A digital and intelligent manifold control system and method

Abstract

This invention discloses a digital intelligent manifold control system, belonging to the technical field of oil and gas fracturing equipment. It includes a high- and low-pressure manifold skid, a diversion manifold, a universal manifold, and a fracturing wellhead connected in sequence. The high- and low-pressure manifold skid is also connected to an automatic grease injection assembly. The high- and low-pressure manifold skid is equipped with bolt loosening sensors, vibration sensors, pressure sensors, and flow meters. The diversion manifold is equipped with bolt loosening sensors, the universal manifold is equipped with bolt loosening sensors and pressure sensors, and the fracturing wellhead is equipped with bolt loosening sensors. The automatic grease injection assembly, vibration sensors, bolt loosening sensors, flow meters, and pressure sensors are all connected to a controller. This system is used to control the high- and low-pressure manifold skid, diversion manifold, universal manifold, and fracturing wellhead, and has functions such as remote control of hydraulic valves, automatic grease injection, pressure monitoring, flow monitoring, vibration monitoring, bolt loosening monitoring, and automatic shutdown under abnormal operating conditions.

Description

Technical Field

[0001] This invention belongs to the technical field of oil and gas fracturing equipment, specifically relating to a digital and intelligent manifold control system and method. Background Technology

[0002] The fracturing manifold system is an important transportation system in oil and gas drilling and production equipment. It is an indispensable transportation system for the exploitation of low-permeability oil and gas resources such as shale gas and sandstone gas, as well as for the production enhancement and renovation of old oil and gas wells.

[0003] A search revealed that Chinese patent CN114658406A discloses a multi-well location fracturing manifold device, which includes a multi-degree-of-freedom well access manifold, a safety valve assembly, a multi-degree-of-freedom extension manifold, a high and low pressure manifold skid, a multi-degree-of-freedom pump assembly connecting manifold, and a fracturing pump assembly. This device simplifies the pipeline layout at the fracturing construction site, eliminates the need for traditional elbow connections, significantly reduces manifold costs, and extends the service life of the manifold.

[0004] The aforementioned inventions and existing traditional fracturing manifold systems all suffer from the drawback of being predominantly modular, lacking flexible assembly capabilities. If the fracturing manifold is too small, it is unsuitable for large-scale fracturing operations; if it is too large, transportation and installation become difficult. Existing fracturing manifold systems and the aforementioned inventions fail to achieve a perfect balance in overall size, making them unsuitable for large-scale fracturing operations in low-permeability oil and gas resources such as shale gas and tight sandstone gas. Furthermore, the control valves used in fracturing manifolds, due to high working pressure and high frictional resistance, are difficult for workers to operate using traditional handwheel drives, resulting in time-consuming and labor-intensive operations and negatively impacting overall work efficiency. Additionally, the high working medium pressure and numerous connections in the fracturing manifold, coupled with rapid wear and tear, contribute to its complexity. In cases of frequent punctures, equipment leaks or ruptures can injure nearby personnel. Existing systems lack stability and sealing between pipelines. The existing fracturing manifolds are bulky and heavy, and the complex terrain makes moving, connecting, and installing equipment difficult. Furthermore, existing fracturing manifold systems require tedious and lengthy manual inspections before operation to ensure proper functioning. Control operations during operation can only be performed on-site, making it difficult to guarantee stable and smooth long-term operation in large-scale fracturing operations involving numerous equipment, materials, personnel, preparation time, and significant costs. Any shutdowns or delays can result in substantial economic losses. Therefore, overall operability and safety are still lacking.

[0005] A search revealed that Chinese patent CN118346244A discloses a single-channel, universally connectable fracturing manifold system, including a fracturing manifold unit, a fracturing diversion manifold, a fracturing wellhead device, and a control cabinet. By employing multiple sets of a specified number of fracturing manifolds, connecting pipeline components, fracturing diversion manifolds, universal devices, and wellhead devices, a fixed number of fracturing pump trucks can be connected, enabling the fracturing operation of multiple oil and gas wells to be completed in one go without interruption or equipment adjustment, greatly improving the overall smoothness of the operation.

