A fracturing pump system

Abstract

The application provides a fracturing pump system, relates to the technical field of fracturing pumps, and comprises a fluid end, a power driving module, a multi-parameter detection module for detecting the operating parameters of the fluid end, a storage module storing a mapping relationship model of the fracturing pump, an operating analysis module for performing operating state analysis and identifying abnormal correlation characteristics through multi-parameter coupling during the analysis process to obtain operating state analysis results, an alarm unit of an alarm module for alarming when corresponding abnormal correlation characteristics exist, and a main control module responsible for receiving the operating state analysis results, directly issuing control instructions to the power driving module based on the mapping relationship model of the storage module, and controlling the start and stop of the alarm module. Through multi-parameter coupling to identify abnormal correlation characteristics, early fault signals that cannot be reflected by a single parameter can be captured. The main control module can directly issue precise control instructions to the power driving module according to the analysis results and in combination with the mapping relationship model.

Description

Technical Field

[0001] This invention relates to the field of fracturing pump technology, specifically to a fracturing pump system. Background Technology

[0002] Hydraulic fracturing technology is a core production enhancement method for developing unconventional resources such as low-permeability oil and gas reservoirs and shale gas. It achieves rock formation fracturing and proppant filling by injecting high-pressure, high-volume fracturing fluid into the formation, directly determining the oil and gas recovery rate. The fracturing pump system, as the power core of hydraulic fracturing technology, is responsible for the high-pressure delivery of fracturing fluid. Its performance stability, parameter control accuracy, and operation and maintenance efficiency have a crucial impact on construction safety and economy. In the entire system, the fracturing end (including the hydraulic end and supporting valve groups, plungers, and other actuators) is the core unit for pressure conversion and media delivery. It is responsible for converting the mechanical energy of the power end into the hydraulic energy of the fracturing fluid, and completing the media intake and high-pressure discharge through the reciprocating motion of the plunger. It is the key hub connecting the power drive and formation construction.

[0003] Existing fracturing pump monitoring systems, such as the real-time monitoring system for hydraulic end working parameters of a fracturing pump (publication number CN107939661A), have the following problems: 1. The system detects the hydraulic end working parameters, analyzes each parameter independently, and displays them in real time through the host computer interface. However, the intelligent diagnosis and alarm mechanism that integrates multiple parameters is not disclosed, and potential faults cannot be identified in advance through the correlation between parameters. 2. It also failed to achieve intelligent control of the fracturing end operation based on the detection results. Summary of the Invention

[0004] The present invention provides a fracturing pump system to solve at least one of the technical problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, the present invention discloses a fracturing pump system, comprising: Hydraulic end and power drive module; the power drive module is used to drive the reciprocating motion of the plunger in the hydraulic end. Multi-parameter detection module: used to detect the operating parameters of the hydraulic end; Storage module: Stores a mapping model of fracturing pumps; Operation Analysis Module: Communicatively connected to the multi-parameter detection module, the operation analysis module performs operation status analysis based on the detection results of the multi-parameter detection module, and identifies abnormal correlation features through multi-parameter coupling during the analysis process to obtain the operation status analysis results; Alarm Module: The alarm module includes multiple alarm units, which are used to issue alarms when corresponding abnormal correlation characteristics exist; Main control module: It is communicatively connected to the multi-parameter detection module, storage module, operation analysis module, alarm module, and power drive module. It is responsible for receiving the operation status analysis results and, based on the mapping relationship model of the storage module, directly issuing control commands to the power drive module, while controlling the start and stop of the alarm module.

[0006] Preferably, the mapping relationship model includes: A mapping model of the "pump stroke interval - calibrated discharge pressure interval - calibrated discharge flow rate interval" under the rated inlet parameters of the fracturing end for each type of fracturing fluid.

[0007] Preferably, the mapping relationship model includes: The mapping relationship model further includes: a mapping relationship model of fracturing fluid type - calibrated viscosity - pre-test duration and calibrated inlet pressure of fracturing fluid at the fracturing end.

[0008] Preferably, the multi-parameter detection module includes: Liquid inlet parameter detection unit: used to detect the liquid inlet parameters at the hydraulic end, including liquid inlet flow rate and liquid inlet pressure; Viscosity detection unit: Periodically detects the viscosity of the fracturing fluid supplied to the hydraulic end.

[0009] Preferably, the multi-parameter detection module also includes: Discharge detection parameters: Used to detect the discharge parameters at the hydraulic end; Drive module detection unit: used to detect the number of plunger strokes at the hydraulic end.

