory, a field bus, an input-output interface and a communication interface; the memory is used to store monitoring data of each monitoring device; the processor retrieves monitoring data from the memory for calculation, judges the working state of the plug valve, and generates an execution instruction; the communication interface is used for data transmission between the processor and each monitoring device and each execution device; the input-output interface is used to obtain monitoring data from each monitoring device or output an execution instruction to each execution device; the field bus is used for data exchange between the processor, the memory, each monitoring device and each execution device. The memory is used to store data or images monitored by the pressure sensor, the torque sensor, the image sensor, the noise sensor, the acoustic emission sensor and the infrared thermal imager in real time, store historical data sets of the working pressure of the plug valve 1 and the torque of the valve stem 2, and an image reference database of the valve stem 2 at different angles. The processor is used to compare the current torque value and the historical torque value of the valve stem 2 at the corresponding working pressure, complete real-time matching of the valve stem image at different rotation angles, calculate the temperature difference between the two ends of the fluid passage in the infrared radiation image of the plug valve 1, extract sound information leaked from the plug valve, and generate corresponding prompt information. The data monitored by each monitoring device is transmitted to the processor through the input-output interface, the communication interface and the field bus in turn, and stored in the memory. The execution instruction of the processor is transmitted to the corresponding execution device through the field bus, the communication interface and the input-output interface in turn. Further, the control unit further comprises a man-machine interaction screen connected with the input-output interface, which is used to display the real-time torque value, working pressure, valve stem 2 rotation angle, plug valve 1 running infrared thermal image, maximum temperature difference between the two ends of the fluid passage of the plug valve 1, receive and display the plug valve sand sticking alarm information, erosion throttling alarm prompt information and grease injection, flushing, sand removal, stop working prompt information generated by the processor, and at the same time, the grease injection, flushing, sand removal and stop working operation contacts are provided for manually starting each operation and maintenance process when the automatic program fails.

[0022] In another technical solution, each of the execution devices is a lubricating device, a cleaning device and a sand discharging device; the plug valve 1 is respectively provided with a lubricating channel, a flushing channel and a sand discharging channel which are in communication with the valve cavity; the lubricating device is connected with the lubricating channel through the lubricating channel control valve 12; the cleaning device is connected with the flushing channel through the flushing channel control valve 11; the sand discharging device is connected with the sand discharging channel through the sand discharging channel control valve 8; the lubricating channel control valve 12, the flushing channel control valve 11 and the sand discharging channel control valve 8 are connected with the control unit respectively. Specifically, the execution mechanisms in the lubricating channel control valve 12, the flushing channel control valve 11 and the sand discharging channel control valve 8 are connected with the input and output interface respectively to receive the execution instructions of the processor.

[0023] With reference to Figure 3 , the lubricating device comprises a lubricating hydraulic cylinder 15, a hydraulic control device and a lubricating pressure sensor 21; the outlet of the lubricating hydraulic cylinder 15 is connected with the lubricating channel control valve 12 through a lubricating pipeline 13; the hydraulic control device is connected with the lubricating hydraulic cylinder 15 through a hydraulic pipeline to control the lubricating amount of the lubricating hydraulic cylinder 15; the lubricating pressure sensor 21 is arranged at the oil outlet of the hydraulic control device to monitor the pressure of the hydraulic oil output by the hydraulic control device. Specifically, the lubricating hydraulic cylinder 15 is fixed near the plug valve 1 through a mounting bracket and comprises a hydraulic cylinder, a grease storage cylinder, a top cover, a displacement sensor 16 and an exhaust valve 14. The exhaust valve 14 is used when adding sealing grease into the grease storage cylinder. The top of the piston of the hydraulic cylinder extends into the grease storage cylinder, the top of the grease storage cylinder is connected with the top cover, and the exhaust valve 14 is installed on the top cover; the displacement sensor 16 is installed at the bottom of the hydraulic cylinder and extends into the core of the piston to detect the position of the piston. A sealing grease outlet is arranged on the top cover and connected with the lubricating channel control valve 12 through the lubricating pipeline 13. The hydraulic control device comprises a first driving motor 20, a hydraulic pump 19, a first reversing valve 17, an overflow valve 18 and a hydraulic oil tank. The hydraulic pump 19 is installed in the hydraulic oil tank, and the first driving motor 20 is installed outside the hydraulic oil tank to drive the hydraulic pump 19. The hydraulic pump 19 is connected with the first reversing valve 17 and the overflow valve 18 through a pipeline. The first reversing valve 17 is connected with the lower cavity of the hydraulic cylinder through an upstroke hydraulic pipeline 22 and connected with the upper cavity of the hydraulic cylinder through a piston reset hydraulic pipeline 23. The first reversing valve 17 is connected with the lubricating pressure sensor 21 to monitor the pressure of the hydraulic oil output by the hydraulic pump 19. The first reversing valve 17 is also connected with the overflow valve 18 to facilitate the return of the hydraulic oil in the pipeline to the hydraulic oil tank.