[0006] During fracturing operations, pipes and valves in fracturing well sites often experience punctures, fatigue fractures, and other phenomena, posing a high safety risk to the operation. Summary of the Invention

[0007] To address the aforementioned technical problems, this invention provides a digital intelligent manifold control system and method for controlling high and low pressure manifold skids, diversion manifolds, universal manifolds, and fracturing wellheads. It features functions such as remote control of hydraulic valves, automatic grease injection, pressure monitoring, flow monitoring, vibration monitoring, bolt loosening monitoring, and automatic shutdown under abnormal operating conditions.

[0008] The objective of this invention is achieved through the following technical solution: A digital intelligent manifold control system includes a high- and low-pressure manifold skid, a diversion manifold, a universal manifold, and a fracturing wellhead connected in sequence. The high- and low-pressure manifold skid is also connected to an automatic grease injection assembly. The high- and low-pressure manifold skid is equipped with a bolt loosening sensor, a vibration sensor, a pressure sensor, and a flow meter. The diversion manifold is equipped with a bolt loosening sensor. The universal manifold is equipped with a bolt loosening sensor and a pressure sensor. The fracturing wellhead is equipped with a bolt loosening sensor. The automatic grease injection assembly, vibration sensor, bolt loosening sensor, flow meter, and pressure sensor are all connected to a controller. The controller is connected to an alarm.

[0009] Preferably, the high and low pressure manifold skid includes a plurality of high and low pressure manifolds connected in sequence.

[0010] Preferably, the high and low pressure manifold includes a high pressure manifold assembly, a low pressure manifold assembly, and a base structure for mounting the high pressure manifold assembly and the low pressure manifold assembly. The high pressure manifold assembly includes a set of studded bottom brackets symmetrically arranged on both sides, with several studded four-way brackets arranged between the two studded bottom brackets. Adjacent studded four-way brackets are connected by double-flange straight pipes, and studded bottom brackets are connected to adjacent studded four-way brackets by double-flange straight pipes. Each studded four-way bracket and each studded bottom bracket has a hydraulic flat valve connected to both ends, and the other end of each hydraulic flat valve is connected to a union flange that matches the high pressure suction port of the pump truck. The hydraulic flat valve is connected to a controller.

[0011] Preferably, the low-pressure manifold assembly includes a low-pressure manifold, and several docking ports are provided on both sides of the low-pressure manifold. Each docking port is connected to a weld union, and one end of the weld union is connected to the low-pressure inlet of the fracturing pump truck.

[0012] Preferably, the automatic grease injection assembly is connected to a corresponding hydraulic stop valve via a corresponding lubrication line, the hydraulic stop valve is connected to the top of a stud-type five-way valve via a union flange, and the hydraulic stop valve is connected to a controller.

[0013] Preferably, a safety valve is also provided on the top of the stud-type bottom bracket.

[0014] Preferably, both the diversion manifold and the fracturing wellhead are equipped with hydraulic gate valves, which are connected to a controller.

[0015] Preferably, the hydraulic system includes a hydraulic station, which is connected to a hydraulic flat valve, a hydraulic plug valve, and a hydraulic gate valve.

[0016] A digital and intelligent hub control method includes the following steps: Step 1: Preset the pressure, flow, vibration, and bolt loosening values ​​in the controller; Step 2: Vibration sensors, bolt loosening sensors, flow meters, and pressure sensors monitor vibration, bolt loosening, flow, and pressure information in real time and compare them with preset values ​​in the controller. When the pressure is abnormal, the controller remotely closes the hydraulic flat valve and hydraulic gate valve. When the vibration and / or bolt loosening and / or flow information is abnormal, the controller activates the alarm to issue an alarm.

[0017] Preferably, it also includes automatic grease injection control, wherein the controller records the working time through vibration and pressure, and / or records the liquid supply volume through a flow meter. When the working time exceeds 9-12 hours or the liquid supply volume reaches 9000-12000m³, the automatic grease injection control is activated. 3 The time controller controls the hydraulic stopcock valve to achieve automatic grease injection.

