Fracturing manifold of remote automatic control and high-pressure early warning system and control method of fracturing manifold

Abstract

The invention discloses a fracturing manifold of a remote automatic control and high-pressure early warning system and a control method of the fracturing manifold. A first high-pressure four-way joint, a second high-pressure four-way joint, a third high-pressure four-way joint and a fourth high-pressure four-way joint are sequentially arranged along a fracturing manifold channel, and an electric control fracturing valve is arranged between every two adjacent high-pressure four-way joints; a front opening of the first high-pressure four-way joint is connected with a six-way fracturing head, a rear opening of the fourth high-pressure four-way joint is connected with an electric control pressure release valve, a left opening of each high-pressure four-way joint is connected with a high-pressure outlet of a left fracturing pump truck through a left electric control plug valve, and a right opening of each high-pressure four-way joint is connected with a high-pressure outlet of a right fracturing pump truck through a right electric control plug valve. Each high-pressure four-way joint is provided with a pressure transmitter, and the control system is in control connection with the electric control fracturing valve, the electric control pressure release valve, the left side electric control plug valve, the right side electric control plug valve and the pressure transmitters. Remote intelligent control, multi-point pressure accurate monitoring and overpressure automatic safety interlocking of the fracturing manifold are achieved, and the operation efficiency and safety are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of oil and gas field development equipment technology, and in particular to a remote automatic control and high-pressure early warning system fracturing manifold and its control method. Background Technology

[0002] Fracturing manifolds are key surface equipment in oil and gas field fracturing operations. They are mainly used for the distribution, transportation, and control of high-pressure fracturing fluids and are widely used in shale gas development and oil reservoir fracturing stimulation.

[0003] As oil and gas extraction extends to unconventional and low-permeability reservoirs, the scale and pressure levels of fracturing operations are constantly increasing, placing higher demands on the control accuracy, response speed, and safety of manifold systems. Currently, traditional fracturing manifold systems mostly use manual or semi-automatic valve control, which has the following problems: First, operators need to frequently operate valves and confirm status near high-pressure areas, resulting in high labor intensity and personal safety risks; second, the system relies on decentralized instruments and manual interpretation to monitor key operating parameters such as pressure and flow, making it difficult to achieve real-time fusion analysis and centralized early warning of multi-channel data; third, when the manifold pressure rises abnormally, existing systems generally lack a rapid and automatic emergency response mechanism, mainly relying on manual intervention for pressure relief, resulting in delayed response and easily causing equipment overpressure damage or even safety accidents.

[0004] Although intelligentization has become a development trend in the oil drilling and production field, and fracturing equipment with certain remote control functions has emerged in the industry, how to build a highly integrated fracturing manifold system that can realize remote automatic control of the entire process and has intelligent high-pressure early warning and rapid safety interlock functions remains a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] The purpose of this invention is to provide a remote automatic control and high-pressure early warning system for fracturing manifolds and its control method, thereby solving the aforementioned problems existing in the prior art.

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: This invention discloses a remote automatic control and high-pressure early warning system for a fracturing manifold, comprising a first high-pressure four-way valve, a second high-pressure four-way valve, a third high-pressure four-way valve, a fourth high-pressure four-way valve, an electrically controlled fracturing valve, a six-way fracturing head, an electrically controlled pressure relief valve, and a control system. The first, second, third, and fourth high-pressure four-way valves are sequentially arranged along the fracturing manifold channel, and the electrically controlled fracturing valve is positioned between adjacent high-pressure four-way valves. The front port of the first high-pressure four-way valve is connected to the six-way fracturing head, and the rear port of the fourth high-pressure four-way valve is connected to the electrically controlled pressure relief valve. The left ports of both the high-pressure four-way valve and the fourth high-pressure four-way valve are connected to the high-pressure outlet of the left fracturing pump truck via a left-side electrically controlled plug valve, and the right ports are connected to the high-pressure outlet of the right fracturing pump truck via a right-side electrically controlled plug valve. A first pressure transmitter is installed at the front port of the first high-pressure four-way valve, a second pressure transmitter and a third pressure transmitter are respectively installed on the main channel pipe sections of the second and third high-pressure four-way valves, and a fourth pressure transmitter is installed at the rear port of the fourth high-pressure four-way valve. The control system is connected to the electrically controlled fracturing valve, the electrically controlled pressure relief valve, the left-side electrically controlled plug valve, the right-side electrically controlled plug valve, and each pressure transmitter.

