Modularized extensible throttle manifold system

Abstract

The invention belongs to the technical field of petroleum and natural gas drilling and production engineering, and particularly relates to a modular extensible choke manifold system which comprises a plurality of functional modules, a central control unit, a main communication bus and a power distribution network. All the function modules are connected through standardized fast-assembly mechanical connectors, a throttling executing mechanism, a local sensing unit, a safety interlocking device and a module identity recognition chip are integrated, and plug and play and automatic recognition are supported. The central control unit dynamically loads a control strategy based on identification information, closed-loop regulation and control and cross-module state mutual verification are achieved through the double-loop redundant communication bus, and through the scheme, non-stop expansion, fault self-isolation, configuration self-consistency and redundant well control capacity under extreme working conditions are achieved.

Description

Technical Field

[0001] This invention belongs to the field of oil and gas drilling and production engineering technology, specifically a modular and scalable throttling manifold system. Background Technology

[0002] In oil and gas drilling and completion operations, the choke manifold system is a core component of well control equipment, undertaking critical functions such as regulating wellhead back pressure, controlling well kick, and implementing well control. Its reliability directly determines operational safety and efficiency. With the development of deepwater, ultra-deepwater, and complex geological drilling projects, higher demands are placed on the adaptability, deployment flexibility, and functional scalability of choke manifold systems. Traditional choke manifolds adopt a fixed integral structure, with each functional unit rigidly connected by welding or flanges to form an inseparable system. In early conventional onshore drilling scenarios, this structure had the advantages of compactness and reliable sealing, meeting the requirements of stable operating conditions.

[0003] As operating environments become more complex and standardized operation and maintenance concepts deepen, traditional integrated throttling manifolds are showing structural limitations. The core contradiction lies in the conflict between the static fixation of system functions and the dynamic adaptation requirements of field conditions: once the system is manufactured, the throttling stage, pipe diameter, and other configurations are locked, making it impossible to flexibly adjust according to well control strategies, formation pressure changes, or emergency needs. Changing the configuration requires shutdown, disassembly, and re-customization and installation, which is time-consuming, labor-intensive, and poses safety risks in emergency situations. Some manufacturers have attempted modular solutions, which only achieve physical disassembly through quick-connect couplings, failing to address the deep coupling between functional logic and control architecture. Each module relies on independent manual or local control, lacking a unified data interface and collaborative control mechanism. After expansion, it is difficult to achieve precise pressure gradient distribution, dynamic flow balancing, and rapid fault isolation.

[0004] The current technological bottleneck stems from a one-sided understanding of the concept of "module," focusing solely on the standardization of mechanical interfaces while neglecting the embedded and cross-module collaboration of control logic, sensor feedback, and safety interlocks. Even with physical unit splicing, the system remains a simple superposition of isolated functional blocks, unable to form an adaptive organic whole. Adding new modules requires manual reconfiguration of parameters and even modification of control logic, easily introducing errors. Furthermore, the lack of state verification mechanisms between modules prevents coordinated compensation in case of failure, potentially leading to uncontrolled pressure. Pseudo-modular designs also increase leakage points and failure sources due to the increased number of interfaces, contradicting the original intention of modularization to improve reliability.

[0005] Therefore, the present invention provides a modular and scalable throttling manifold system. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, at least one technical problem raised in the background art is solved.

[0007] The technical solution adopted by this invention to solve its technical problem is as follows: A modular and scalable throttling manifold system, comprising several functional modules, a central control unit, a backbone communication bus, and a power distribution network; wherein, each functional module includes a throttling actuator, a local sensing unit, a safety interlock device, a module identification chip, and a dual-redundant communication interface; the functional module is connected to adjacent modules or main pipelines through standardized quick-connect mechanical connectors, and is connected to the backbone communication bus through dual-redundant communication interfaces, and connected to the power distribution network through independent power supply terminals; the central control unit establishes a bidirectional data link with all functional modules through the backbone communication bus, for real-time acquisition of the operating status of each module, issuance of control commands, and execution of system-level coordination strategies.