[0018] Preferably, the preset pressure value is as follows: the preset pressure value is adjusted according to the rated pressure, the upper limit of the pressure is 0.8 times the rated pressure, when the actual working pressure is lower than the upper limit of the pressure, the preset pressure value is 1.1 times the actual working pressure; when the actual working pressure is higher than the upper limit of the pressure but lower than the rated pressure, the preset pressure value is 1.05 times the actual working pressure; when the real-time pressure detected by the pressure sensor is higher than the preset pressure value, the controller controls the alarm to sound, and when the real-time pressure continues to increase, it controls the hydraulic flat valve and the hydraulic gate valve to achieve remote closure.

[0019] Preferably, the preset flow rate value is: when the actual operating flow rate is less than 10m³ / h. 3At a flow rate of 10-15 m³ / min, the preset flow rate values ​​are 0.85 and 1.15 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.15 times the actual operating flow rate or lower than 0.85 times the actual operating flow rate, the controller activates the alarm to issue an alarm message. 3 At a flow rate of 15-20 m³ / min, the preset flow rate values ​​are 0.9 and 1.1 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.1 times or lower than 0.9 times the actual operating flow rate, the controller activates the alarm to issue an alarm message. 3 At a flow rate of / min, the preset flow rate values ​​are 0.925 times and 1.075 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.075 times the actual operating flow rate or lower than 0.925 times the actual operating flow rate, the controller controls the alarm to issue an alarm message.

[0020] Preferably, the preset vibration value is as follows: During the first operation, the controller automatically classifies the manifold vibration, grouping those with similar values ​​into one category. The classified data is compared with the data in the vibration database, and automatic correction is performed to assign a normal vibration value. When a sudden change occurs in the vibration of this data, the controller controls the alarm to issue an alarm message. The sudden change value is set to 20%. When the vibration shows a trend change, that is, the vibration slowly increases over time, the controller controls the alarm to issue an alarm message.

[0021] Preferably, the preset bolt loosening value is as follows: During the initial operation, the controller automatically classifies the loosening of the manifold bolts, grouping those with similar values ​​into one category. The classified data is compared with the data in the bolt loosening database, and automatic correction is performed to assign a normal bolt loosening value. When a sudden change occurs in the bolt loosening in this data column, the controller controls the alarm to issue an alarm message, with the sudden change value set at 20%. When the bolt loosening shows a trend change, that is, the bolt loosening slowly increases over time, the controller controls the alarm to issue an alarm message.

[0022] The beneficial effects of this technical solution are as follows: I. The present invention provides a digital intelligent manifold control system, wherein a pressure sensor monitors the pressure on the high and low pressure manifold skid and the universal manifold, a vibration sensor monitors the vibration on the high and low pressure manifold skid, a bolt loosening sensor monitors the loosening of bolts on the high and low pressure manifold skid, the diversion manifold, the single-pipe universal manifold, and the fracturing wellhead, and a flow meter monitors the flow on the high and low pressure manifold skid. The pressure information, vibration information, bolt loosening information, and flow information are transmitted to the controller, and the controller controls the automatic grease injection component to automatically inject grease.

[0023] II. The present invention provides a digital intelligent manifold control system, wherein the controller controls the hydraulic flat valve, the hydraulic plug valve and the hydraulic gate valve, thereby realizing automatic grease injection, as well as the connection and disconnection of high and low pressure manifold skids, diversion manifolds and fracturing wellheads.

[0024] Third, the present invention provides a digital intelligent manifold control method, which remotely opens and closes a hydraulic flat valve and a hydraulic gate valve by controlling the controller. The real-time monitored pressure information is compared with the preset value in the controller. When the pressure is abnormal, the controller controls the hydraulic flat valve and the hydraulic gate valve to remotely close, so as to avoid further damage caused by failure to close in time due to abnormal working conditions. The real-time monitored vibration information, bolt loosening information and flow information are compared with the preset value in the controller. When a certain parameter is abnormal, the controller controls the alarm to issue an alarm information. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a front view of the high and low pressure manifold skid in this invention; Figure 3 This is a top view of the high and low pressure manifold skid in this invention; Among them: 100, high and low pressure manifold skid; 110, high pressure manifold assembly; 111, stud-type five-way connector; 112, stud-type four-way connector; 113, double flange straight pipe; 114, hydraulic flat valve; 115, union flange; 120, low pressure manifold assembly; 121, low pressure manifold; 122, welded union; 130, base structure; 200, diversion manifold; 300, universal manifold; 400, fracturing wellhead. Detailed Implementation

[0026] The present invention will be further described in detail below with reference to embodiments, but the implementation of the present invention is not limited thereto.