[0010] Preferably, the main control module includes: Acquisition Unit: Used to acquire the required fracturing fluid pressure and fracturing fluid flow rate for the current application scenario at the hydraulic end; Control Unit 1: Controls the flow rate of the fracturing fluid inlet pipe at the fracturing end to the rated inlet flow rate of the corresponding fracturing fluid for the pre-test duration, and controls the multi-parameter detection module to collect the inlet parameters at the fracturing end within the pre-test duration; Control Unit 2: Controls the flow rate of the fracturing fluid inlet pipe at the fracturing end to the rated inlet flow rate of the corresponding fracturing fluid, and simultaneously controls the operation of the power drive module according to the target pump stroke range; The runtime analysis module includes: Analysis Unit 1: Used to determine the current actual pressure-viscosity characteristic coefficient by combining the fluid inlet parameter detection values ​​at the fracturing end within the pre-test time and the viscosity of the fracturing fluid supplied to the fracturing end detected before the preset time; if the current actual pressure-viscosity characteristic coefficient is not within the corresponding requirement range, then the current actual pressure-viscosity characteristic coefficient is determined to be an abnormal correlation feature; Analysis Unit 2: Based on the current actual pressure-viscosity characteristic coefficient and the preset model of actual pressure-viscosity characteristic coefficient - discharged fracturing fluid pressure compensation coefficient - discharged fracturing fluid flow rate compensation coefficient, and the required discharged fracturing fluid pressure and flow rate of the current application scenario at the fracturing end, the compensated discharged fracturing fluid pressure and flow rate at the fracturing end are determined. Analysis Unit 3: Used to analyze the target pump stroke range corresponding to the "pump stroke range - calibrated discharge pressure range - calibrated discharge flow rate range mapping relationship model" under the rated inlet parameters of the fracturing end corresponding to the current type of fracturing fluid, where the pressure and flow rate of the fracturing fluid discharged from the compensated fracturing end are as follows.

[0011] Preferably, during the operation of the power drive module, the main control module periodically controls the liquid inlet parameter detection unit to perform detection within a set time window; The runtime analysis module includes: Pressure fluctuation analysis unit: Analyzes and determines the current inlet pressure fluctuation coefficient based on the detection results of the inlet parameters within the currently set time window; Liquid inlet disturbance analysis unit: Based on the current liquid inlet pressure fluctuation coefficient and the liquid inlet flow rate detection results within the current set time window, the current liquid inlet flow disturbance coefficient is determined to be an abnormal correlation feature; if the current liquid inlet flow disturbance coefficient is not within the corresponding requirement range, the current liquid inlet flow disturbance coefficient is determined to be an abnormal correlation feature. Pump stroke adjustment analysis unit: When the inlet flow disturbance coefficient is greater than or equal to the adjustment trigger threshold but less than the alarm threshold, it determines the current corrected pump stroke based on the inlet flow disturbance coefficient and the current pump stroke. The main control module controls the power drive module to work based on the current corrected pump stroke. During the operation, the main control module controls the multi-parameter detection module to collect the discharge parameters and verify whether the discharge parameters under the corrected pump stroke meet the process requirements. If the verification passes, the power drive module continues to work based on the current corrected pump stroke. If the verification fails, the current inlet flow disturbance coefficient is also determined to be an abnormal correlation feature.

[0012] Preferably, the analysis module also includes: Screening and Analysis Unit: When the discharge pressure fluctuation coefficient is greater than the preset discharge pressure fluctuation coefficient, the unit screens the detection time-discharge pressure curve and the detection time-inlet pressure curve of the same set time window in history, and determines the detection time difference corresponding to the peak value of the detection time-discharge pressure curve and the detection time-inlet pressure curve. Pressure fluctuation amplitude analysis unit: When the current inlet flow disturbance coefficient is not within the corresponding required range, it determines the current discharge pressure fluctuation amplitude and the current inlet pressure fluctuation amplitude based on the acquisition results of the multi-parameter detection module within the set time window corresponding to the current inlet flow disturbance coefficient. Inlet / outlet pressure correlation analysis unit: Based on the current inlet / outlet pressure fluctuation amplitude and the current outlet pressure fluctuation amplitude and the detection time difference, determine the current outlet / outlet pressure interference coefficient; if the current outlet / outlet pressure interference coefficient is not within the corresponding requirement range, then determine the current outlet / outlet pressure interference coefficient as an abnormal correlation feature; The main control module includes: a control strategy unit, which determines the control strategy based on the discharge / intake pressure interference coefficient. When the discharge pressure interference coefficient is greater than the preset value of 1, it indicates that the discharge pressure fluctuation is the main influencing factor of the inlet pressure fluctuation, and the discharge end fluctuation suppression strategy is activated. When the discharge pressure interference coefficient is less than the preset value of two, it indicates that the discharge pressure fluctuation is not the main influencing factor of the inlet pressure fluctuation, and the system switches to the independent diagnosis and control mode at the inlet end.

[0013] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0014] Compared with the prior art, the present invention has the following beneficial effects: This system overcomes the limitations of traditional systems that only monitor a single parameter at the hydraulic end. It simultaneously collects multi-dimensional operating parameters from both the hydraulic end and the power drive module, and identifies abnormal correlation features through multi-parameter coupling, enabling it to capture early fault signals that cannot be detected by a single parameter. This design significantly advances the fault identification time window, avoiding the delayed fault detection problem caused by isolated monitoring in traditional systems, and significantly reducing the probability of sudden equipment shutdowns.

[0015] The alarm module contains multiple alarm units, which can trigger alarms for different types of abnormal correlation features, allowing maintenance personnel to quickly locate the type and location of the fault without having to check isolated parameters one by one.