[0007] Furthermore, the first high-voltage four-way valve, the second high-voltage four-way valve, the third high-voltage four-way valve, and the fourth high-voltage four-way valve are all arranged in a cross shape on the horizontal plane.

[0008] Furthermore, a first electrically controlled fracturing valve is provided between the first high-pressure four-way valve and the second high-pressure four-way valve, a second electrically controlled fracturing valve is provided between the second high-pressure four-way valve and the third high-pressure four-way valve, and a third electrically controlled fracturing valve is provided between the third high-pressure four-way valve and the fourth high-pressure four-way valve.

[0009] Furthermore, the left and right ports of the first high-pressure four-way valve are respectively connected to a first left-side electrically controlled plug valve and a first right-side electrically controlled plug valve; the left and right ports of the second high-pressure four-way valve are respectively connected to a second left-side electrically controlled plug valve and a second right-side electrically controlled plug valve; the left and right ports of the third high-pressure four-way valve are respectively connected to a third left-side electrically controlled plug valve and a third right-side electrically controlled plug valve; and the left and right ports of the fourth high-pressure four-way valve are respectively connected to a fourth left-side electrically controlled plug valve and a fourth right-side electrically controlled plug valve.

[0010] Furthermore, when any of the pressure transmitters detects a pressure exceeding its corresponding preset safety threshold, the control system triggers a high-pressure warning and automatically controls the electrically controlled pressure relief valve to open.

[0011] Furthermore, the electrically controlled fracturing valve, the electrically controlled pressure relief valve, the left electrically controlled plug valve, and the right electrically controlled plug valve are all intelligent electrically controlled valves, with built-in position sensors for feedback on the valve's on / off status.

[0012] This invention also provides a control method for a fracturing manifold in a remote automatic control and high-pressure early warning system, comprising the following steps: S1: System Initialization and Self-Check: Before fracturing operations begin, the control system sends self-check commands to each electrically controlled fracturing valve, electrically controlled plug valve, pressure transmitter, and flow meter, and receives feedback status information to verify whether the system is in normal working condition; S2: Process Configuration and Command Reception: Based on the fracturing construction design, generate manifold process configuration commands. These commands include the opening and closing status of each electrically controlled valve, target pressure and flow parameters, and the control strategy for determining the sand mixing ratio. The commands are then sent to the corresponding electrically controlled actuators. S3: Fracturing Operation Execution and Real-time Monitoring: Upon initiating fracturing operations, pressure data within the manifold is acquired in real-time via pressure transmitters. Simultaneously, the control system receives downhole sensing data. Based on the fusion analysis of pressure and downhole sensing data, the opening degree of each electrically controlled valve and / or the pumping rate of the fracturing pump truck are dynamically adjusted. S4: High Pressure Early Warning and Safety Response: Continuously compares pressure data with preset safety thresholds. When any pressure data exceeds its corresponding safety threshold, a high pressure early warning is triggered, and a safety interlock operation is automatically executed. The safety interlock operation includes controlling the opening of the electrically controlled pressure relief valve. S5: Construction Completion and Process Reset: After the fracturing operation is completed, control the fracturing manifold to depressurize and vent, and reset all electrically controlled valves to their initial safe state.

[0013] Furthermore, the fracturing operation in step S3 includes the following sub-steps that are executed automatically in sequence: S31: Pressure testing and circulation: Control the manifold to form a circulation loop, start the fracturing pump truck to circulate, and monitor pressure changes to detect leaks; S32: Fracturing and injection: Control the manifold to inject fracturing fluid into the target formation and continuously monitor the wellhead pressure; S33: Sand Addition and Displacement: Coordinate the sand mixing truck and manifold, inject proppant according to the set sand mixing ratio, and after sand addition is completed, switch the process to perform displacement, displacing the sand-carrying fluid in the manifold and wellbore into the formation fracture.

[0014] Furthermore, the safety interlock operation in step S4 also includes: emergency shutdown of the relevant electrically controlled fracturing valve and / or electrically controlled plug valve, and / or stopping the fracturing pump truck's pumping.