[0008] Furthermore, the functional modules are divided into throttle valve modules, pressure monitoring modules, isolation valve modules, buffer tank interface modules, and end-of-line sealing modules according to their functional roles in the manifold system. Each type of module integrates dedicated hardware components that match its function and has pre-set corresponding control logic programs. The throttle valve module includes an electrically driven throttle valve body, a position feedback sensor, a torque limiter, and a local controller. The pressure monitoring module includes a high-precision pressure transmitter, a temperature compensation circuit, and a data calibration memory. The isolation valve module includes a pneumatically or hydraulically driven shut-off valve, a travel limit switch, and an emergency locking solenoid valve. The buffer tank interface module includes a flange adapter, a level detection probe, and an anti-siphon check structure. The end-of-line sealing module includes a blind flange, a leakage detection hole, and a grounding protection terminal.

[0009] In a preferred embodiment of the present invention, each functional module has a unique physical code identification area on the outside of its housing, and a non-volatile module identification chip is embedded inside; the module identification chip has a module type code, factory serial number, rated operating parameter range, initial value of communication address and functional logic version number embedded in it; when any functional module is connected to the system through a quick-connect mechanical connector, its dual redundant communication interface automatically establishes a physical layer connection with the backbone communication bus; the central control unit then starts the module identification process, reads the identification chip information of the module through a polling or event triggering mechanism, and loads the corresponding device driver and control strategy template accordingly.

[0010] Furthermore, the backbone communication bus adopts a dual-ring redundant topology structure conforming to the industrial Ethernet standard and supports time-sensitive network protocols. The dual-redundant communication interfaces of each functional module are respectively connected to two independent loops of the backbone communication bus to ensure that the data path can still be maintained in the event of a single point of communication link failure. The communication protocol adopts the extended IEC 61850 control specification based on the publish-subscribe model, which defines four basic message formats: module registration message, status reporting message, instruction issuance message, and fault broadcast message. All messages include source address, destination address, function code, data payload, and integrity verification fields, and TLS 1.3 secure channel is enabled for encryption and authentication during transmission.

[0011] In a preferred embodiment of the present invention, the central control unit includes a main control processor, a real-time operating system kernel, an equipment management service module, a collaborative control engine, and a human-machine interface. The equipment management service module is responsible for maintaining a dynamic registry of the connected functional modules, recording the current communication status, functional role, measurement range, and health score of each module. The collaborative control engine constructs a system topology based on the registry information and automatically generates throttling cascade paths, pressure gradient distribution schemes, and flow balancing strategies according to the well control operation mode. The human-machine interface provides a graphical configuration interface, allowing operators to select preset operating condition templates or manually specify target settings for each module.

[0012] Furthermore, the local controller is built into each functional module, running a lightweight real-time task scheduler and executing local closed-loop control logic. For the throttle valve module, the local controller receives the target opening command from the central control unit and performs PID adjustment in conjunction with the position feedback sensor signal, while monitoring the torque limiter output to prevent overload. For the pressure monitoring module, the local controller periodically acquires the raw signal from the pressure transmitter, generates an engineering unit value after temperature compensation and nonlinear correction, and uploads it to the central control unit through the communication interface. For the isolation valve module, after receiving the closing command, the local controller synchronously activates the emergency locking solenoid valve to ensure rapid shut-off and verifies the valve's position status through the travel limit switch.

[0013] In a preferred embodiment of the present invention, the system is equipped with a cross-module status verification mechanism. When a functional module detects that its own operation is abnormal or exceeds the safety boundary, in addition to sending a fault broadcast message to the central control unit, it also sends a status warning signal to its upstream and downstream adjacent modules through the backbone communication bus. After receiving the signal, the local controller of the adjacent module immediately starts a preset compensation control program, such as adjusting the throttling opening to maintain downstream pressure stability, or closing the isolation valve in advance to isolate the fault area. The triggering conditions, action logic and duration of the compensation control program are all pre-written into the firmware of each module and are strictly bound to the module type.

[0014] Furthermore, the power distribution network adopts a dual-path DC power supply architecture, with two independent uninterruptible power supply devices supplying power to the functional modules on both sides of the main communication bus respectively; each functional module is equipped with a power management unit, which monitors the input voltage, current and power factor, and switches to the local energy storage capacitor to maintain the operation of critical circuits when the power supply is abnormal; the power management unit communicates with the local controller, incorporates the power supply status into the module health score calculation, and actively notifies the central control unit to prepare for degraded operation before the voltage drops below the preset safety threshold.