[0024] When the stopcock valve 1 needs grease injection, the processor issues an execution command to sequentially control the lubrication channel control valve 12 and the first drive motor 20 to open. The first drive motor 20 drives the hydraulic pump 19 to draw low-pressure oil from the hydraulic oil tank and pressurize it into high-pressure hydraulic oil. The processor also controls the first reversing valve 17 to open, allowing the high-pressure hydraulic oil to enter the lower chamber of the hydraulic cylinder through the piston-up hydraulic line 22, pushing the piston upward to the required position. As the piston moves upward, the grease flows from the grease outlet on the top cover of the grease injection cylinder through the grease injection line 13 and the lubrication channel control valve 12 into the valve chamber. The displacement sensor and the grease injection pressure sensor 21 are both communicatively connected to the control unit. The processor calculates the grease injection amount based on the piston position and determines whether to stop grease injection. It also uses the hydraulic oil pressure to determine whether the hydraulic pump 19 is working properly and whether it is delivering grease correctly, preventing the grease injection line 13 from becoming blocked due to cold weather or aging. After grease injection is complete, the processor issues an execution command to sequentially control the first reversing valve 17, the lubrication channel control valve 12, and the first drive motor 20 to close.

[0025] Reference Figure 4 The cleaning device includes a stainless steel crankshaft pump 25, a reversing valve 26, a cleaning pressure sensor 30, an acid tank 27, and an alkali tank 28. The output ends of the stainless steel crankshaft pump 25 and the reversing valve 26 are connected, and the input ends of the reversing valve 26 are connected to the acid tank 27 and the alkali tank 28, respectively. The cleaning pressure sensor 30 is located at the outlet end of the stainless steel crankshaft pump 25. The outlet end of the stainless steel crankshaft pump 25 is connected to the flushing channel control valve 11 through a flushing pipeline 10, and a first pressure regulating valve 24 is provided on the flushing pipeline 10. The stainless steel crankshaft pump 25 is driven by a second drive motor 29.

[0026] When the stopcock valve 1 needs cleaning, first disconnect the sand discharge pipeline 8 from the sand discharge channel control valve 9; the processor issues an execution command to control the lubrication channel control valve 12 and the sand discharge channel control valve 9 to close; then sequentially control the flushing channel control valve 11, the reversing valve 26, and the second drive motor 29 to open; at this time, the reversing valve 26 connects the stainless steel crankshaft pump 25 to the acid tank 27 or the alkali tank 28, and the stainless steel crankshaft pump 25 draws in low-pressure cleaning fluid from the acid tank 27 or the alkali tank 28 and pressurizes it into high-pressure cleaning fluid; the processor obtains the data monitored by the cleaning pressure sensor 30, and then adjusts the pressure of the high-pressure cleaning fluid output by the stainless steel crankshaft pump by adjusting the first pressure regulating valve 24; when the monitored high-pressure cleaning fluid pressure drops significantly compared to the start of cleaning, it indicates that the thickened and clumped impurities inside the stopcock valve have been significantly softened and loosened; then the sand discharge channel control valve 9 is controlled to drain the reacted acid or alkali from the stopcock valve. After the cleaning work is completed, the processor issues an execution command to sequentially control the sand discharge channel control valve 9, the cleaning channel control valve 11, the reversing valve 26, and the second drive valve 29 to close.

[0027] Reference Figure 5 The sand removal device includes a stainless steel high-temperature plunger pump 32, a sand removal pressure sensor 38, a shut-off valve 33, and a sand removal liquid tank 35. The stainless steel high-temperature plunger pump 32 is connected to the shut-off valve 33, and the shut-off valve 33 is connected to the sand removal liquid tank 35. The sand removal pressure sensor 38 is located at the outlet end of the stainless steel high-temperature plunger pump 32. The outlet end of the stainless steel high-temperature plunger pump 32 is connected to the sand removal channel control valve 9 through a sand removal pipeline 8, and a second pressure regulating valve 31 is provided on the sand removal pipeline 8. The stainless steel high-temperature plunger pump 32 is driven by a third drive motor 37.