[0015] Compared with the prior art, the beneficial technical effects of the present invention are as follows: The remote automatic control and high-pressure early warning system for fracturing manifolds and its control method of this invention utilizes an integrated manifold structure composed of multiple high-pressure four-way valves connected in series, and is equipped with corresponding electrically controlled fracturing valves, plug valves, and a centralized control system. This enables remote one-button operation of the fracturing process. Operators can control all valves, switch processes, and manage pump truck operations from the central control room without entering the high-pressure zone, completely isolating humans from machines and fundamentally eliminating the personal safety risks of high-pressure operations. Automated operation replaces cumbersome manual steps, significantly reducing labor intensity and greatly improving operational efficiency. Simultaneously, by deploying multiple pressure transmitters at key nodes such as the first high-pressure four-way valve inlet, the middle four-way valve main channel, and the fourth high-pressure four-way valve outlet, and combining them with flow and temperature sensors, the control system can acquire pressure data from each channel in real time and integrate it with downhole geological data for analysis. This allows for dynamic, precise, and adaptive adjustment of parameters such as fracturing pump injection rate and valve opening, ensuring that construction is carried out strictly according to the design. It can quickly respond to complex changes downhole; and the system has an embedded early warning algorithm based on real-time pressure monitoring. When the data detected by any pressure transmitter exceeds the preset safety threshold, the system can instantly trigger multi-level early warnings and automatically execute a series of preset safety interlock operations, such as emergency opening of the electrically controlled pressure relief valve, closing relevant channel valves, and stopping pumping. Through the integrated active protection mechanism of "monitoring-judgment-execution", it changes the traditional passive emergency mode that relies on manual judgment and operation, greatly shortens the emergency response time, effectively prevents overpressure accidents, and provides a solid safety guarantee for ultra-high pressure fracturing operations. Each electrically controlled valve has a built-in position sensor, which can feed back the valve opening and closing status to the control system in real time, realizing dual-loop confirmation (command execution and status feedback), effectively preventing misoperation and signal loss. In addition, the system has a power-on self-test function, which can quickly diagnose the status of key components such as valves and sensors, facilitating early detection and troubleshooting of faults, and improving the reliability and maintainability of the equipment. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic diagram of the front view of the fracturing manifold of the remote automatic control and high pressure early warning system of the present invention; Figure 2 This is a top view of the fracturing manifold of the remote automatic control and high pressure early warning system of the present invention; Figure 3This is a schematic diagram of the left-hand structure of the fracturing manifold of the remote automatic control and high-pressure early warning system of the present invention.

[0018] Explanation of reference numerals in the attached drawings: 1. First high-pressure four-way valve; 2. Second high-pressure four-way valve; 3. Third high-pressure four-way valve; 4. Fourth high-pressure four-way valve; 5. First electrically controlled fracturing valve; 6. Second electrically controlled fracturing valve; 7. Third electrically controlled fracturing valve; 8. Six-way fracturing head; 9. Electrically controlled pressure relief valve; 10. First left-side electrically controlled plug valve; 11. Second left-side electrically controlled plug valve; 12. Third left-side electrically controlled plug valve; 13. Fourth left-side electrically controlled plug valve; 14. First right-side electrically controlled plug valve; 15. Second right-side electrically controlled plug valve; 16. Third right-side electrically controlled plug valve; 17. Fourth right-side electrically controlled plug valve; 18. First pressure transmitter; 19. Second pressure transmitter; 20. Third pressure transmitter; 21. Fourth pressure transmitter. Detailed Implementation

[0019] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0020] In the description of this invention, it should be understood that the terms "length," "width," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified.