[0016] The main control module can directly issue precise control commands to the power drive module based on the analysis results and the mapping relationship model, and simultaneously realize the start and stop control of the alarm module. This achieves automated and intelligent control of the fracturing end operation, and realizes the linkage response between control and alarm, which greatly improves the timeliness of fault handling and the accuracy of control, and completely solves the defect of the existing technology that "does not realize intelligent control of the fracturing end operation based on the detection results". Attached Figure Description

[0017] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the system composition of the present invention; Figure 2 This is a schematic diagram of the hydraulic end of the present invention. Detailed Implementation

[0018] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0019] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0020] The present invention provides the following embodiments: Example 1: This embodiment of the invention provides a fracturing pump system, such as... Figures 1-2 As shown, it includes: a hydraulic end and a power drive module, the power drive module being used to drive the reciprocating motion of the plunger in the hydraulic end; Multi-parameter detection module: used to detect the operating parameters of the hydraulic end; Storage module: Stores a mapping model of fracturing pumps; Operation Analysis Module: Communicatively connected to the multi-parameter detection module, the operation analysis module performs operation status analysis based on the detection results of the multi-parameter detection module, and identifies abnormal correlation features through multi-parameter coupling during the analysis process to obtain the operation status analysis results; Alarm Module: The alarm module includes multiple alarm units, which are used to issue alarms when corresponding abnormal correlation characteristics exist; Main control module: It is communicatively connected to the multi-parameter detection module, storage module, operation analysis module, alarm module, and power drive module. It is responsible for receiving the operation status analysis results and, based on the mapping relationship model of the storage module, directly issuing control commands to the power drive module, while controlling the start and stop of the alarm module.

[0021] Figure 1 A schematic diagram of a hydraulic end for the application of this invention can be found in CN116624353A; This invention can also be applied to other existing hydraulic terminals.

[0022] The beneficial effects of the above technical solution are as follows: This system overcomes the limitations of traditional systems that only monitor a single parameter at the hydraulic end. It simultaneously collects multi-dimensional operating parameters from both the hydraulic end and the power drive module, and identifies abnormal correlation features through multi-parameter coupling, enabling it to capture early fault signals that cannot be detected by a single parameter. This design significantly advances the fault identification time window, avoiding the delayed fault detection problem caused by isolated monitoring in traditional systems, and significantly reducing the probability of sudden equipment shutdowns.

[0023] The alarm module contains multiple alarm units, which can trigger alarms for different types of abnormal correlation features, allowing maintenance personnel to quickly locate the type and location of the fault without having to check isolated parameters one by one.

[0024] The main control module can directly issue precise control commands to the power drive module based on the analysis results and the mapping relationship model, and simultaneously realize the start and stop control of the alarm module. This achieves automated and intelligent control of the fracturing end operation, and realizes the linkage response between control and alarm, which greatly improves the timeliness of fault handling and the accuracy of control, and completely solves the defect of the existing technology that "does not realize intelligent control of the fracturing end operation based on the detection results".

[0025] Example 2, based on Example 1, the mapping relationship model includes: The mapping relationship model of "pump stroke interval - calibrated discharge pressure interval - calibrated discharge flow rate interval" under the rated inlet parameters of the fracturing end for each type of fracturing fluid; the mapping relationship model of the calibrated inlet pressure of the fracturing fluid at the fracturing end for fracturing fluid type - calibrated viscosity - pre-test duration.

[0026] Fracturing fluid refers to the working fluid used in fracturing operations. Common types include slickwater, cross-linked guar gum, and linear guar gum. The viscosity of different fracturing fluids varies greatly, which directly affects the operating parameters of the pump set.

[0027] The rated fluid inlet parameters at the fracturing end are the standard fluid inlet conditions required by the design or operation of the fracturing end, mainly including the fluid inlet flow rate.

[0028] The multi-parameter detection module includes: Liquid inlet parameter detection unit: used to detect the liquid inlet parameters at the hydraulic end, including liquid inlet flow rate and liquid inlet pressure; Viscosity detection unit: Periodically detects the viscosity of the fracturing fluid supplied to the hydraulic end.

[0029] The main control module includes: Acquisition Unit: Used to acquire the required fracturing fluid pressure (which can be a range, and the intermediate value can be selected in the calculation below) and fracturing fluid flow rate (which can be a range, and the intermediate value can be selected in the calculation below) for the current application scenario of the hydraulic end. Control Unit 1: Controls the flow rate of the fracturing fluid inlet pipe at the fracturing end to the rated inlet flow rate of the corresponding fracturing fluid for the pre-test duration, and controls the multi-parameter detection module to collect the inlet parameters at the fracturing end within the pre-test duration; Analysis Unit 1: Used to determine the current actual pressure-viscosity characteristic coefficient by combining the measured values ​​of the fluid inlet parameters at the fracturing end within the pre-test duration and the viscosity of the fracturing fluid supplied to the fracturing end measured before the preset duration (the viscosity needs to be measured once before the preset duration begins); if the current actual pressure-viscosity characteristic coefficient is not within the corresponding requirement range, the current fluid inlet flow disturbance coefficient is determined to be an abnormal correlation feature. Analysis Unit 2: Based on the current actual pressure-viscosity characteristic coefficient and the preset model of actual pressure-viscosity characteristic coefficient - discharge fracturing fluid pressure compensation coefficient - discharge fracturing fluid flow rate compensation coefficient, and the requirements of the current application scenario of the fracturing end for discharge fracturing fluid pressure and flow rate, determine the compensated discharge fracturing fluid pressure and flow rate of the fracturing end. Analysis Unit 3: Used to analyze the target pump stroke range corresponding to the "pump stroke range - calibrated discharge pressure range - calibrated discharge flow rate range mapping relationship model" under the rated fluid inlet parameters of the fracturing end corresponding to the current type of fracturing fluid, where the pressure and flow rate of the fracturing fluid discharged from the compensated fracturing end are at the compensated fracturing end. Control Unit 2: Controls the flow rate of the fracturing fluid inlet pipe at the fracturing end to the rated inlet flow rate of the corresponding fracturing fluid, and simultaneously controls the power drive module to work according to the target pump stroke range (within the target pump stroke range, the system will first take the middle value of the range as the initial value, and then fine-tune the actual discharged pressure and flow rate).