[0015] In a preferred embodiment of the present invention, the system supports online expansion and hot-swapping operations. When a new functional module is connected, the central control unit automatically detects the online event of the new device and determines whether it is a legitimate authorized module based on its identification information. If the verification is successful, it is included in the system topology and the global control strategy is recalculated. If the verification fails, its communication request is rejected and an illegal access log is recorded. During the expansion process, the original functional modules maintain normal operation, and only the affected local areas perform a brief state synchronization process to ensure that the entire manifold system does not shut down or interrupt the control function.

[0016] Furthermore, the quick-connect mechanical connector adopts a self-centering sealing structure, including an axial positioning keyway, a radial locking clamp, and a double O-ring sealing pair. During module docking, the axial positioning keyway ensures precise alignment of the flow channel centerline, the radial locking clamp applies uniform clamping force through a hydraulic or pneumatic actuator, and the double O-ring sealing pair is located on the high-pressure side and the low-pressure side respectively, forming a double sealing barrier. The quick-connect mechanical connector integrates an electrical contact array to establish a physical path for power and communication while the mechanical connection is completed. The electrical contact array adopts a gold-plated spring pin structure, which has vibration resistance, corrosion resistance, and low contact resistance characteristics.

[0017] As a preferred embodiment of the present invention, the system is equipped with a full lifecycle configuration management mechanism; the central control unit loads the latest system configuration snapshot each time it starts up and compares it with the actual status of the currently accessed modules; if a module is found to be missing, of a different type, or with drifting parameters, it automatically enters a security-restricted mode and prompts the operator to check; all configuration changes, module replacements, and control policy updates generate tamper-proof operation logs, which are digitally signed by the security element chip and stored in the local audit database.

[0018] Furthermore, the safety interlock device is integrated near the key execution components of each functional module, including a mechanical limit stop, an electronic interlock relay, and an emergency relief channel. In the throttle valve module, the safety interlock device ensures that the throttle valve automatically returns to the preset safe opening when the motor is powered off or the control system fails. In the isolation valve module, the safety interlock device forcibly triggers the emergency locking solenoid valve when it detects overpressure or abnormal temperature in the pipeline. The emergency relief channel is connected to a dedicated pressure relief pipeline, and its opening is controlled by an independent pressure pilot valve, without relying on any electronic signals.

[0019] As a preferred embodiment of the present invention, the system supports a multi-level redundant control architecture; in addition to the central control unit, any two adjacent functional modules can exchange key status information through a local communication channel. In the event of a complete failure of the central control unit, the basic well control function can still be maintained based on preset degradation control rules; the degradation control rules include minimum throttling level protection, maximum back pressure limit and fault module bypass logic, all of which are fixed in the read-only memory of each module.

[0020] The beneficial effects of this invention are as follows:

[0021] 1. The modular and scalable throttling manifold system described in this invention avoids control logic conflicts caused by manual configuration errors through an automatic matching mechanism between module identification chips and the central control unit; it utilizes the dual-ring redundant topology of the backbone communication bus and time-sensitive network protocol to maintain deterministic transmission of multi-node control commands in high-noise industrial environments; it enables functional modules to complete logic registration and strategy loading simultaneously with physical access, ensuring that system expansion requires no downtime intervention; it ensures that when any module fails, its upstream and downstream units can initiate compensation actions based on a state verification mechanism, preventing local failures from evolving into systemic loss of control; and through the integrated design of quick-connect mechanical joints and electrical contact arrays, it effectively suppresses the risk of sealing failure and signal interruption caused by frequent disassembly and assembly; at the same time, the full lifecycle configuration management mechanism ensures that the system maintains configuration consistency throughout long-term operation and maintenance, preventing safety hazards caused by equipment replacement or parameter drift; in addition, the multi-level redundant control architecture gives the system basic survivability under extreme operating conditions, ensuring the core safety bottom line of well control operations. Attached Figure Description

[0022] The invention will now be further described with reference to the accompanying drawings.