[0021] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0022] The technical solutions provided by the various embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0023] Example 1 like Figures 1 to 3 As shown, the remote automatic control and high-pressure early warning system fracturing manifold of this embodiment 1 includes a first high-pressure four-way valve 1, a second high-pressure four-way valve 2, a third high-pressure four-way valve 3, a fourth high-pressure four-way valve 4, an electrically controlled fracturing valve, a six-way fracturing head 8, an electrically controlled pressure relief valve 9, and a control system. The first high-pressure four-way valve 1, the second high-pressure four-way valve 2, the third high-pressure four-way valve 3, and the fourth high-pressure four-way valve 4 are arranged sequentially along the fracturing manifold channel, and an electrically controlled fracturing valve is installed between adjacent high-pressure four-way valves. The electrically controlled fracturing valve is used to control the main channel for fracturing fluid to flow into the fracturing wellhead. The front port of the first high-pressure four-way valve 1 is connected to the six-way fracturing head 8. The six-way fracturing head 8 is the channel connecting the fracturing manifold and the fracturing fluid diversion device, and is also the main channel between the manifold and the fracturing wellhead. The rear port of the fourth high-pressure four-way valve 4 is connected to the electrically controlled pressure relief valve 9. The electrically controlled pressure relief valve 9 is installed on the main channel of the fracturing manifold. It automatically starts to relieve pressure in the event of a high-pressure warning or danger, effectively protecting the downstream facilities of the device and ensuring the safe use of the fracturing manifold. The left ports of the first high-pressure four-way valve 1, the second high-pressure four-way valve 2, the third high-pressure four-way valve 3, and the fourth high-pressure four-way valve 4 are all connected to the high-pressure outlet of the left fracturing pump truck through the left electrically controlled plug valve, and the right ports are all connected to the high-pressure outlet of the right fracturing pump truck through the right electrically controlled plug valve. At this time, the left electrically controlled plug valve is used to control the channel between the high-pressure outlet of the left fracturing pump truck and the intelligent fracturing manifold, and the right electrically controlled plug valve is used to control the channel between the high-pressure outlet of the right fracturing pump truck and the intelligent fracturing manifold.

[0024] Furthermore, a first pressure transmitter 18 is installed at the front end of the first high-pressure four-way 1, a second pressure transmitter 19 and a third pressure transmitter 20 are respectively installed on the main channel sections of the second high-pressure four-way 2 and the third high-pressure four-way 3, and a fourth pressure transmitter 21 is installed at the rear end of the fourth high-pressure four-way 4. By installing each pressure transmitter on each section of the main channel of the intelligent fracturing skid, it is a component used to control and monitor the fracturing hydraulic pressure in the fracturing manifold channel.

[0025] Specifically, the control system is connected to the electrically controlled fracturing valve, the electrically controlled pressure relief valve 9, the left electrically controlled plug valve, the right electrically controlled plug valve, and each pressure transmitter.

[0026] Among them, the first high-voltage four-way valve 1, the second high-voltage four-way valve 2, the third high-voltage four-way valve 3, and the fourth high-voltage four-way valve 4 are all distributed in a cross shape on the horizontal plane.

[0027] The main structure of the fracturing manifold of the remote automatic control and high pressure early warning system in this embodiment 1 is centered on a high pressure four-way valve, and is distributed in a cross shape on the horizontal plane. It is connected to the fracturing head at the front, and to the fracturing pump truck on the left and right respectively. A high pressure early warning and pressure relief valve is installed at the rear and connected to the fracturing fluid tank.

[0028] Specifically, a first electrically controlled fracturing valve 5 is installed between the first high-pressure four-way valve 1 and the second high-pressure four-way valve 2, a second electrically controlled fracturing valve 6 is installed between the second high-pressure four-way valve 2 and the third high-pressure four-way valve 3, and a third electrically controlled fracturing valve 7 is installed between the third high-pressure four-way valve 3 and the fourth high-pressure four-way valve 4.

[0029] Furthermore, the left and right ports of the first high-pressure four-way valve 1 are respectively connected to the first left-side electrically controlled plug valve 10 and the first right-side electrically controlled plug valve 14; the left and right ports of the second high-pressure four-way valve 2 are respectively connected to the second left-side electrically controlled plug valve 11 and the second right-side electrically controlled plug valve 15; the left and right ports of the third high-pressure four-way valve 3 are respectively connected to the third left-side electrically controlled plug valve 12 and the third right-side electrically controlled plug valve 16; and the left and right ports of the fourth high-pressure four-way valve 4 are respectively connected to the fourth left-side electrically controlled plug valve 13 and the fourth right-side electrically controlled plug valve 17.

[0030] Furthermore, when the pressure detected by any pressure transmitter exceeds its corresponding preset safety threshold, the control system triggers a high-pressure warning and automatically controls the electrically controlled pressure relief valve 9 to open.