[0030] 1. Regarding the mapping relationship model: Both models are based on high-quality fracturing fluid (fresh fracturing fluid that meets industry standards, has stable performance, and is free from degradation or contamination; using this as the experimental benchmark ensures that the collected parameters such as pressure and flow rate reflect only the pump unit's operating characteristics, rather than interference caused by the fracturing fluid's own deterioration, thus guaranteeing the model's accuracy and reliability) and a hydraulic end in normal working condition. They were constructed through experimental testing, multi-dimensional data fitting, and field condition verification. The range of the number of reciprocating motions of the fracturing pump plunger per minute (e.g., 10-20 times / minute is the low-stroke range, and 20-30 times / minute is the high-stroke range) is the core control variable of the power drive module, which directly determines the pump's output capacity.

[0031] The model defines a mapping relationship between pump stroke interval, calibrated discharge pressure interval, and calibrated discharge flow rate interval for each fracturing fluid under the rated inlet parameters at the fracturing end. The mapping group consists of the actual (distinguished by calibration) discharge pressure interval and the actual discharge flow rate interval (the outlet at the hydraulic end) determined experimentally under a specific pump stroke interval. For example, for a certain fracturing fluid, when the pump stroke interval is between 10 and 15 strokes / minute, the corresponding calibrated discharge pressure typically falls within the range of 18 to 22 MPa, and the calibrated discharge flow rate is fixed within the range of 1.8 to 2.2 m³ / min. The fracturing fluid type-calibrated viscosity-pre-test duration fracturing fluid inlet pressure mapping model at the fracturing end is the actual viscosity (called calibrated viscosity) of a specific fracturing fluid (high-quality fracturing fluid) at common temperatures under its operating conditions. The pre-test duration is as follows, which is a short duration (e.g., 30s to 2min) for pre-testing the fracturing fluid state. 2. Current Application Scenario Requirements for Fracturing Fluid Discharge Pressure and Flow Rate at the Hydraulic End: The hydraulic end of the fracturing pump, under specific well conditions and construction stages, requires the fracturing fluid discharge pressure and flow rate to meet formation injection requirements and construction techniques. 3. A branch pipe can be installed in front of the outlet of the inlet pipe at the hydraulic end. The branch pipe can be controlled by a valve to prevent the fracturing fluid from entering the hydraulic end during the pre-test period. The fluid is only used to collect viscosity and inlet pressure parameters.

[0032] Current actual compressive viscosity coefficient = Current viscosity factor × ; Current viscosity factor = ; Current stress factor = ; The pressure influence coefficient is the coefficient of influence of the current fracturing fluid on viscosity at pressure calibrated with a corresponding higher quality quantity of fracturing fluid. A higher quality quantity of the current fracturing fluid is taken and kept at a constant temperature in a constant-temperature container, with only the system pressure varied (gradients of 3 MPa, 5 MPa, 7 MPa, 9 MPa, etc.). At each pressure point, the viscosity value of the fracturing fluid is directly measured using a viscometer, and multiple sets of pressure-viscosity data are recorded. The coefficient is calculated by comparing the measured viscosity at different pressures with the reference viscosity at a reference pressure (e.g., 5 MPa), and the pressure influence coefficient is calculated. The pressure influence coefficient is taken as 1 ± 0.1. The current viscosity factor is the viscosity-dominant term: when the current viscosity factor is greater than 1, the viscosity increases, the flow resistance increases, and the pressure increases and the flow rate decreases for the same number of strokes; when the current viscosity factor is less than 1, the viscosity decreases, the flow resistance decreases, and the pressure decreases and the flow rate increases for the same number of strokes. The current pressure factor is greater than 1, leading to increased inlet pressure, more dissolved gas in the fracturing fluid, a decrease in the effective proportion of the liquid phase, and a further amplification of changes in flow resistance. If the viscosity is already low, the effect of increasing flow rate will be more pronounced; if the viscosity is already high, the pressure increase will be even greater. The current pressure factor is less than 1, resulting in a decrease in inlet pressure, gas release from the fracturing fluid, an increase in the effective proportion of the liquid phase, and a further amplification of changes in flow resistance. If the viscosity is already high, the effect of reducing the flow rate will be more pronounced; if the viscosity is already low, the pressure reduction will be even greater. The lower limit of the fracturing fluid inlet pressure at the fracturing end (which can be set differently for different fracturing fluids) is the minimum inlet pressure threshold that enables the hydraulic end of the fracturing pump to operate stably and safely. It is a key parameter derived from equipment design and long-term experimental verification. Taking common fracturing fluids such as slickwater and cross-linked guar gum as examples, the required range for the compressive viscosity coefficient is 0.9 to 1.1. In the model with preset actual viscosity-pressure characteristic coefficient - discharge fracturing fluid pressure compensation coefficient - discharge fracturing fluid flow rate compensation coefficient: Fracturing fluid discharge pressure compensation coefficient = Fracturing fluid discharge pressure after compensation ÷ Fracturing fluid discharge pressure required for the current application scenario; Fracturing fluid discharge flow rate compensation coefficient = Fracturing fluid discharge flow rate after compensation ÷ Fracturing fluid discharge flow rate required for the current application scenario; Current discharge fracturing fluid pressure compensation coefficient = ; Current discharge fracturing fluid flow rate compensation coefficient = ; (0.7~1.3) and (0.5~1.0) are the pressure correction index and flow correction index, respectively. Based on different current actual pressure viscosity coefficients, the actual pressure / flow rate of the fracturing fluid discharged at the fracturing end that meets the demand can be determined by comparing the corresponding pressure / flow rate of the fracturing fluid discharged at the fracturing end with the demand pressure / flow rate of the fracturing end in the corresponding mapping table. Due to factors such as long-term storage of fracturing fluid, the pressure and viscosity of fracturing fluid can vary even at the rated inlet flow rate. Therefore, in order to ensure that the fracturing fluid meets the required discharge pressure and flow rate, it is necessary to conduct tests for a preset duration to reflect the actual pressure and viscosity characteristics. The pressure and flow rate of the fracturing fluid discharged from the fracturing end after compensation are affected by the actual compressive viscosity characteristics, resulting in different actual fracturing fluid discharge pressure and flow rate at the same number of strokes. In order to more accurately determine the control stroke based on the required fracturing fluid discharge pressure and flow rate, the factors need to be determined based on the pressure and flow rate of the fracturing fluid discharged from the fracturing end after compensation. 4. In analysis unit three: In the above mapping relationship model, find the target pump stroke interval that simultaneously matches the set of parameters "compensated fracturing fluid discharge pressure and compensated fracturing fluid discharge flow rate". If the pressure and flow rate of the fracturing fluid discharged from the compensated fracturing end fall into two different pump stroke intervals, then the pump stroke interval corresponding to the pressure of the fracturing fluid discharged from the compensated fracturing end shall be taken as the target pump stroke interval.