[0023] Figure 1 This is a block diagram of the overall structure of the modular and scalable throttling manifold system of the present invention;

[0024] Figure 2 This is a structural block diagram of the functional modules of the present invention;

[0025] Figure 3This is a system block diagram showing the connection relationship between the main communication bus and functional modules of the present invention. Detailed Implementation

[0026] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.

[0027] like Figure 1 - Figure 3 As shown in the embodiment of the present invention, a modular and scalable throttling manifold system comprises several functional modules, a central control unit, a backbone communication bus, and a power distribution network. Each functional module is physically connected to adjacent modules or main pipelines via standardized quick-connect mechanical connectors, and simultaneously connected to the backbone communication bus via dual redundant communication interfaces, and connected to the power distribution network via independent power supply terminals. The central control unit establishes a bidirectional data link with all functional modules through the backbone communication bus, used for real-time acquisition of operating status, issuance of control commands, and execution of system-level coordination strategies.

[0028] Each functional module includes a throttling actuator, a local sensing unit, a safety interlock device, a module identification chip, and a dual-redundant communication interface. Based on their functional roles within the manifold system, the modules are divided into a throttling valve module, a pressure monitoring module, an isolation valve module, a buffer tank interface module, and an end-of-line sealing module. The throttling valve module integrates an electrically driven throttling valve body, a position feedback sensor, a torque limiter, and a local controller; the pressure monitoring module includes a high-precision pressure transmitter, a temperature compensation circuit, and a data calibration memory; the isolation valve module includes a pneumatically or hydraulically driven shut-off valve, a travel limit switch, and an emergency locking solenoid valve; the buffer tank interface module includes a flange adapter, a level detection probe, and an anti-siphon check valve structure; and the end-of-line sealing module includes a blind flange, a leak detection port, and a grounding protection terminal.

[0029] In a preferred embodiment of the present invention, each functional module has a unique physical code identification area on its outer casing, and a non-volatile module identification chip is embedded inside. This chip contains a module type code, factory serial number, rated operating parameter range, initial communication address value, and functional logic version number. When any functional module is connected to the system via a quick-connect mechanical connector, its dual-redundant communication interface automatically establishes a physical layer connection with the main communication bus. The central control unit then initiates the module identification process, reading the module's identification chip information through a polling or event-triggered mechanism, and loading the corresponding device driver and control strategy template accordingly.

[0030] The backbone communication bus adopts a dual-ring redundant topology conforming to the industrial Ethernet standard and supports the Time-Sensitive Networking (TSN) protocol. The dual-redundant communication interfaces of each functional module are connected to two independent loops of the backbone communication bus, ensuring data continuity even in the event of a single point of failure. The communication protocol adopts the extended IEC 61850 control specification based on the publish-subscribe model, defining four basic message formats: module registration messages, status reporting messages, command issuance messages, and fault broadcast messages. All messages include source address, destination address, function code, data payload, and integrity check fields, and are encrypted and authenticated using a TLS 1.3 secure channel during transmission.

[0031] The central control unit comprises a main control processor, a real-time operating system kernel, an equipment management service module, a collaborative control engine, and a human-machine interface. The equipment management service module maintains a dynamic registry of connected functional modules, recording each module's current communication status, functional role, measurement range, and health score. The collaborative control engine constructs a system topology based on the registry information and automatically generates throttling cascade paths, pressure gradient distribution schemes, and flow balancing strategies according to the well control operation mode. The human-machine interface provides a graphical configuration interface, allowing operators to select preset operating condition templates or manually specify target settings for each module.

[0032] The local controller is built into each functional module, running a lightweight real-time task scheduler and executing local closed-loop control logic. For the throttle valve module, the local controller receives the target opening command from the central control unit and performs PID adjustment in conjunction with the position feedback sensor signal, while simultaneously monitoring the torque limiter output to prevent overload. Its control law is expressed as:

[0033]

[0034] in, This indicates the control voltage applied to the electrically driven throttle valve body (unit: V). The difference between the set opening degree and the actual opening degree (unit: %). , , These are the proportional, integral, and differential gain coefficients (units: V / %, V·s / %, V·s⁻¹ / %), and their typical value ranges are as follows: , , The specific values ​​are adjusted online based on the valve body size and the viscosity of the medium.

