Intelligent and automated control of high pressure manifold systems

Abstract

The application discloses an intelligent and automatic control high-pressure manifold system and relates to the field of oil and gas equipment. The application discloses an intelligent and automatic control high-pressure manifold system, which comprises a control system, an intelligent control center, a grease injection system, a manifold system and a wellhead module. The manifold system is connected with the wellhead module and is used for conveying pressure liquid to the wellhead module. The grease injection system is used for injecting grease into valves arranged in the manifold system and the wellhead module. The control system is respectively connected with the grease injection system, the manifold system and the wellhead module. The intelligent control center is connected with the control system. The application can at least solve the problem that the oil and gas system cannot be monitored.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of oil and gas equipment, and particularly relates to a high-pressure manifold system with intelligent and automatic control. BACKGROUND

[0002] In the related art, some oil and gas systems are mainly manually operated when operating in a well site, and the operation of the oil and gas system cannot be monitored, so that the oil and gas system is prone to failure. CONTENT OF THE UTILITY MODEL

[0003] The application aims to provide a high-pressure manifold system with intelligent and automatic control, which can at least solve the problem that the oil and gas system cannot be monitored.

[0004] In order to solve the above technical problems, the application is implemented as follows:

[0005] The application provides a high-pressure manifold system with intelligent and automatic control, which comprises a control system, an intelligent control center, a grease injection system, a manifold system and a wellhead module.

[0006] The manifold system is connected with the wellhead module and used for conveying pressure liquid to the wellhead module.

[0007] The grease injection system is used for injecting grease for valves respectively arranged in the manifold system and the wellhead module.

[0008] The control system is respectively signal-connected with the grease injection system, the manifold system and the wellhead module.

[0009] The intelligent control center is signal-connected with the control system.

[0010] Optionally, the grease injection system comprises a power module, a pumping module, a distribution module and a control module.

[0011] The power module is drivingly connected with the pumping module, the pumping module is connected with the distribution module, and the pumping module pumps sealing grease to the distribution module by driving of the power module.

[0012] The control module is respectively signal-connected with the power module, the pumping module and the distribution module.

[0013] Optionally, the power module comprises an air compressor, an air tank and a pneumatic booster pump, the distribution module comprises a power cylinder, and the pumping module comprises a grease injection pump.

[0014] The air outlet end of the air compressor is communicated with the gas tank, the gas outlet of the gas tank is communicated with the pneumatic booster pump, the air outlet end of the pneumatic booster pump is communicated with the air inlet of the power cylinder, and the air outlet of the power cylinder is communicated with the grease injection pump;

[0015] Under the action of the air compressor, the gas in the gas tank enters the booster pump and is delivered to the power cylinder by the pump pressure pump, and the gas is pressed into the grease injection pump by the power cylinder to inject grease to the valve by the grease injection pump.

[0016] Optionally, the control system is used for monitoring the operation of the manifold system and the wellhead module by at least one of pressure, displacement, flow and displacement monitoring.

[0017] Optionally, the manifold system and the wellhead module each include a driving device, which is in driving connection with the corresponding valve to drive the valve to move and adjust the opening degree of the valve, wherein the driving device includes one of an electric drive, a hydraulic drive and a pneumatic drive.

[0018] Optionally, the manifold system includes a pipeline and a leakage detection device;

[0019] The interface area of the pipeline is provided with a leakage passage;

[0020] The leakage detection device includes a pressure transmitter, an instrument and a power supply, the pressure transmitter is arranged at the leakage passage and is in signal connection with the instrument, and the power supply is connected with the pressure transmitter and the instrument respectively to supply power to the pressure transmitter and the instrument respectively.

[0021] Optionally, a valve position monitoring element is arranged at the valve, which is used for monitoring the position of the valve, wherein the valve position monitoring element monitors the position of the valve by at least one of distance measurement, displacement monitoring and electromagnetic proximity sensing.

[0022] Optionally, a sealing grease detection element is further arranged at the valve, which is used for detecting at least one of the grease injection pressure and the grease injection amount at the valve.

[0023] Optionally, the manifold system includes a pipeline, a quick-change connector body, a flange plate, a split type retaining ring and a snap ring;

[0024] One end of the quick-change connector body is detachably connected with the pipeline;

[0025] The split type retaining ring is connected between the other end of the quick-change connector body and the flange plate, and the snap ring is connected with the split type retaining ring to fold the split type retaining ring.