[0033] In this application, each pump stroke specifically refers to a plunger stroke. The beneficial effects of the above technical solution are as follows: An independent mapping model was established for each fracturing fluid, achieving precise adaptation to differences in fluid properties. The model built based on experimental and field data provides a reliable basis for the linkage of pump strokes, pressure, and flow rate, enabling control to shift from experience-based judgment to precise quantification. The dual-model design (pump stroke-pressure-flow mapping + fluid property-inlet pressure mapping) covers the entire chain from fluid properties to output, ensuring the integrity of the control logic.

[0034] Traditional fracturing operations rely on experience to pre-set pump strokes, which cannot cope with the dynamic changes in the viscosity-pressure characteristics of fracturing fluid caused by storage time, degradation, temperature changes, and shear degradation. This solution, through simultaneous monitoring of inlet pressure, flow rate, and viscosity during the pre-test period, calculates the current actual viscosity-pressure characteristic coefficient in real time, transforming the invisible fluid property changes into quantifiable numerical indicators, thus eliminating the interference of fluid property fluctuations on the operation at the source.

[0035] Based on the current actual compressive viscosity coefficient, the compensation algorithm can dynamically adjust the target pressure and flow rate, ensuring that the final output can still stably meet core process indicators such as formation fracturing pressure and fracture propagation flow rate even when the fracturing fluid performance deteriorates or fluctuates. This mechanism avoids uncontrolled fracture morphology caused by changes in fluid properties, significantly improving the uniformity and effectiveness of fracturing stimulation.

[0036] The innovation achieves precise closed-loop locking of rated inlet flow rate and synchronous real-time detection of liquid properties and operating parameters, thus avoiding pump load fluctuations caused by sudden changes in flow rate from the source.

[0037] Example 3: Based on Example 1, during the operation of the power drive module, the main control module periodically controls the liquid inlet parameter detection unit to perform detection within a set time window. The runtime analysis module includes: Pressure fluctuation analysis unit: Analyzes and determines the current inlet pressure fluctuation coefficient based on the detection results of the inlet parameters within the currently set time window; Liquid inlet disturbance analysis unit: Based on the current liquid inlet pressure fluctuation coefficient and the liquid inlet flow rate detection results within the current set time window, the current liquid inlet flow disturbance coefficient is determined to be an abnormal correlation feature; if the current liquid inlet flow disturbance coefficient is not within the corresponding requirement range, the current liquid inlet flow disturbance coefficient is determined to be an abnormal correlation feature. Pump stroke adjustment analysis unit: When the inlet flow disturbance coefficient is greater than or equal to the adjustment trigger threshold but less than the alarm threshold, it determines the current corrected pump stroke based on the inlet flow disturbance coefficient and the current pump stroke. The main control module controls the power drive module based on the current corrected pump stroke count. During operation, the main control module controls the multi-parameter detection module to collect discharge parameters and verify whether the discharge parameters under the corrected pump stroke count meet the process requirements. If the verification passes (the actual discharge parameters meet the corresponding target discharge pressure and flow range), the power drive module continues to operate based on the current corrected pump stroke count. If the verification fails (the actual discharge parameters do not meet the corresponding target discharge pressure and flow range), the current inlet flow disturbance coefficient is also determined to be an abnormal correlation feature (triggering an alarm and triggering a warning to implement corresponding measures to reduce inlet parameter disturbance, such as replenishing the inlet buffer tank with gas and dynamically fine-tuning the inlet flow equalization valve).

[0038] Current infeed pressure fluctuation coefficient = (maximum infeed pressure detection value in the current set time window - minimum infeed pressure detection value in the current set time window) ÷ median value of the calibrated discharge pressure range corresponding to the current pump stroke of the fracturing fluid (e.g., if the calibrated pressure is 15~18 MPa, the median value is 0.5×(15+18) MPa). Current inlet flow disturbance coefficient = current inlet pressure fluctuation coefficient × current inlet flow rate detection value of the current set time window ÷ reference inlet flow rate; The baseline infeed flow rate can be set to the minimum allowable infeed flow rate for normal operation of the current fracturing fluid; Inlet pressure fluctuation coefficient: High-frequency pressure fluctuation is one of the typical characteristics of flow disturbance. This coefficient directly quantifies the intensity of pressure field fluctuation disturbance in the inlet pipeline and is a core prerequisite parameter for evaluating flow stability.