[0035] For the pressure monitoring module, the local controller periodically acquires the raw signal from the pressure transmitter, generates an engineering unit value after temperature compensation and nonlinear correction, and uploads it to the central control unit via the communication interface. The temperature compensation uses the following piecewise linear model:

[0036]

[0037] in, The pressure value after compensation (unit: MPa). The original sensor output (unit: V or mA, mapped to the equivalent pressure value after analog-to-digital conversion) is shown. The measured ambient temperature (unit: °C) To calibrate the reference temperature, This is the temperature drift coefficient, which is stored in the data calibration memory and written during the module's factory calibration.

[0038] For the isolation valve module, upon receiving a shutdown command, the local controller simultaneously activates the emergency shut-off solenoid valve to ensure rapid shut-off and verifies the valve's position via a limit switch. If the limit switch operates within a preset time limit... If no "all off" signal is returned, it is determined to be an execution error, triggering a fault broadcast message.

[0039] The system incorporates a cross-module status verification mechanism. When a functional module detects an operational anomaly or exceeds its safety boundaries, in addition to sending a fault broadcast message to the central control unit, it also sends a status warning signal to its upstream and downstream adjacent modules via the backbone communication bus. Upon receiving this signal, the local controller of the adjacent module immediately initiates a preset compensation control program. For example, if the upstream throttle valve module enters a power-limiting mode due to motor overheating, causing a sudden drop in downstream pressure, the downstream pressure monitoring module transmits this anomaly to its downstream throttle valve module via a status warning signal. The latter then reduces its opening to maintain pressure stability. The trigger threshold for this compensation action is a pressure change rate exceeding [a certain threshold]. The duration does not exceed It only takes effect when the central control unit is unresponsive.

[0040] The power distribution network employs a dual-path DC power supply architecture, with two independent uninterruptible power supplies (UPS) supplying power to the functional modules on either side of the main communication bus. Each functional module has a power management unit (PMU) to monitor input voltage, current, and power factor, and switches to local energy storage capacitors to maintain critical circuit operation in case of power failure. The PMU communicates with the local controller, incorporating the power supply status into the module health score calculation. Calculate using the following formula:

[0041]

[0042] in, The measured input voltage (unit: V) Rated voltage, Load current (unit: A). The module's rated current (in A) is given by PF, which is the measured power factor (dimensionless). The weighting factor is... , , .when At that time, the module proactively notifies the central control unit to prepare for degraded operation.

[0043] The system supports online expansion and hot-swapping. When a new functional module is added, the central control unit automatically detects the new device's online event and determines whether it is a legitimate authorized module based on its identity information. Authentication employs a two-way authentication mechanism based on the Elliptic Curve Digital Signature Algorithm (ECDSA), with the public key certificate pre-stored in the secure element of the central control unit. If authentication succeeds, the module is incorporated into the system topology, and the global control policy is recalculated; if authentication fails, its communication request is rejected, and an unauthorized access log is recorded. During expansion, existing functional modules continue to operate normally; only the affected local areas undergo a brief state synchronization process, with the synchronization window duration not exceeding [a certain value]. This ensures that the entire manifold system operates without interruption of its control functions.

[0044] The quick-connect mechanical joint adopts a self-aligning sealing structure, including an axial positioning keyway, a radial locking clamp, and a double O-ring sealing pair. During module docking, the axial positioning keyway ensures precise alignment of the flow channel centerline, with an alignment error of less than [value missing]. The radial locking clamp applies clamping force via a hydraulic actuator. satisfy:

[0045]

[0046] in, The inner diameter of the pipe (unit: m). To the maximum working pressure of the system, For safety, the double O-ring seals are located on the high-pressure and low-pressure sides respectively, and are made of fluororubber (FKM) with a hardness of [missing information]. Compression ratio controlled at The quick-connect mechanical connector integrates an electrical contact array to establish a physical path for power and communication simultaneously with the completion of the mechanical connection. This electrical contact array uses a gold-plated spring pin structure, resulting in a contact resistance of less than [value missing]. The vibration resistance rating meets the IEC 60068-2-6 standard, and the corrosion resistance performance passes the ISO 9227 neutral salt spray test. .