[0027] Example 1 like Figures 1-3 As shown, an intelligent manifold control system includes a high- and low-pressure manifold skid 100, a diversion manifold 200, a universal manifold 300, and a fracturing wellhead 400 connected in sequence. The high- and low-pressure manifold skid 100 is also connected to an automatic grease injection assembly. The high- and low-pressure manifold skid 100 is equipped with a bolt loosening sensor, a vibration sensor, a pressure sensor, and a flow meter. The diversion manifold 200 is equipped with a bolt loosening sensor. The universal manifold 300 is equipped with a bolt loosening sensor and a pressure sensor. The fracturing wellhead 400 is equipped with a bolt loosening sensor. The automatic grease injection assembly, vibration sensor, bolt loosening sensor, flow meter, and pressure sensor are all connected to a controller, and the controller is connected to an alarm.

[0028] Example 2 like Figure 1 As shown, an intelligent manifold control system includes a high- and low-pressure manifold skid 100, a diversion manifold 200, a universal manifold 300, and a fracturing wellhead 400 connected in sequence. The high- and low-pressure manifold skid 100 is also connected to an automatic grease injection assembly. The high- and low-pressure manifold skid 100 is equipped with a bolt loosening sensor, a vibration sensor, a pressure sensor, and a flow meter. The diversion manifold 200 is equipped with a bolt loosening sensor. The universal manifold 300 is equipped with a bolt loosening sensor and a pressure sensor. The fracturing wellhead 400 is equipped with a bolt loosening sensor. The automatic grease injection assembly, vibration sensor, bolt loosening sensor, flow meter, and pressure sensor are all connected to a controller.

[0029] The high and low pressure manifold skid 100 includes multiple high and low pressure manifolds connected in sequence.

[0030] The high and low pressure manifold includes a high pressure manifold assembly 110, a low pressure manifold assembly 121, and a base structure 130 for mounting the high pressure manifold assembly 110 and the low pressure manifold assembly 120. The high pressure manifold assembly 110 includes a set of stud-type bottom brackets 111 arranged symmetrically on both sides. Several stud-type four-way brackets 112 are arranged between the two stud-type bottom brackets 111. A double-flange straight pipe 113 is connected between adjacent stud-type four-way brackets 112. A double-flange straight pipe 113 is connected between the stud-type bottom bracket 111 and the adjacent stud-type four-way bracket 112. Each stud-type four-way bracket 112 and each stud-type bottom bracket 111 has a hydraulic flat valve 114 connected to both ends. The other end of each hydraulic flat valve 114 is connected to a union flange 115 that matches the high pressure suction port of the pump truck. The hydraulic flat valve 114 is connected to a controller. Several hydraulic flat valves 114 are connected to a multi-valve assembly via pipelines. The multi-valve assembly is connected to a hydraulic system and is connected to a controller.

[0031] The low-pressure manifold assembly 120 includes a low-pressure manifold 121, and several docking ports are provided on both sides of the low-pressure manifold 121. Each docking port is connected to a weld union 122, and one end of the weld union 122 is connected to the low-pressure suction port of the fracturing pump truck.

[0032] The automatic grease injection assembly is connected to a corresponding hydraulic plug valve via a corresponding lubrication line. The hydraulic plug valve is connected to the top of a stud-type five-way valve 111 via a union flange 115, and is connected to a controller. Several hydraulic plug valves are connected to a multi-valve assembly via pipelines. The multi-valve assembly is connected to a hydraulic system and is also connected to the controller.

[0033] The stud-type five-way valve 111 is also equipped with a safety valve at its top.

[0034] Hydraulic gate valves are installed on both the diversion manifold 200 and the fracturing wellhead 400, and these hydraulic gate valves are connected to a controller. Several hydraulic gate valves are connected to a multi-valve assembly via pipelines. The multi-valve assembly is connected to a hydraulic system and is also connected to the controller.