[0039] The inlet flow disturbance coefficient is a core indicator characterizing the overall flow field disturbance of the inlet system. It couples the pressure fluctuation intensity with the flow field flow dimension to quantify the overall fluctuation disturbance of the inlet system. The larger the inlet flow rate, the greater the energy of the fluctuating flow field, and the more significant the range, transmission effect and impact on the system caused by the pressure fluctuation. When the forward fluid flow disturbance coefficient is greater than 0 and less than 0.15 within the required range, the trigger threshold is adjusted to 0.12 and the alarm threshold is adjusted to 0.15; these thresholds are determined based on the fault statistics of the fracturing pump system during long-term operation. Current corrected pump strokes = Current pump strokes × Correction value; Correction value = 1 - (the arithmetic mean of the required range of the current inlet flow disturbance coefficient and the adjustment trigger threshold) × pump stroke correction coefficient; The pump stroke correction factor is a dimensionless calibration factor used to quantify the correspondence between the inlet flow disturbance coefficient and the pump stroke adjustment range. The pump stroke correction factor is obtained through two-stage experiments: bench pre-calibration and field closed-loop calibration. The bench test uses standard fracturing fluid as the medium and artificially introduces inlet pressure disturbances at 50%, 70%, and 100% of the rated pump stroke to trigger the inlet flow disturbance coefficient to exceed the standard. The correction factor is selected in a stepwise manner from 0.05 to 0.30 for testing, and a value that can make the inlet flow disturbance coefficient fall back to the normal range within two testing cycles and have no abnormality in drainage performance is fitted. The value range of the pump stroke correction factor is 0.08 to 0.12.

[0040] The beneficial effects of the above technical solution are as follows: The pressure fluctuation analysis unit eliminates the interference of absolute values ​​under different construction pressures by normalizing the pressure fluctuation coefficient (peak-valley difference divided by the median of the calibrated drainage pressure range), making the disturbance intensity comparable across all operating conditions. This avoids misjudgments where the absolute value of the peak-valley difference is large but the relative disturbance is small under high-pressure conditions. At the same time, as a preliminary early warning indicator for flow stability, it can capture high-frequency pressure fluctuations in the inlet pipeline in real time, providing reliable raw data for subsequent flow assessment and helping the system to identify potential flow deterioration risks in advance.

[0041] The liquid inlet disturbance analysis unit couples pressure fluctuation intensity with flow energy and liquid inlet flow disturbance coefficient, which truly reflects the physical law that "the greater the flow, the higher the disturbance energy", and realizes accurate quantification of the overall disturbance degree of the liquid inlet system. When the disturbance coefficient exceeds the normal range, it can be directly marked as an abnormal correlation feature, triggering subsequent control or alarm, reducing fault diagnosis time and improving system response speed.

[0042] The pump stroke adjustment analysis unit calculates the corrected pump stroke based on the disturbance coefficient and the current pump stroke. Through dynamic calibration of the pump stroke correction coefficient, it ensures that the adjustment force is always adapted to the current working conditions, which can effectively suppress disturbances without causing abnormal drainage performance.

[0043] During on-site construction, the passive buffer control strategy reduces the frequency of pump stroke adjustments, lowers the risk of construction interruption, and improves the continuity of operations and overall efficiency. Precise disturbance assessment can also detect the deterioration trend of pump chamber sealing performance in advance, and remind maintenance personnel to maintain valves in a timely manner through early warning, so as to avoid downtime maintenance due to seal failure, thereby reducing maintenance costs and safety risks.

[0044] Example 4, based on Example 3, further includes the following in the analysis module: Screening and Analysis Unit: When the discharge pressure fluctuation coefficient is greater than the preset discharge pressure fluctuation coefficient, the unit screens the detection time-discharge pressure curve and the detection time-inlet pressure curve of the same set time window in history, and determines the detection time difference corresponding to the peak value of the detection time-discharge pressure curve and the detection time-inlet pressure curve. Pressure fluctuation amplitude analysis unit: When the current inlet flow disturbance coefficient is not within the corresponding required range, it determines the current discharge pressure fluctuation amplitude and the current inlet pressure fluctuation amplitude based on the acquisition results of the multi-parameter detection module within the set time window corresponding to the current inlet flow disturbance coefficient. Inlet / outlet pressure correlation analysis unit: Based on the current inlet / outlet pressure fluctuation amplitude and the current outlet pressure fluctuation amplitude and the detection time difference, determine the current outlet / outlet pressure interference coefficient; if the current outlet / outlet pressure interference coefficient is not within the corresponding requirement range, then determine the current outlet / outlet pressure interference coefficient as an abnormal correlation feature; The main control module includes: a control strategy unit, which determines the control strategy based on the discharge / intake pressure interference coefficient. When the discharge pressure interference coefficient is greater than the preset value of 1, it indicates that the discharge pressure fluctuation is the main influencing factor of the inlet pressure fluctuation. The discharge end fluctuation suppression strategy is activated (dynamically adjusting the opening and closing sequence of the discharge valve, adding a damping device to the discharge pipeline (e.g., the opening degree of the damping device can be determined based on the discharge pressure interference coefficient) to weaken the pressure fluctuation at the discharge end from the source (the larger the discharge pressure interference coefficient, the greater the pressure fluctuation at the discharge end that needs to be reduced), and reduce its reverse transmission to the inlet end). When the preset value of the discharge pressure interference coefficient is two, it indicates that the discharge pressure fluctuation is the main influencing factor of the inlet pressure fluctuation. Switch to the independent diagnosis and control mode of the inlet end (focus on checking and optimizing the action sequence of the inlet valve and the buffer strength of the air replenishment valve to stabilize the inlet pressure).