[0047] The system features a full lifecycle configuration management mechanism. The central control unit loads the latest system configuration snapshot upon each startup and compares it with the actual status of the currently connected modules. The configuration snapshot includes the expected type, serial number, communication address, and control parameter set for each module. If a module is found to be missing, of a mismatched type, or with parameter drift (e.g., pressure transmitter zero-point offset exceeding a certain threshold), the system will take action. If the configuration changes, module replacements, and control policy updates are detected, the system will automatically enter a restricted security mode and prompt the operator to verify the changes. All configuration changes, module replacements, and control policy updates generate immutable operation logs. Log entries include timestamps, operator IDs, parameter values ​​before and after the change, and digital signatures. The digital signatures are generated by the secure element chip using the SHA-384 hash algorithm and an RSA-3072 private key, stored in a local audit database, and retained for at least 10 years.

[0048] Safety interlock devices are integrated near the critical actuators of each functional module, including mechanical limit stops, electronic interlock relays, and emergency release channels. In the throttle valve module, the safety interlock device ensures that the throttle valve automatically returns to the preset safe opening degree in the event of motor power failure or control system malfunction. The return motion is performed by an internal spring with a spring stiffness of [missing information]. Pre-compression amount This is sufficient to overcome the friction of the valve stem. In the isolation valve module, the safety interlock device detects pipeline overpressure ( ) or abnormal temperature ( When [the emergency] occurs, the emergency locking solenoid valve is forcibly activated. The emergency relief channel is connected to a dedicated pressure relief line, and its opening is controlled by an independent pressure pilot valve, with the pilot valve opening pressure set at [pressure value missing]. Response time It does not rely on any electronic signals.

[0049] The system supports a multi-level redundant control architecture. Besides the central control unit, any two adjacent functional modules can exchange critical status information via a local communication channel. This local communication channel is based on the CAN FD protocol and has a baud rate of [missing information]. The physical layer uses shielded twisted-pair cable, with a length not exceeding [a certain value]. In the event of a complete failure of the central control unit, each module can still maintain basic well control functions based on preset degradation control rules. These degradation control rules include: minimum throttling stage guarantee (at least two throttling stages must be maintained), maximum back pressure limit (…). The rules also include bypass logic for faulty modules (automatically skipping communication interruption modules and reconstructing throttling paths). All of these rules are embedded in the read-only memory (ROM) of each module and cannot be modified remotely.

[0050] The technical effects of the present invention are further illustrated below through three embodiments and three comparative examples.

[0051] Example 1: Deploying the modular and scalable throttling manifold system described in this invention on a deep-water drilling platform in the South China Sea. The system configuration includes 4 throttling valve modules (model TV-70), 2 pressure monitoring modules (model PM-100), 2 isolation valve modules (model IV-50), 1 buffer tank interface module (model BI-30), and 1 end-sealing module (model EB-25). All modules are connected in series via quick-connect mechanical connectors. The main communication bus uses a dual-ring gigabit industrial Ethernet. The central control unit runs on an ARM Cortex-A72 processor, and the real-time operating system is VxWorks 7. The system completes all module identification and strategy loading within 12 seconds of startup, and the throttling valve module opening control accuracy reaches [percentage missing]. The pressure monitoring module is in Comprehensive error within the range In the simulated power failure test of the central control unit, adjacent throttle valve modules maintained downstream pressure fluctuations through local communication channels. Duration Until the backup control unit takes over.

[0052] Example 2: Online expansion test conducted at an onshore high-pressure gas well in Xinjiang. The initial system included three throttle valve modules and two pressure monitoring modules. While the system was running, an operator connected a new isolation valve module (serial number IV50-20240501) on-site. The central control unit completed authentication, topology update, and control strategy recalculation within 320 ms, with no control interruption for the existing modules. The new module completed its self-test and entered standby mode within 5 seconds of connection, with an emergency interlock response time of [time missing]. It meets the requirements of API 6A standard.