[0031] Preferably, the electrically controlled fracturing valve, the electrically controlled pressure relief valve 9, the left electrically controlled plug valve, and the right electrically controlled plug valve are all intelligent electrically controlled valves. They have an integrated position sensor for real-time feedback of the valve's opening and closing status. This position sensor is electrically connected to the control system, enabling the valve's execution status to be remotely monitored in real time and verified through dual channels.

[0032] The remote automatic control and high-pressure early warning system fracturing manifold of this embodiment 1 includes the following steps when in use: System Initialization and Self-Check: Before fracturing operations begin, the central control system sends a self-check command to the manifold system. The intelligent electrically controlled valves on the manifold (including the first electrically controlled fracturing valve 5, the second electrically controlled fracturing valve 6, the third electrically controlled fracturing valve 7, the first left-side electrically controlled plug valve 10, the second left-side electrically controlled plug valve 11, the third left-side electrically controlled plug valve 12, the fourth left-side electrically controlled plug valve 13, the first right-side electrically controlled plug valve 14, the second right-side electrically controlled plug valve 15, the third right-side electrically controlled plug valve 16, the fourth right-side electrically controlled plug valve 17, and the electrically controlled pressure relief valve 9), pressure transmitters (the first pressure transmitter 18, the second pressure transmitter 19, the third pressure transmitter 20, and the fourth pressure transmitter 21), flow meters, and other equipment perform self-diagnostics and provide real-time feedback on valve opening / closing status, sensor readings, system pressure, and other status information to the on-site fracturing control center. The system verifies that all critical components are in normal working order to ensure the integrity and safety of the manifold process. Process Configuration and Command Reception: Based on the fracturing operation design (such as segment cluster division and pumping procedure), the central decision-making system generates precise manifold process configuration commands. These commands include: the opening and closing status of each manifold channel, target flow and pressure settings, and sand mixing ratio control strategies. After the operator confirms the commands in the control room, the system automatically sends the parameters to the intelligent electrical control actuators of the manifold. Real-time monitoring and dynamic adjustment: During fracturing operations, data from distributed optical fibers and microseismic sensors continuously monitor the propagation of underground fractures. The central decision-making system integrates underground information with real-time pressure and flow data from surface manifolds. Based on the analysis results, the system automatically and dynamically adjusts the opening degree of each valve and switches the number of fluid channels to precisely control the number of fracturing pumps started and stopped, the pumping volume, and the pressure. This ensures that the operation proceeds according to the predetermined plan and can quickly respond to downhole changes (such as fracture extension and changes in formation fluid absorption capacity). Automated execution of key processes: Pressure testing and circulation: The system automatically controls the manifold process, connects the circulation loop, starts the fracturing truck to circulate, and automatically monitors pressure changes to ensure that there are no leaks in the process.

[0033] Trial extrusion and fracturing: During the trial extrusion and formal fracturing stages, the system automatically controls the manifold to precisely inject high-pressure fracturing fluid into the target formation according to the preset program, and continuously monitors the wellhead pressure.

[0034] Propane Addition and Displacement: When proppant addition is required, the system automatically coordinates the proppant mixing truck and manifold to uniformly inject the proppant according to the designed mixing ratio. After proppant addition is completed, the system automatically switches processes and initiates the displacement procedure, completely displacing the proppant-carrying fluid in the manifold and wellbore into the formation fractures. High-Pressure Early Warning, Safety Interlocking, and Emergency Response: The system incorporates a high-pressure early warning and multiple safety interlocking mechanisms. When the system detects that the manifold pressure exceeds the safe value, the flow rate is abnormal, or the equipment malfunctions, it immediately triggers a high-pressure early warning and automatically executes protective procedures such as emergency closure of relevant valves, stopping pumping, switching to a safety circuit, and opening the intelligent electrically controlled pressure relief valve, to maximize the safety of personnel and equipment. Construction Completion and Process Reset: After the fracturing operation is completed, the central system issues an instruction to automatically control the manifold process to depressurize and vent, and reset all valves to their initial safe state to prepare for subsequent construction.

[0035] The remote automatic control and high-pressure early warning system fracturing manifold in Example 1 uses its control process as a core component. Through an integrated control system, it achieves precise, safe, and efficient management of high-pressure fracturing fluid. This process is linked with the closed-loop system of "geological modeling - underground sensing - central decision-making - surface execution" in intelligent fracturing operations, together forming a complete operation control system.