[0045] Discharge pressure interference coefficient = ; When the drainage pressure fluctuation coefficient exceeds the preset drainage pressure fluctuation coefficient (with a value of 0.05 to 0.15), the system will extract the complete curves of the inlet pressure and drainage pressure changing with time within the same detection time window, locate the detection time corresponding to the pressure peak on the two curves respectively, and calculate the time difference between the two (i.e., the detection time difference, detection time difference = detection time corresponding to the drainage pressure peak - detection time corresponding to the inlet pressure peak). This is used to determine the propagation direction and delay of the pressure disturbance, providing key timing basis for subsequent accurate tracing of the disturbance source and optimization of control timing.

[0046] Fluid pressure fluctuation range: The difference between the maximum and minimum values ​​of the inlet pressure within the set time window corresponding to the current fluid flow disturbance coefficient (peak-valley difference). Discharge pressure fluctuation range: The difference between the maximum and minimum values ​​of the discharge pressure within the set time window corresponding to the current inlet flow disturbance coefficient (peak-valley difference). The inlet, pump chamber, and outlet pipeline of the hydraulic end of a fracturing pump form a closed, continuous cavity filled with fracturing fluid. As a continuous fluid medium, the fracturing fluid transmits pressure changes. When pressure fluctuations occur at the outlet due to rapid opening and closing of the outlet valve (causing water hammer), downstream pipeline resistance changes, disturbances in the manifold of multiple pumps operating in parallel, or fluid resonance, these pressure changes are transmitted in all directions through the continuous fracturing fluid in the pipeline, not just forward with the pumping direction. Therefore, they are transmitted in the opposite direction to the inlet, causing hysteretic fluctuations in the inlet pressure. This is an inherent physical characteristic of continuous fluids transmitting pressure changes in closed pipelines. Amplitude ratio (discharge pressure fluctuation amplitude / inlet pressure fluctuation amplitude): directly reflects the degree of energy attenuation or amplification when the fluctuation at the discharge end is transmitted back to the inlet end. This reflects the delay effect of the disturbance propagating from the drain end to the inlet end. The longer the delay time, the larger the correction term. By combining the amplitude ratio with the time delay, the intensity of the disturbance of the drain fluctuation to the inlet end can be intuitively judged.

[0047] The contribution of discharge pressure fluctuation to inlet pressure fluctuation can be determined based on the discharge pressure interference coefficient.

[0048] The beneficial effects of the above technical solution are as follows: The pressure fluctuation analysis unit eliminates the influence of different construction pressures on the amplitude ratio of the discharge pressure interference coefficient and the time delay correction by using a normalized pressure fluctuation coefficient (peak-to-valley difference divided by the median of the calibrated discharge pressure range). This allows for accurate differentiation between "disturbances transmitted in reverse at the discharge end" and "fluctuations at the inlet end," preventing the misjudgment of independent problems such as stuck inlet valves or leaking suction pipes as interference at the discharge end. This significantly improves the accuracy of fault location and reduces ineffective troubleshooting time.

[0049] The interference coefficient can be directly used as the input variable of the PID controller to dynamically calculate specific control parameters such as the phase adjustment of the drain valve, the opening of the damping device, and the pump stroke compensation value. This achieves an upgrade from "qualitative judgment" to "quantitative control", effectively attenuating reverse pressure fluctuations and reducing risks such as cavitation of the inlet valve and decreased pump efficiency, thereby improving the pressure stability of the fracturing process.