[0035] The hydraulic system includes a hydraulic station, which is connected to a hydraulic flat valve 114, a hydraulic plug valve, and a hydraulic gate valve.

[0036] The beneficial effects of this technical solution are as follows: I. The present invention provides a digital intelligent manifold control system, wherein a pressure sensor monitors the pressure on the high and low pressure manifold skid 100 and the universal manifold 300, a vibration sensor monitors the vibration on the high and low pressure manifold skid 100, a bolt loosening sensor monitors the loosening of bolts on the high and low pressure manifold skid 100, the diversion manifold 200, the single-pipe universal manifold and the fracturing wellhead 400, and a flow meter monitors the flow on the high and low pressure manifold skid 100. The pressure information, vibration information, bolt loosening information and flow information are transmitted to the controller, and the controller controls the automatic grease injection component to automatically inject grease.

[0037] II. The present invention provides a digital intelligent manifold control system, wherein the controller controls the hydraulic flat valve 114, the hydraulic plug valve and the hydraulic gate valve, thereby realizing automatic grease injection, as well as the connection and disconnection of the high and low pressure manifold skid 100, the diversion manifold 200 and the fracturing wellhead 400.

[0038] Third, the present invention provides a digital intelligent manifold control method, which remotely opens and closes the hydraulic flat valve 114 and the hydraulic gate valve by controlling the controller. The real-time monitored pressure information is compared with the preset value in the controller. When the pressure is abnormal, the controller controls the hydraulic flat valve 114 and the hydraulic gate valve to remotely close, so as to avoid further damage caused by failure to close in time due to abnormal working conditions. The real-time monitored vibration information, bolt loosening information and flow information are compared with the preset value in the controller. When a certain parameter is abnormal, the controller controls the alarm to issue an alarm information.

[0039] Example 3 The difference between this embodiment and embodiment 2 is that the high and low pressure manifold skid 100 includes 4 high and low pressure manifolds, and its design and manufacture should comply with API 6A 21TH and API 16C standards. When used in a 6+6+6+6 arrangement, it can simultaneously connect 24 fracturing trucks to participate in fracturing operations. The diameter of the double-flange straight pipe 113 is 180mm, and each high-pressure manifold assembly 110 is connected by a single double-flange straight pipe 113 (7 1 / 16 x 20K). A fracturing eight-way assembly (7 1 / 16" x 20K(2) - 3 1 / 16" x 20K(6)) is installed at the front end of the first high-pressure manifold assembly 110. The fracturing eight-way assembly includes a blind flange (7 1 / 16" 20K) and 6 union flanges with blind plugs (3 1 / 16" 20K). The main channel is 7 1 / 16" 20K and includes three studded bottom brackets 111 (7 1 / 16" x 20K(2) - 3 1 / 16" x 20K(3)) and two double-flanged straight pipes 113 (7 1 / 16" x 20K). The top of the first studded bottom bracket 111 is equipped with a union flange (3 1 / 16" x 20K - 2" FIG2002) and a pressure sensor. The top of the second studded bottom bracket 111 is connected to a union flange (1 / 16" x 20K FIG2002F) and two hydraulic plug valves (2" x 20K FIG2002FM) connected in series, with the plug valve ends blocked by blind plugs. The top of the last studded bottom bracket 111 is connected to a flanged safety valve (3 1 / 16" x 20K). Each studded four-way 112 on the main channel is supported by a fixed bracket.

[0040] The main channels of the other three high-pressure manifold assemblies 110 are 7 1 / 16" 20K, including two sets of studded four-way 112 (7 1 / 16" x 20K(2) - 3 1 / 16" x 20K(2)) and one set of studded five-way 111 (7 1 / 16" x 20K(2) - 3 1 / 16" x 20K(3)) with a union flange (3 1 / 16" x 20K-2" FIG2002) on top. The top of the studded five-way 111 is connected to a pressure sensor via a union flange. Each studded four-way 112 on the main channel is supported by a fixed bracket. All high-pressure manifold assemblies 110 side channels are equipped with 6 union flanges (3 Each plug valve (1 / 16" x 20K-3" FIG2002F) is connected to a union flange and fitted with a hydraulic plug valve (3" FIG2002FM). The union end is equipped with a plug, chain, and wing nut. All 24 plug valves have hydraulic actuators with position sensors connected to the controller, providing feedback on the valve's open or closed status. Each hydraulic plug valve has an adjustable bracket for secure mounting on the side channel. Each hydraulic plug valve is equipped with an automatic grease injection assembly. Grease is injected via a high-pressure hose connected to the grease injection port on the valve body.