[0026] Optionally, the valve comprises a flat valve, a plug valve, a check valve or a safety valve. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1 A schematic diagram of a high-pressure manifold system according to an embodiment of the present application;

[0028] Figure 2 A first structural schematic diagram of a manifold system according to an embodiment of the present application;

[0029] Figure 3 A second structural schematic diagram of a manifold system according to an embodiment of the present application;

[0030] Figure 4 A third structural schematic diagram of a manifold system according to an embodiment of the present application;

[0031] Figure 5 A partial structural schematic diagram of a manifold system according to an embodiment of the present application;

[0032] Figure 6 A schematic diagram of a driving device according to an embodiment of the present application;

[0033] Figure 7 A schematic diagram of a valve according to an embodiment of the present application;

[0034] Figure 8 A first schematic diagram of a pipeline according to an embodiment of the present application;

[0035] Figure 9 A second schematic diagram of a pipeline according to an embodiment of the present application;

[0036] Figure 10 A schematic diagram of an automatic control module according to an embodiment of the present application;

[0037] Figure 11 A schematic diagram of a first form of control system according to an embodiment of the present application;

[0038] Figure 12 A schematic diagram of a second form of control system according to an embodiment of the present application;

[0039] Figure 13 A control schematic diagram of a valve according to an embodiment of the present application;

[0040] Figure 14 A pipeline detection and early warning flowchart according to an embodiment of the present application;

[0041] Figure 15 A schematic diagram of a grease injection system according to an embodiment of the present application;

[0042] Figure 16Schematic diagram of the intelligent manifold system disclosed in the embodiments of the present application;

[0043] Figure 17 Schematic diagram of the leak detection disclosed in the embodiments of the present application;

[0044] Figure 18 First control flowchart of the control system disclosed in the embodiments of the present application;

[0045] Figure 19 Second control flowchart of the control system disclosed in the embodiments of the present application;

[0046] Figure 20 Third control flowchart of the control system disclosed in the embodiments of the present application;

[0047] Figure 21 Fourth control flowchart of the control system disclosed in the embodiments of the present application. DETAILED DESCRIPTION

[0048] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all of them. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of protection of the present application.

[0049] The terms "first", "second", and the like in the specification and claims of the present application are used to distinguish similar objects, and are not used to describe a specific order or sequence. It should be understood that the data used in this way can be interchanged under appropriate circumstances, so that the embodiments of the present application can be implemented in an order other than those illustrated or described herein, and the objects distinguished by "first", "second", etc. are usually a class, not limited to the number of objects, for example, the first object can be one or more. In addition, "and / or" in the specification and claims indicates at least one of the connected objects, and the character " / ", generally indicates that the front and rear associated objects are in an "or" relationship.

[0050] The embodiments of the present application will be described in detail below with reference to the drawings and specific embodiments and their application scenarios.

[0051] Reference Figures 1 to 21 The embodiments of the present application disclose an intelligent and automatic control high-pressure manifold system, the disclosed high-pressure manifold system includes a control system, an intelligent control center, a grease injection system, a manifold system, and a wellhead module, each of the systems can be adjusted and laid out according to the actual operation condition of the well site.

[0052] Reference Figures 2 to 5, the pipe manifold system can include a high-low pressure pipe manifold skid device, which includes a bottom skid, a low pressure pipe manifold assembly, a high pressure pipe manifold assembly, a control module assembly and the like arranged from bottom to top, and each part is independent in structure and does not affect each other in disassembly and maintenance, and the control module assembly can realize the interconnection between each part, so as to realize modular arrangement and facilitate maintenance. The high pressure pipe manifold assembly is connected with the pump outlet, and the input high pressure fluid flows back into the main channel; the low pressure pipe manifold assembly delivers the low pressure fluid of the operation to each pump truck to realize high-low pressure conversion through the pump truck. Alternatively, the pump truck can adopt electric drive, hydraulic drive, diesel drive and the like. Of course, other driving forms can also be used, which are not limited here.

[0053] In addition, the control module assembly as a whole can be built-in in each control box, and the control module assembly includes a hydraulic assembly and an electric control assembly. The hydraulic assembly can include a motor, various hydraulic elements, a hydraulic oil tank and a hydraulic branch pipeline and the like; the electric control assembly can include a control component, a control cabinet and an electric control branch pipeline. Based on this, through reasonable arrangement of each control part, the overall height in the control box can be ensured to be not more than the upper limit requirement of the traffic transportation regulation. When local operation is needed, the operator standing on the bottom skid can normally operate each part to meet the human-machine engineering requirement.

[0054] Each control box can be integrated on the upper surface of the four-way in the high pressure pipe manifold assembly, reasonably utilizing the upper space of the high-low pressure pipe manifold skid device, and the four-way can be used as the support of the control module assembly to reduce the use of unnecessary support brackets. The weight and the outer dimension of the entire high-low pressure pipe manifold skid device are not additionally increased to reduce the transportation difficulty.

[0055] A damping component can be added between the control box and the four-way, which can adopt spring damping, rubber damping, mechanical shock absorber and the like, which is beneficial to prolong the service life of each component in the control module assembly by damping the vibration of the bottom skid, each pipe manifold and each control box caused by high speed fluid in operation. Of course, the control box can also be dispersed as an independent control box in the skid space position.