[0036] This system integrates the high and low pressure manifolds, fracturing diversion manifolds, and fracturing unit control systems. By connecting the data from the intelligent control fracturing manifold valves and the fracturing unit control system, precise remote control of all equipment can be achieved from the on-site fracturing control room. The system supports remote one-button self-check, one-button fluid supply, and one-button start / stop operations, thereby significantly improving the overall efficiency of fracturing operations.

[0037] In terms of safety control, the system implements a valve linkage logic of "open the valve before starting the pump, and stop the pump before closing the valve" to improve the safety of equipment operation. The manifold skid integrates multiple valve groups, remote controllers, and high-pressure pipelines, with a simple and clear electrical control pipeline layout. Each remote-controlled valve is equipped with pressure sensors and contact position sensors, achieving real-time monitoring and reliable feedback of the valve's opening and closing status through dual methods, comprehensively preventing misoperation.

[0038] The intelligent control valves of the fracturing manifold are linked with the fracturing pump truck for coordinated control, and the high-pressure fracturing manifold and the diversion manifold are interconnected. The entire control system supports remote operation from the central control room or terminals such as tablet computers, and is equipped with a high-definition video system that enables remote, local, and multi-point monitoring, facilitating real-time monitoring of the operational status. The system adopts a one-button control mode, which can obtain the valve operating status in real time, significantly reducing the labor intensity of operators and effectively ensuring the safety of fracturing operations.

[0039] The high-pressure early warning system within the fracturing manifold performs real-time monitoring, safety protection, and process optimization functions. Through a sensor mechanism linked to an intelligent electrically controlled fracturing valve, it monitors the pressure status of the fracturing fluid within the manifold pipeline in real time and can predict erosion risks based on fluid velocity fluctuations, enabling automatic pipeline switching to optimize flow efficiency. Under ultra-high pressure conditions, the system uses built-in sensors to monitor parameters such as pressure and temperature in real time. When the pressure exceeds a set threshold (e.g., 140 MPa), it triggers an early warning and automatically adjusts the pump injection rate to prevent equipment deformation or seal failure. The early warning system maintains stable operation even under extreme pressure conditions. The intelligent fracturing valve sealing mechanism employs a spring-buffered, flexible support structure, using dynamic adjustment of the sliding tube and guide tube to weaken the impact force. The early warning module compares real-time pressure with rated values ​​to prevent overheating or overpressure operations and can automatically release pressure in emergencies by linking with the intelligent electrically controlled pressure relief valve. To ensure the accuracy of the early warning system, comprehensive improvements are needed in sensor technology, algorithm optimization, structural design, and maintenance standards. Operators should receive professional training to ensure timely shutdown when abnormal vibrations or leaks are detected, thereby guaranteeing the safe operation of fracturing operations under ultra-high pressure conditions.

[0040] Example 2 The control method for the fracturing manifold of the remote automatic control and high-pressure early warning system in Embodiment 2 includes the following steps: S1: System Initialization and Self-Check: Before fracturing operations begin, the control system sends self-check commands to each electrically controlled fracturing valve (including the first electrically controlled fracturing valve 5, the second electrically controlled fracturing valve 6, and the third electrically controlled fracturing valve 7), electrically controlled plug valves (including the first left-side electrically controlled plug valve 10, the second left-side electrically controlled plug valve 11, the third left-side electrically controlled plug valve 12, the fourth left-side electrically controlled plug valve 13, the first right-side electrically controlled plug valve 14, the second right-side electrically controlled plug valve 15, the third right-side electrically controlled plug valve 16, and the fourth right-side electrically controlled plug valve 17), pressure transmitters (including the first pressure transmitter 18, the second pressure transmitter 19, the third pressure transmitter 20, and the fourth pressure transmitter 21), and flow meter, and receives feedback status information to verify whether the system is in normal working condition; S2: Process Configuration and Command Reception: Based on the fracturing construction design, generate manifold process configuration commands, including the opening and closing status of each electrically controlled valve, target pressure and flow parameters, and control strategies for determining the sand mixing ratio. These commands are then sent to the corresponding electrically controlled actuators. S3: Fracturing Operation Execution and Real-time Monitoring: Upon initiating fracturing operations, pressure data within the manifold is acquired in real-time via pressure transmitters. Simultaneously, the control system receives downhole sensing data. Based on the fusion analysis of pressure and downhole sensing data, the opening degree of each electrically controlled valve and / or the pumping rate of the fracturing pump truck are dynamically adjusted. S4: High Pressure Warning and Safety Response: Continuously compares pressure data with preset safety thresholds. When any pressure data exceeds its corresponding safety threshold, a high pressure warning is triggered, and safety interlock operations are automatically executed. These safety interlock operations include controlling the opening of the electrically controlled pressure relief valve. S5: Construction Completion and Process Reset: After the fracturing operation is completed, control the fracturing manifold to depressurize and vent, and reset all electrically controlled valves to their initial safe state.