[0053] Example 3: Verifying the cross-module status verification mechanism under a simulated fault scenario. The motor driver of the No. 2 throttle valve module is artificially overheated (temperature rises to...). This module immediately sent a fault broadcast to the central control unit and status warnings to upstream and downstream modules. Upon receiving the warning, the No. 3 throttle valve module automatically adjusted its opening from... Adjust to This keeps downstream pressure at The pressure fluctuation of the control system without cross-validation mechanism reached [amount missing]. .

[0054] Comparative Example 1: A traditional fixed throttling manifold is used, with all valves and sensors hardwired to the centralized control cabinet. Under the same well control conditions, system expansion requires more than 8 hours of downtime, manual configuration errors cause two control logic conflicts, and pressure control response is delayed. .

[0055] Comparative Example 2: A modular manifold with only mechanical quick-installation capabilities but lacking identification and automatic configuration functions was used. After adding a new module, device parameters needed to be manually entered, with an average configuration time of 15 minutes, and one malfunction occurred due to incorrect parameter input.

[0056] Comparative Example 3: A modular system employing a single-loop communication bus and lacking a local compensation mechanism. After the central control unit fails, the system completely loses its regulatory capability, and the downstream pressure rises to [a certain level] within 30 seconds. This triggers the safety valve to open.

[0057] The table below summarizes the key performance indicators of the embodiments and comparative examples:

[0058] project Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 System startup to readiness time (s) 12 12 12 1800 900 15 Module hot-swap configuration time (s) — 5 — Not supported 900 600 Pressure control accuracy (±% FS) 0.1 0.1 0.1 0.8 0.5 0.3 Pressure fluctuation (MPa) after central control failure ±1.2 ±1.1 ±0.8 ±15.0 ±8.0 ±22.0 Fault propagation suppression success rate (%) 100 100 100 0 40 0 Number of malfunctions caused by misconfiguration 0 0 0 2 1 0

[0059] In summary, this invention avoids manual configuration errors through an automatic matching mechanism between the module identification chip and the central control unit; it ensures deterministic transmission of multi-node control commands by utilizing the dual-ring redundant topology of the backbone communication bus and the time-sensitive network protocol; it enables functional modules to complete logical registration and policy loading simultaneously with physical access; it prevents local failures from evolving into systemic loss of control through a cross-module status verification mechanism; it improves sealing reliability and signal integrity through the integrated design of quick-connect mechanical joints and electrical contact arrays; it ensures long-term operational consistency through a full lifecycle configuration management mechanism; and it endows the system with basic survivability under extreme operating conditions through a multi-level redundant control architecture.

[0060] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A modular and scalable throttling manifold system, characterized in that, include: Several functional modules, a central control unit, a backbone communication bus, and a power distribution network; The aforementioned functional modules are connected to adjacent modules or main pipelines via standardized quick-connect mechanical connectors, and are respectively connected to the main communication bus via dual redundant communication interfaces, and to the power distribution network via independent power supply terminals; Each functional module includes a throttling actuator, a local sensing unit, a safety interlock device, a module identification chip, and the aforementioned dual-redundant communication interface; The central control unit establishes a bidirectional data link with all functional modules through the backbone communication bus, which is used to collect the operating status of each module in real time, issue control commands, and execute system-level coordination strategies. The functional modules are divided into throttle valve module, pressure monitoring module, isolation valve module, buffer tank interface module and end-seal module according to their functional roles in the manifold system. Each type of module integrates dedicated hardware components that match its function and has a pre-set corresponding control logic program. The backbone communication bus adopts a dual-ring redundant topology structure that conforms to the industrial Ethernet standard and supports time-sensitive network protocols. The dual-redundant communication interfaces of each functional module are respectively connected to two independent loops of the backbone communication bus.

2. The modular and scalable throttling manifold system according to claim 1, characterized in that, Each functional module has a unique physical code identification area on its outer shell and a non-volatile module identification chip embedded inside. The module identification chip contains the module type code, factory serial number, rated operating parameter range, initial value of communication address and functional logic version number. When any functional module is connected to the system, the central control unit reads the identification chip information of the module through a polling or event triggering mechanism, and loads the corresponding device driver and control strategy template accordingly.