[0028] When the stopcock valve 1 needs to discharge sand, the flushing pipeline 10 is disconnected from the flushing channel control valve 11; the processor issues an execution command to control the lubrication channel control valve 12 and the flushing channel control valve 11 to close; the processor then sequentially controls the sand discharge channel control valve 9, the shut-off valve 33, and the third drive motor 37 to open, and the third drive motor 37 drives the stainless steel high-temperature plunger pump 32 to draw low-pressure sand discharge liquid from the sand discharge liquid tank 35 and pressurize it into high-pressure sand discharge liquid; the processor obtains the data monitored by the sand discharge pressure sensor 38 to determine whether the stainless steel plunger pump 32 is normally supplying high-pressure sand discharge liquid to the stopcock valve 1, preventing abnormal pressure rise caused by the blockage of the stopcock valve from impacting the stainless steel high-temperature plunger pump 32, and can adjust the pressure of the high-pressure sand discharge liquid output by the stainless steel high-temperature plunger pump 32 by adjusting the second pressure regulating valve 31. When the monitored high-pressure sand-discharging fluid pressure drops significantly compared to the initial sand-discharging pressure, it indicates that the sand and gravel inside the stopcock valve have been gradually emptied. Then, the cleaning channel control valve 11 is opened to drain the reacted sand and sand-discharging fluid from the stopcock valve 1. After the sand-discharging process is complete, the processor issues an execution command to close the cleaning channel control valve 11, the sand-discharging channel control valve 9, the shut-off valve 33, and the third drive motor 37. Preferably, the sand-discharging device further includes a heating device 36 and a temperature sensor 34. The heating device 36 heats the sand-discharging fluid in the sand-discharging fluid tank 35, and the temperature sensor 34 monitors the temperature of the sand-discharging fluid. When the sand-discharging fluid temperature is insufficient, the heating device 36 is simultaneously activated when the sand-discharging channel valve is opened.

[0029] This invention also provides an intelligent operation and maintenance method for fracturing plug valves, which, using the aforementioned intelligent operation and maintenance system for fracturing plug valves, includes the following steps: S1. Collect historical data on the working pressure of the plug valve 1 during normal operation and the corresponding torque of the valve stem 2 when the plug valve is opened. Obtain the real-time working pressure of the plug valve and the current torque of the valve stem when it is opened. Compare the current torque value with the historical torque value under the corresponding working pressure. If 1.1 times the historical torque value < the current torque value ≤ 1.3 times the historical torque value, issue a prompt message for grease injection and start the actuator to inject grease into the plug valve. If the current torque value > 1.3 times the historical torque value, proceed to step S2. The historical data of the working pressure and the corresponding torque are stored in the memory. The processor compares the current torque value with the historical torque value under the same working pressure. When the current torque value ≤ 1.1 times the historical torque value, it indicates that the plug valve is working normally and does not require maintenance.

[0030] S2. Set the valve stem to be at 0° when the plug valve is fully open and at 90° when the plug valve is fully closed; obtain the rotation angle of the plug valve stem. If 0° < valve stem rotation angle < 15° or 75° < valve stem rotation angle < 90°, and 1.3 times the historical torque value < current torque value ≤ 1.5 times the historical torque value, issue a prompt for grease injection and cleaning operations, activate the actuator to first clean the valve cavity of the plug valve, and then grease the plug valve; if 15° ≤ valve stem rotation angle ≤ 75°, and 1.3 times the historical torque value < current torque value ≤ 1.5 times the historical torque value, issue a sand jam alarm prompt; stop the fracturing operation, activate the actuator to sequentially clean and remove sand from the valve cavity of the plug valve, and then grease the plug valve; The rotation angle of valve stem 2 is calibrated as follows: A magnetic angle sensor is installed on valve stem 2. A full-stroke opening and closing operation of the plug valve 1 is performed in a low electromagnetic interference environment. The magnetic angle sensor transmits the detected rotation angle of valve stem 2 to the processor. Simultaneously, the image sensor 3 transmits the captured images of the valve stem during the full-stroke opening and closing process of the plug valve 1 to the processor. The processor matches the images of the valve stem corresponding to different rotation angles according to timestamps and records and stores them in the memory as a reference database. After the plug valve is put into use, to avoid electromagnetic interference in the working environment, the magnetic angle sensor is no longer installed on valve stem 2. During the real-time operation of the plug valve, the image of valve stem 2 monitored by the image sensor 3 received by the processor is compared with the reference database to obtain the rotation angle value of the valve stem. The valve stem of a plug valve rotates 90° from the fully open position to the fully closed position. The 0° and 90° positions are the two normal states of the plug valve, which are fully open and fully closed. The other angles are abnormal states. When the valve stem rotation angle is between 15° and 75°, it indicates that the plug valve has a serious sand jamming fault. The other angles, which deviate slightly from 0° and 90°, may be due to minor faults in the valve actuator or valve core position drift caused by fluid fluctuations.