[0050] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. A fracturing pump system, characterized in that: include: Hydraulic end and power drive module; the power drive module is used to drive the reciprocating motion of the plunger in the hydraulic end. Multi-parameter detection module: used to detect the operating parameters of the hydraulic end; Storage module: Stores a mapping model of fracturing pumps; Operation Analysis Module: Communicatively connected to the multi-parameter detection module, the operation analysis module performs operation status analysis based on the detection results of the multi-parameter detection module, and identifies abnormal correlation features through multi-parameter coupling during the analysis process to obtain the operation status analysis results; Alarm Module: The alarm module includes multiple alarm units, which are used to issue alarms when corresponding abnormal correlation characteristics exist; Main control module: It is communicatively connected to the multi-parameter detection module, storage module, operation analysis module, alarm module and power drive module. It is responsible for receiving the operation status analysis results and, based on the mapping relationship model of the storage module, directly issuing control commands to the power drive module, and controlling the start and stop of the alarm module. The mapping relationship model includes: the mapping relationship model of pump stroke interval - calibrated discharge pressure interval - calibrated discharge flow rate interval under the rated inlet parameters of each fracturing fluid at the fracturing end; The mapping relationship model includes: the mapping relationship model of fracturing fluid type-calibrated viscosity-pre-test duration and the calibrated inlet pressure of fracturing fluid at the fracturing end; The main control module includes: Acquisition Unit: Used to acquire the required fracturing fluid pressure and fracturing fluid flow rate for the current application scenario at the hydraulic end; Control Unit 1: Controls the flow rate of the fracturing fluid inlet pipe at the fracturing end to the rated inlet flow rate of the corresponding fracturing fluid for the pre-test duration, and controls the multi-parameter detection module to collect the inlet parameters at the fracturing end within the pre-test duration; Control Unit 2: Controls the flow rate of the fracturing fluid inlet pipe at the fracturing end to the rated inlet flow rate of the corresponding fracturing fluid, and simultaneously controls the operation of the power drive module according to the target pump stroke range; The runtime analysis module includes: Analysis Unit 1: Used to determine the current actual pressure-viscosity characteristic coefficient by combining the fluid inlet parameter detection values ​​at the fracturing end within the pre-test time and the viscosity of the fracturing fluid supplied to the fracturing end detected before the preset time; if the current actual pressure-viscosity characteristic coefficient is not within the corresponding requirement range, then the current actual pressure-viscosity characteristic coefficient is determined to be an abnormal correlation feature; Analysis Unit 2: Based on the current actual pressure-viscosity characteristic coefficient and the preset model of actual pressure-viscosity characteristic coefficient - discharged fracturing fluid pressure compensation coefficient - discharged fracturing fluid flow rate compensation coefficient, and the required discharged fracturing fluid pressure and flow rate of the current application scenario at the fracturing end, the compensated discharged fracturing fluid pressure and flow rate at the fracturing end are determined. Analysis Unit 3: This unit is used to analyze the target pump stroke range corresponding to the mapping relationship model of the pump stroke range - calibrated discharge pressure range - calibrated discharge flow rate range under the rated inlet parameters of the fracturing end corresponding to the current type of fracturing fluid, where the pressure and flow rate of the fracturing fluid discharged from the compensated fracturing end are calculated.

2. The fracturing pump system according to claim 1, characterized in that: The multi-parameter detection module includes: Liquid inlet parameter detection unit: used to detect the liquid inlet parameters at the hydraulic end, including liquid inlet flow rate and liquid inlet pressure; Viscosity detection unit: Periodically detects the viscosity of the fracturing fluid supplied to the hydraulic end.

3. A fracturing pump system according to claim 2, characterized in that: The multi-parameter detection module also includes: Discharge detection parameters: Used to detect the discharge parameters at the hydraulic end; Drive module detection unit: used to detect the number of plunger strokes at the hydraulic end.

4. A fracturing pump system according to claim 1, characterized in that: During the operation of the power drive module, the main control module periodically controls the liquid inlet parameter detection unit to perform detection within a set time window; The runtime analysis module includes: Pressure fluctuation analysis unit: Analyzes and determines the current inlet pressure fluctuation coefficient based on the detection results of the inlet parameters within the currently set time window; Liquid inlet disturbance analysis unit: Based on the current liquid inlet pressure fluctuation coefficient and the liquid inlet flow rate detection results within the current set time window, the current liquid inlet flow disturbance coefficient is determined to be an abnormal correlation feature; if the current liquid inlet flow disturbance coefficient is not within the corresponding requirement range, the current liquid inlet flow disturbance coefficient is determined to be an abnormal correlation feature. Pump stroke adjustment analysis unit: When the inlet flow disturbance coefficient is greater than or equal to the adjustment trigger threshold but less than the alarm threshold, it determines the current corrected pump stroke based on the inlet flow disturbance coefficient and the current pump stroke. The main control module controls the power drive module to work based on the current corrected pump stroke. During the operation, the main control module controls the multi-parameter detection module to collect the discharge parameters and verify whether the discharge parameters under the corrected pump stroke meet the process requirements. If the verification passes, the power drive module continues to work based on the current corrected pump stroke. If the verification fails, the current inlet flow disturbance coefficient is also determined to be an abnormal correlation feature.

5. A fracturing pump system according to claim 4, characterized in that: The runtime analysis module also includes: Screening and Analysis Unit: When the discharge pressure fluctuation coefficient is greater than the preset discharge pressure fluctuation coefficient, the unit screens the detection time-discharge pressure curve and the detection time-inlet pressure curve of the same set time window in history, and determines the detection time difference corresponding to the peak value of the detection time-discharge pressure curve and the detection time-inlet pressure curve. Pressure fluctuation amplitude analysis unit: When the current inlet flow disturbance coefficient is not within the corresponding required range, it determines the current discharge pressure fluctuation amplitude and the current inlet pressure fluctuation amplitude based on the acquisition results of the multi-parameter detection module within the set time window corresponding to the current inlet flow disturbance coefficient. Inlet / outlet pressure correlation analysis unit: Based on the current inlet / outlet pressure fluctuation amplitude and the current outlet pressure fluctuation amplitude and the detection time difference, determine the current outlet / outlet pressure interference coefficient; if the current outlet / outlet pressure interference coefficient is not within the corresponding requirement range, then determine the current outlet / outlet pressure interference coefficient as an abnormal correlation feature; The main control module includes: a control strategy unit, which determines the control strategy based on the discharge / intake pressure interference coefficient. When the discharge pressure interference coefficient is greater than the preset value of 1, it indicates that it is the main influencing factor, and the discharge end fluctuation suppression strategy is activated. When the discharge pressure interference coefficient is less than the preset value of two, it indicates that it is not the main influencing factor, and the system switches to the independent diagnosis and control mode at the inlet end.

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