[0041] The low-pressure manifold assembly 120 has a main bore of 10" and 12 side outlets. The low-pressure pipes are connected to the skids via flexible hoses. The low-pressure manifold assembly 120 is located below the high-pressure manifold assembly 110. The main bore outlets at both ends are 10" female unions with chains, wing nuts, and caps. The side outlets are 4" female unions with chains, wing nuts, and caps.

[0042] All high-pressure manifold assemblies 110 and components shall be subjected to a static pressure test at their rated working pressure after assembly. The test standard shall be in accordance with the relevant provisions in API Spec 6A, and a test report shall be provided. After the low-pressure manifold assembly 120 is assembled, a water test shall be conducted, and no leakage shall be observed. Space shall be reserved at the base of each manifold skid for the installation of a solenoid valve transfer case.

[0043] The manifold 200 comprises four identical manifold skids. Each manifold skid contains one studded bottom 111 (7 1 / 16" 20K(2) x 2 1 / 16" 20K(2) x 3 1 / 16" 20K), one hydraulic gate valve (7 1 / 16" 20K), and one manual gate valve (7 1 / 16" 20K). The manifold is skid-mounted at the bottom, with each component supported by a fixed bracket. The manifold skids are connected by double-flanged straight pipes 113. The outlets of the high and low pressure manifolds are connected to the double-flanged straight pipes 113, studded four-way valves 112, and the manifold skids. The entire manifold is arranged in a "dry" configuration. All union end interfaces on the manifold skids are fitted with caps and protected by chains.

[0044] The vibration sensor is installed on the manifold connector by magnetic attraction, the flow meter is installed on the high and low pressure manifold skid 100, and the pressure sensor is installed on the high and low pressure manifold skid 100 and the universal manifold 300.

[0045] Example 4 This embodiment employs a digital intelligent manifold control method based on the digital intelligent manifold control system described in Embodiment 3, including the following steps: A digital and intelligent hub control method includes the following steps: Step 1: Preset the pressure, flow, vibration, and bolt loosening values ​​in the controller; Step 2: Vibration sensors, bolt loosening sensors, flow meters, and pressure sensors monitor vibration, bolt loosening, flow, and pressure information in real time and compare them with preset values ​​in the controller. When the pressure is abnormal, the controller remotely closes the hydraulic flat valve 114 and the hydraulic gate valve. When the vibration and / or bolt loosening and / or flow information is abnormal, the controller activates the alarm to issue an alarm.

[0046] This also includes automatic grease injection control, which is as follows: the controller records the working time through vibration and pressure, and / or records the liquid supply through a flow meter. When the working time exceeds 9-12 hours or the liquid supply reaches 9000-12000 m3, the controller controls the hydraulic stop valve to achieve automatic grease injection.

[0047] Specifically, the preset pressure value is adjusted according to the rated pressure, with the upper limit of the pressure being 0.8 times the rated pressure. When the actual working pressure is lower than the upper limit, the preset pressure value is 1.1 times the actual working pressure. When the actual working pressure is higher than the upper limit but lower than the rated pressure, the preset pressure value is 1.05 times the actual working pressure. When the real-time pressure detected by the pressure sensor is higher than the preset pressure value, the controller controls the alarm to sound. When the real-time pressure continues to increase, the controller controls the hydraulic flat valve 114 and the hydraulic gate valve to achieve remote closure.