[0031] S3. Obtain the temperatures of the inlet and outlet ends of the fluid channel of the plug valve. If the temperature difference between the two ends is ≥10℃, issue an erosion throttling alarm message; stop the fracturing operation and replace the valve core of the plug valve; the processor can obtain the temperature values ​​of the inlet and outlet ends of the fluid channel by acquiring the thermal image of the plug valve taken by the infrared thermal imager, and then calculate the temperature difference between the two ends. The temperature difference can be used to determine whether the plug valve has experienced erosion throttling.

[0032] S4. Acquire the sound at both ends of the fluid passage of the plug valve and the connection with external equipment. If a fluid leakage sound is detected, issue a leakage alarm message; stop the fracturing operation and replace the seals of the plug valve. The processor acquires the sound data monitored by the acoustic emission sensor to determine whether a leakage sound has occurred.

[0033] The intelligent operation and maintenance method for fracturing plug valves analyzes and processes multiple parameters collected during the real-time operation of the plug valves, enabling precise determination of the timing and specific maintenance measures for the plug valves.

[0034] Although embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for the present invention. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. An intelligent operation and maintenance system for fracturing plug valves, characterized in that, include: The system comprises multiple monitoring devices, a control unit, and multiple actuators. The monitoring devices monitor the working pressure of the plug valve, the torque value of the valve stem when the plug valve is opened and closed, the rotation angle of the valve stem, the temperature at the inlet and outlet ends of the fluid channel of the plug valve, and the sound at the connection points between the fluid channel and external equipment. The actuators perform grease injection, cleaning, and sand removal operations on the plug valve. The control unit communicates with each monitoring device and each actuator, determines whether the plug valve requires maintenance based on the data monitored by each monitoring device, and controls the corresponding actuator to perform grease injection, cleaning, sand removal operations on the plug valve, or stop fracturing operations, and sends corresponding prompts.

2. The intelligent operation and maintenance system for fracturing plug valves as described in claim 1, characterized in that, The multiple monitoring devices include a pressure sensor, a torque sensor, an image sensor, an infrared thermal imager, and an acoustic emission sensor; the pressure sensor is installed in the fluid passage of the plug valve to monitor the working pressure of the plug valve; the torque sensor is installed on the valve stem of the plug valve to monitor the torque value of the valve stem when the plug valve is opened and closed; the image sensor is installed above the plug valve to monitor the rotation angle of the valve stem. The infrared thermal imager is positioned above the stopcock valve to monitor the temperature at both ends of the fluid channel; the acoustic emission sensors are respectively positioned at the connection points between the fluid channel and external equipment at both ends to monitor whether leakage sounds occur at the corresponding locations.

3. The intelligent operation and maintenance system for fracturing plug valves as described in claim 1, characterized in that, The control unit includes a processor, a memory, a fieldbus, an input / output interface, and a communication interface. The memory stores monitoring data from each of the monitoring devices. The processor retrieves the monitoring data from the memory, performs calculations, determines the operating status of the stopcock valve, and generates execution instructions and prompts. The communication interface is used for data transmission between the processor and each of the monitoring devices and the execution devices. The input / output interface is used to obtain monitoring data from each of the monitoring devices or to output execution instructions to each of the execution devices. The fieldbus is used for data exchange between the processor, the memory, the monitoring devices, and the execution devices.