3. The modular and scalable throttling manifold system according to claim 1, characterized in that, The central control unit includes a main control processor, a real-time operating system kernel, an equipment management service module, a collaborative control engine, and a human-machine interface. The equipment management service module maintains a dynamic registry of the connected functional modules, recording the current communication status, functional role, range, and health score of each module. The collaborative control engine constructs a system topology based on the registry information and automatically generates throttling cascade paths, pressure gradient distribution schemes, and flow balancing strategies according to the well control operation mode.

4. A modular and scalable throttling manifold system according to claim 1, characterized in that, Each functional module has a built-in local controller that runs a lightweight real-time task scheduler and executes local closed-loop control logic. Specifically, the local controller of the throttle valve module receives the target opening command from the central control unit and performs PID adjustment in conjunction with the position feedback sensor signal, while monitoring the torque limiter output to prevent overload. The local controller of the pressure monitoring module periodically collects the raw signal from the pressure transmitter, generates engineering unit values ​​after temperature compensation and nonlinear correction, and uploads them. The local controller of the isolation valve module activates the emergency locking solenoid valve synchronously after receiving the closing command and verifies the valve's position through the travel limit switch.

5. A modular and scalable throttling manifold system according to claim 1, characterized in that, The system has a cross-module status verification mechanism. When a functional module detects that it is malfunctioning or exceeds the safety boundary, in addition to sending a fault broadcast message to the central control unit, it also sends a status warning signal to its upstream and downstream adjacent modules through the backbone communication bus. After receiving the signal, the local controller of the adjacent module immediately starts the preset compensation control program. The triggering conditions, action logic and duration of the compensation control program are pre-written into the firmware of each module and bound to the module type.

6. A modular and scalable throttling manifold system according to claim 1, characterized in that, The power distribution network adopts a dual-path DC power supply architecture, with two independent uninterruptible power supply devices supplying power to the functional modules on both sides of the main communication bus. Each functional module is equipped with a power management unit to monitor the input voltage, current and power factor, and to switch to the local energy storage capacitor to maintain the operation of critical circuits when the power supply is abnormal. The power management unit communicates with the local controller, incorporates the power supply status into the module health score calculation, and actively notifies the central control unit to prepare for degraded operation before the voltage drops below a preset safety threshold.

7. A modular and scalable throttling manifold system according to claim 1, characterized in that, The system supports online expansion and hot-swapping operations; when a new functional module is connected, the central control unit automatically detects the new device coming online and verifies its legitimacy based on its identification information; if the verification is successful, it is incorporated into the system topology and the global control strategy is recalculated. If the verification fails, the communication request will be rejected and an illegal access log will be recorded. During the expansion process, the original functional modules will continue to operate normally, and only the affected local areas will perform a state synchronization process of no more than 500ms.

8. A modular and scalable throttling manifold system according to claim 1, characterized in that, The quick-connect mechanical joint adopts a self-centering sealing structure, including an axial positioning keyway, a radial locking clamp, and a double O-ring sealing pair; the axial positioning keyway ensures that the centerline alignment error of the flow channel is less than ±0.1mm; the radial locking clamp applies clamping force through a hydraulic or pneumatic actuator to meet the requirements. in k=1.5; The quick-connect mechanical connector integrates an electrical contact array to establish a physical path for power and communication while the mechanical connection is completed. The electrical contact array adopts a gold-plated spring pin structure with a contact resistance of less than 10 mΩ.

9. A modular and scalable throttling manifold system according to claim 1, characterized in that, The system has a full lifecycle configuration management mechanism; the central control unit loads the latest system configuration snapshot each time it starts up and compares it with the actual status of the currently connected modules; if a module is found to be missing, of an incompatible type, or with parameters drifting beyond the preset tolerance, it will automatically enter a security-restricted mode. All configuration changes, module replacements, and control policy updates generate immutable operation logs, which are then digitally signed by the security element chip and stored in the local audit database.

10. A modular and scalable throttling manifold system according to claim 1, characterized in that, The system supports a multi-level redundant control architecture; apart from the central control unit, any two adjacent functional modules can exchange key status information through a local communication channel based on the CAN FD protocol; in the event of a complete failure of the central control unit, each module maintains basic well control functions based on preset degradation control rules, which include minimum throttling level protection, maximum back pressure limit and fault module bypass logic, and are fixed in the read-only memory of each module.

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