[0048] Specifically, the preset flow rates are as follows: When the actual operating flow rate is less than 10 m³ / min, the preset flow rate values ​​are 0.85 times and 1.15 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.15 times or lower than 0.85 times the actual operating flow rate, the controller will control the alarm to issue an alarm message. When the actual operating flow rate is 10-15 m³ / min, the preset flow rate values ​​are 0.9 times and 1.1 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.1 times or lower than 0.9 times the actual operating flow rate, the controller will control the alarm to issue an alarm message. When the actual operating flow rate is 15-20 m³ / min, the preset flow rate values ​​are 0.925 times and 1.075 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.075 times or lower than 0.925 times the actual operating flow rate, the controller will control the alarm to issue an alarm message.

[0049] Specifically, the preset vibration value is as follows: During the first operation, the controller automatically classifies the manifold vibration, grouping those with similar values ​​into one category. The classified data is compared with the data in the vibration database, and automatic correction is performed to assign a normal vibration value. When a sudden change occurs in the vibration of this data, the controller controls the alarm to issue an alarm message. The sudden change value is set to 20%. When the vibration shows a trend change, that is, the vibration slowly increases over time, the controller controls the alarm to issue an alarm message.

[0050] Specifically, the preset bolt loosening value is as follows: During the initial operation, the controller automatically classifies the loosening of manifold bolts, grouping those with similar values ​​into one category. The classified data is compared with the data in the bolt loosening database, and automatic correction is performed to assign a normal bolt loosening value. When a sudden change occurs in the bolt loosening in this data column, the controller controls the alarm to issue an alarm message. The sudden change value is set to 20%. When the bolt loosening shows a trend change, that is, the bolt loosening slowly increases over time, the controller controls the alarm to issue an alarm message.

[0051] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the present invention.

Claims

1. A digital intelligent manifold control system, characterized in that: The system includes a high- and low-pressure manifold skid (100), a diversion manifold (200), a universal manifold (300), and a fracturing wellhead (400) connected in sequence. The high- and low-pressure manifold skid (100) is also connected to an automatic grease injection assembly. The high- and low-pressure manifold skid (100) is equipped with a bolt loosening sensor, a vibration sensor, a pressure sensor, and a flow meter. The diversion manifold (200) is equipped with a bolt loosening sensor. The universal manifold (300) is equipped with a bolt loosening sensor and a pressure sensor. The fracturing wellhead (400) is equipped with a bolt loosening sensor. The automatic grease injection assembly, vibration sensor, bolt loosening sensor, flow meter, and pressure sensor are all connected to a controller. The controller is connected to an alarm.

2. The intelligent data management system according to claim 1, characterized in that: The high and low pressure manifold skid (100) includes multiple high and low pressure manifolds connected in sequence.

3. The intelligent data management system according to claim 2, characterized in that: The high and low pressure manifold (121) includes a high pressure manifold assembly (110), a low pressure manifold assembly (120), and a base structure (130) for mounting the high pressure manifold assembly (110) and the low pressure manifold assembly (120). The high pressure manifold assembly (110) includes a set of studded bottom brackets (111) arranged symmetrically on both sides. Several studded four-way brackets (112) are arranged between the two studded bottom brackets (111), and adjacent studded four-way brackets (112) are connected. There is a double-flange straight pipe (113), and a double-flange straight pipe (113) is connected between the stud-type 5-way (111) and the adjacent stud-type 4-way (112). Each stud-type 4-way (112) and stud-type 5-way (111) has a hydraulic flat valve (114) connected to both ends. Each hydraulic flat valve (114) has a union flange (115) connected to the high-pressure suction port of the pump truck at the other end. The hydraulic flat valve (114) is connected to the controller.

4. The intelligent manifold control system according to claim 3, characterized in that: The low-pressure manifold assembly (120) includes a low-pressure manifold (121), and several docking ports are provided on both sides of the low-pressure manifold (121). Each docking port is connected to a welding union (122), and one end of the welding union (122) is connected to the low-pressure inlet of the fracturing pump truck.

5. The intelligent data management system according to claim 4, characterized in that: The automatic grease injection assembly is connected to the corresponding hydraulic plug valve through the corresponding lubrication line. The hydraulic plug valve is connected to the top of the stud-type five-way valve (111) through the union flange (115). The hydraulic plug valve is connected to the controller.

6. The intelligent data management system according to claim 5, characterized in that: A safety valve is also provided on the top of the stud-type five-way valve (111).