[0041] The fracturing operation in step S3 includes the following sub-steps that are executed automatically in sequence: S31: Pressure testing and circulation: Control the manifold to form a circulation loop, start the fracturing pump truck to circulate, and monitor pressure changes to detect leaks; S32: Fracturing and injection: Control the manifold to inject fracturing fluid into the target formation and continuously monitor the wellhead pressure; S33: Sand Addition and Displacement: Coordinate the sand mixing truck and manifold, inject proppant according to the set sand mixing ratio, and after sand addition is completed, switch the process to perform displacement, displacing the sand-carrying fluid in the manifold and wellbore into the formation fracture.

[0042] Preferably, the safety interlock operation in step S4 further includes: emergency shutdown of the relevant electrically controlled fracturing valve and / or electrically controlled plug valve, and / or stopping the pumping of the fracturing pump truck.

[0043] The remote automatic control and high-pressure early warning system control method for fracturing manifolds in Embodiment 2 is based on an integrated "perception-decision-execution" closed-loop control logic, realizing full automation and intelligence of fracturing operations from system initialization, process configuration, execution monitoring to safety response. This method dynamically adjusts valve and pump parameters through real-time acquisition of pressure data and fusion analysis of downhole sensing information, ensuring precise and controllable construction. Its built-in high-pressure early warning and multi-level safety interlocking mechanism can automatically trigger rapid emergency responses, including pressure relief, valve closure, and pump shutdown, when the pressure exceeds the limit, significantly improving the operational safety and system reliability under ultra-high pressure conditions. At the same time, standardized, one-click process execution and process reset greatly reduce the intensity of manual operation and the risk of misoperation, improving the overall efficiency and inherent safety level of fracturing construction.

[0044] The embodiments described above are merely preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

Claims

1. A fracturing manifold for a remote automatic control and high-pressure early warning system, characterized in that, The system includes a first high-pressure four-way valve, a second high-pressure four-way valve, a third high-pressure four-way valve, a fourth high-pressure four-way valve, an electrically controlled fracturing valve, a six-way fracturing head, an electrically controlled pressure relief valve, and a control system. The first, second, third, and fourth high-pressure four-way valves are sequentially arranged along the fracturing manifold channel, and the electrically controlled fracturing valve is located between adjacent high-pressure four-way valves. The front port of the first high-pressure four-way valve is connected to the six-way fracturing head, and the rear port of the fourth high-pressure four-way valve is connected to the electrically controlled pressure relief valve. The left ports of all four high-pressure four-way valves are connected to the high-pressure outlet of the left fracturing pump truck via a left-side electrically controlled plug valve, and the right ports are connected to the high-pressure outlet of the right fracturing pump truck via a right-side electrically controlled plug valve. A first pressure transmitter is installed at the front port of the first high-pressure four-way valve. A second pressure transmitter and a third pressure transmitter are respectively installed on the main channel pipe sections of the second and third high-pressure four-way valves. A fourth pressure transmitter is installed at the rear port of the fourth high-pressure four-way valve. The control system is connected to the electrically controlled fracturing valve, the electrically controlled pressure relief valve, the left-side electrically controlled plug valve, the right-side electrically controlled plug valve, and each pressure transmitter.

2. The fracturing manifold of the remote automatic control and high-pressure early warning system according to claim 1, characterized in that, The first high-voltage four-way valve, the second high-voltage four-way valve, the third high-voltage four-way valve, and the fourth high-voltage four-way valve are all arranged in a cross shape on the horizontal plane.