4. The intelligent operation and maintenance system for fracturing plug valves as described in claim 1, characterized in that, Each of the aforementioned actuators is a grease injection device, a cleaning device, and a sand removal device; the plug valve is respectively provided with a lubrication channel, a flushing channel, and a sand removal channel communicating with the valve cavity; the grease injection device is connected to the lubrication channel through a lubrication channel control valve; the cleaning device is connected to the flushing channel through a flushing channel control valve; the sand removal device is connected to the sand removal channel through a sand removal channel control valve; the lubrication channel control valve, the flushing channel control valve, and the sand removal channel control valve are respectively connected to the control unit.

5. The intelligent operation and maintenance system for fracturing plug valves as described in claim 4, characterized in that, The grease injection device includes a grease injection hydraulic cylinder, a hydraulic control device, and a grease injection pressure sensor; the outlet end of the grease injection hydraulic cylinder is connected to the lubrication channel control valve through a grease injection pipeline; the hydraulic control device is connected to the grease injection hydraulic cylinder through a hydraulic pipeline to control the amount of grease injected by the grease injection hydraulic cylinder; the grease injection pressure sensor is located at the oil outlet end of the hydraulic control device to monitor the pressure of the hydraulic oil output by the hydraulic control device.

6. The intelligent operation and maintenance system for fracturing plug valves as described in claim 4, characterized in that, The cleaning device includes a stainless steel crankshaft pump, a reversing valve, a cleaning pressure sensor, an acid tank, and an alkali tank. The output ends of the stainless steel crankshaft pump and the reversing valve are connected, and the input ends of the reversing valve are connected to the acid tank and the alkali tank, respectively. The cleaning pressure sensor is located at the outlet end of the stainless steel crankshaft pump. The outlet end of the stainless steel crankshaft pump is connected to the flushing channel control valve through a flushing pipeline, and a first pressure regulating valve is provided on the flushing pipeline.

7. The intelligent operation and maintenance system for fracturing plug valves as described in claim 4, characterized in that, The sand removal device includes a stainless steel high-temperature plunger pump, a sand removal pressure sensor, a shut-off valve, and a sand removal liquid tank; the stainless steel high-temperature plunger pump is connected to the shut-off valve, and the shut-off valve is connected to the sand removal liquid tank; the sand removal pressure sensor is located at the outlet end of the stainless steel high-temperature plunger pump; the outlet end of the stainless steel high-temperature plunger pump is connected to the sand removal channel control valve through a sand removal pipeline, and a second pressure regulating valve is provided on the sand removal pipeline.

8. A method for intelligent operation and maintenance of fracturing plug valves, using the intelligent operation and maintenance system for fracturing plug valves as described in claim 1, characterized in that, Includes the following steps: S1. Collect historical data on the working pressure of the plug valve during normal operation and the corresponding valve stem torque when the plug valve is opened. Obtain the real-time working pressure of the plug valve and the current torque of the valve stem when it is opened. Compare the current torque value with the historical torque value under the corresponding working pressure. If 1.1 times the historical torque value < current torque value ≤ 1.3 times the historical torque value, issue a prompt message for grease injection and start the actuator to inject grease into the plug valve. If the current torque value > 1.3 times the historical torque value, proceed to step S2. S2. Set the valve stem to be at 0° when the plug valve is fully open and at 90° when the plug valve is fully closed; obtain the rotation angle of the plug valve stem. If 0° < valve stem rotation angle < 15° or 75° < valve stem rotation angle < 90°, and 1.3 times the historical torque value < current torque value ≤ 1.5 times the historical torque value, issue a prompt for grease injection and cleaning operations, activate the actuator to first clean the valve cavity of the plug valve, and then grease the plug valve; if 15° ≤ valve stem rotation angle ≤ 75°, and 1.3 times the historical torque value < current torque value ≤ 1.5 times the historical torque value, issue a sand jam alarm prompt; stop the fracturing operation, activate the actuator to sequentially clean and remove sand from the valve cavity of the plug valve, and then grease the plug valve; S3. Obtain the temperature of the inlet and outlet ends of the fluid passage of the plug valve. If the temperature difference between the two ends is ≥10℃, issue an erosion throttling alarm message; stop the fracturing operation and replace the valve core of the plug valve. S4. Obtain the sound at both ends of the fluid passage of the plug valve and the connection with the external equipment. If the sound of fluid leakage is heard, issue a leakage alarm message. Stop fracturing operations and replace the seals on the plug valve.

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