7. The intelligent data management system according to claim 6, characterized in that: Both the diversion manifold (200) and the fracturing wellhead (400) are equipped with hydraulic gate valves, which are connected to the controller.

8. The intelligent data management system according to claim 7, characterized in that: The hydraulic system includes a hydraulic station, which is connected to a hydraulic flat valve (114), a hydraulic plug valve, and a hydraulic gate valve.

9. A digital intelligent manifold control method, characterized in that, Includes the following steps: Step 1: Preset the pressure, flow, vibration, and bolt loosening values ​​in the controller; Step 2: The vibration sensor, bolt loosening sensor, flow meter and pressure sensor monitor the vibration information, bolt loosening information, flow information and pressure information in real time, and compare them with the preset values ​​in the controller. When the pressure is abnormal, the controller controls the hydraulic flat valve (114) and the hydraulic gate valve to achieve remote closure. When the vibration information and / or bolt loosening information and / or flow information are abnormal, the controller controls the alarm to issue an alarm message.

10. The intelligent data management system control method according to claim 9, characterized in that: It also includes automatic grease injection control, wherein the controller records the working time through vibration and pressure, and / or records the liquid supply volume through a flow meter. When the working time exceeds 9-12 hours or the liquid supply volume reaches 9000-12000m³, the automatic grease injection control is activated. 3 The time controller controls the hydraulic stopcock valve to achieve automatic grease injection.

11. The intelligent data management system control method according to claim 10, characterized in that: The preset pressure value is as follows: the preset pressure value is adjusted according to the rated pressure, the upper limit of the pressure is 0.8 times the rated pressure, when the actual working pressure is lower than the upper limit of the pressure, the preset pressure value is 1.1 times the actual working pressure; when the actual working pressure is higher than the upper limit of the pressure but lower than the rated pressure, the preset pressure value is 1.05 times the actual working pressure; when the real-time pressure detected by the pressure sensor is higher than the preset pressure value, the controller controls the alarm to sound, and when the real-time pressure continues to increase, it controls the hydraulic flat valve (114) and the hydraulic gate valve to achieve remote closure.

12. The intelligent data management system control method according to claim 11, characterized in that: The preset flow rate value is as follows: when the actual operating flow rate is less than 10m³ / h. 3 At a flow rate of 10-15 m³ / min, the preset flow rate values ​​are 0.85 and 1.15 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.15 times the actual operating flow rate or lower than 0.85 times the actual operating flow rate, the controller activates the alarm to issue an alarm message. 3 At a flow rate of 15-20 m³ / min, the preset flow rate values ​​are 0.9 and 1.1 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.1 times or lower than 0.9 times the actual operating flow rate, the controller activates the alarm to issue an alarm message. 3 At a flow rate of / min, the preset flow rate values ​​are 0.925 times and 1.075 times the actual operating flow rate. When the real-time flow rate detected by the flow meter is higher than 1.075 times the actual operating flow rate or lower than 0.925 times the actual operating flow rate, the controller controls the alarm to issue an alarm message.

13. The intelligent data management system control method according to claim 12, characterized in that: The preset vibration values ​​are as follows: During the first operation, the controller automatically classifies the manifold vibration, grouping those with similar values ​​into one category. The classified data is compared with the data in the vibration database, and automatic correction is performed to assign a normal vibration value. When a sudden change occurs in the vibration of this data, the controller controls the alarm to issue an alarm message. The sudden change value is set to 20%. When the vibration shows a trend change, that is, the vibration slowly increases over time, the controller controls the alarm to issue an alarm message.

14. The intelligent data management system control method according to claim 13, characterized in that: The preset bolt loosening value is as follows: During the initial operation, the controller automatically classifies the loosening of manifold bolts, grouping those with similar values ​​into one category. The classified data is compared with the data in the bolt loosening database, and automatic correction is performed to assign a normal bolt loosening value. When a sudden change occurs in the bolt loosening in this data column, the controller controls the alarm to issue an alarm message. The sudden change value is set to 20%. When the bolt loosening shows a trend change, that is, the bolt loosening slowly increases over time, the controller controls the alarm to issue an alarm message.

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