3. The fracturing manifold of the remote automatic control and high-pressure early warning system according to claim 1, characterized in that, A first electrically controlled fracturing valve is provided between the first high-pressure four-way valve and the second high-pressure four-way valve, a second electrically controlled fracturing valve is provided between the second high-pressure four-way valve and the third high-pressure four-way valve, and a third electrically controlled fracturing valve is provided between the third high-pressure four-way valve and the fourth high-pressure four-way valve.

4. The fracturing manifold of the remote automatic control and high-pressure early warning system according to claim 1, characterized in that, The left and right ports of the first high-pressure four-way valve are respectively connected to a first left-side electrically controlled plug valve and a first right-side electrically controlled plug valve; the left and right ports of the second high-pressure four-way valve are respectively connected to a second left-side electrically controlled plug valve and a second right-side electrically controlled plug valve; the left and right ports of the third high-pressure four-way valve are respectively connected to a third left-side electrically controlled plug valve and a third right-side electrically controlled plug valve; and the left and right ports of the fourth high-pressure four-way valve are respectively connected to a fourth left-side electrically controlled plug valve and a fourth right-side electrically controlled plug valve.

5. The fracturing manifold of the remote automatic control and high-pressure early warning system according to claim 1, characterized in that, When the pressure detected by any of the pressure transmitters exceeds its corresponding preset safety threshold, the control system triggers a high-pressure warning and automatically controls the electrically controlled pressure relief valve to open.

6. The fracturing manifold of the remote automatic control and high-pressure early warning system according to any one of claims 1-5, characterized in that, The electrically controlled fracturing valve, the electrically controlled pressure relief valve, the left electrically controlled plug valve, and the right electrically controlled plug valve are all intelligent electrically controlled valves, with built-in position sensors for feedback on the valve's open / closed status.

7. A control method for a fracturing manifold in a remote automatic control and high-pressure early warning system, characterized in that, The fracturing manifold using the remote automatic control and high-pressure early warning system according to any one of claims 1-6 includes the following steps: S1: System Initialization and Self-Check: Before fracturing operations begin, the control system sends self-check commands to each electrically controlled fracturing valve, electrically controlled plug valve, pressure transmitter, and flow meter, and receives feedback status information to verify whether the system is in normal working condition; S2: Process Configuration and Command Reception: Based on the fracturing construction design, generate manifold process configuration commands. These commands include the opening and closing status of each electrically controlled valve, target pressure and flow parameters, and the control strategy for determining the sand mixing ratio. The commands are then sent to the corresponding electrically controlled actuators. S3: Fracturing Operation Execution and Real-time Monitoring: Upon initiating fracturing operations, pressure data within the manifold is acquired in real-time via pressure transmitters. Simultaneously, the control system receives downhole sensing data. Based on the fusion analysis of pressure and downhole sensing data, the opening degree of each electrically controlled valve and / or the pumping rate of the fracturing pump truck are dynamically adjusted. S4: High Pressure Early Warning and Safety Response: Continuously compares pressure data with preset safety thresholds. When any pressure data exceeds its corresponding safety threshold, a high pressure early warning is triggered, and a safety interlock operation is automatically executed. The safety interlock operation includes controlling the opening of the electrically controlled pressure relief valve. S5: Construction Completion and Process Reset: After the fracturing operation is completed, control the fracturing manifold to depressurize and vent, and reset all electrically controlled valves to their initial safe state.

8. The control method for the fracturing manifold of the remote automatic control and high-pressure early warning system according to claim 7, characterized in that, The fracturing operation in step S3 includes the following sub-steps that are executed automatically in sequence: S31: Pressure testing and circulation: Control the manifold to form a circulation loop, start the fracturing pump truck to circulate, and monitor pressure changes to detect leaks; S32: Fracturing and injection: Control the manifold to inject fracturing fluid into the target formation and continuously monitor the wellhead pressure; S33: Sand Addition and Displacement: Coordinate the sand mixing truck and manifold, inject proppant according to the set sand mixing ratio, and after sand addition is completed, switch the process to perform displacement, displacing the sand-carrying fluid in the manifold and wellbore into the formation fracture.

9. The control method for the fracturing manifold of the remote automatic control and high-pressure early warning system according to claim 7, characterized in that, The safety interlock operation in step S4 also includes: emergency shutdown of the relevant electrically controlled fracturing valve and / or electrically controlled plug valve, and / or stopping the pumping of the fracturing pump truck.

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