[0056] Reference Figure 5 and Figure 15The grease injection system mainly includes a power module, a pumping module, a distribution module, and a control module. The power module includes an electric, gas, and liquid driving unit and a sealed grease pumping unit; the pumping module mainly includes a high-pressure grease injection pump and a sealed grease switching device; the distribution module mainly includes branch valves, connecting pipes, power cylinders, and other execution and control elements, which inject the sealing grease into each valve according to a preset program under the control of the control system. The power module is connected to the 380 / 220V power supply at the construction site to drive the electric air compressor, and the high-pressure gas is stored in the gas tank. The rear end pumps and pressurizes the hydraulic oil through the pneumatic booster pump. The kinetic energy supply of the entire grease injection system is realized. The pumping module and the distribution module: customize the high-pressure grease injection pump to pump the sealing grease to each distribution module. After receiving the grease injection instruction, the distribution module realizes efficient grease injection through the power cylinder and two-stage pressurization. The control module: controls the grease injection action, monitors and controls the pressure and flow of the grease injection circuit in real time. Communicate with the well site intelligent control platform, receive the instructions of the control personnel, and at the same time can sense the well site operation state, perform self-diagnosis and alarm, and prevent personnel from misoperation.

[0057] With reference to the foregoing Figure 5 In some embodiments, the grease injection system can mainly include a hydraulic power source, a grease injection booster cylinder, a grease injection booster cylinder control valve, a high-pressure sealing grease distribution solenoid valve, a valve, and related delivery pipelines, transition joints, etc.

[0058] The hydraulic power source can provide power for the grease injection booster cylinder. The hydraulic power source includes a power source (such as an electric motor, an internal combustion engine, a hydraulic motor, a pneumatic motor, etc.), a hydraulic pump, a hydraulic oil tank, a check valve, a relief valve, an overflow valve, an oil suction filter, an oil return filter, etc., which has the characteristic that under the condition of constant speed of the power source, two or more different flow rates can be output according to different load pressures, i.e., a small flow rate is output under high-pressure load, and a large flow rate is output under low-pressure load.

[0059] The grease injection booster cylinder is used to inject the sealing grease after pressurization into the valve grease injection point. The structure is divided into a low-pressure part and a high-pressure part. The low-pressure part is connected to the oil port of the control valve, and the control valve can control the reciprocating motion of the plunger inside the cylinder. The high-pressure part is filled with sealing grease, which is pressurized by the plunger inside the cylinder at a fixed ratio and then injected into the valve. The maximum pressure of the pressurized sealing grease can reach 15000 psi.

[0060] The above-mentioned control box can include an intelligent control part for monitoring the pressure of the valve, the amount of grease injection, and setting the maintenance period, etc. The sealing grease monitoring element in the grease injection booster cylinder can be one or more sensors of electromagnetic induction monitoring, ultrasonic monitoring, laser monitoring, and visual monitoring. Exemplarily, the sealing grease detection element can be a magnetostrictive sensor, and a scale visual display is configured outside, so that the injection condition can be clearly seen through the remote control system or local observation.

[0061] The hydraulic grease injection principle is that a plurality of (for example, eight) valve grease injection hydraulic control circuits are provided, before starting the hydraulic power, the high-pressure part of the grease injection pressure cylinder is filled with sealing grease, after the hydraulic power source is started, one of the grease injection pressure cylinder control valves is electrified, the hydraulic oil output by the electromagnetic valve drives the plunger inside the grease injection pressure cylinder to move and extrude the sealing grease, after the sealing grease is pressurized, the high-pressure sealing grease is distributed through the high-pressure sealing grease distribution electromagnetic valve to the grease injection point on one side of the valve, after the grease injection point is fully injected, the high-pressure sealing grease distribution electromagnetic valve is reversed, so that the high-pressure sealing grease is injected into the grease injection point on the other side of the valve, after the grease injection point on the other side is fully injected, the valve completes one injection process, and the other valves are injected in the same way.

[0062] The control module assembly can intelligently topologize the manifold flow according to the layout of the manifold system, send instructions according to requirements to form one-key flow switching and state feedback real-time indication, at the same time, the flow forms a linkage instruction sent to the related associated equipment to form linkage interlocking, and the safety of equipment operation is provided; in addition, the system can also form the management of the life cycle, real-time view the manifold associated data and the use time, effectively reduce the risk of overload use of the manifold, realize the statistical analysis and life management of the manifold.

[0063] The control software of the control module assembly is integrated with the control software of the fracturing pump truck on the instrument car, a program control logical relationship that the valve is first opened and then the fracturing pump truck is run, and then the valve is closed is formed, misoperation is avoided, and the safety of equipment and the smooth progress of construction are ensured.

[0064] After the local control system receives the switching instruction, the valve is controlled to act, when the valve is switched to the specified position, the sensor sends a signal to the local control box, the control element in the local control box sends an instruction and the operation interface displays that the valve is switched to the position. The valve switching state is displayed on the computer operation interface in the instrument car and the local control box operation interface, the switching of a single valve or multiple valves can be controlled. The local control system can be operated on the touch screen operation interface of the local control box or directly operated through the button, forming control redundancy.

[0065] The remote control system can be used in the fracturing construction process and the manifold without pressure state, the operator operates the operation terminal in the control center to send an operation instruction, the signal can form a link with the local control system in the form of a bus (modbus, profinet, canOpen, etc.), wireless form (wifi, lora, zigbee, etc.), the valve is opened or closed through remote control, at the same time, the valve switching state signal is fed back to the remote terminal and displayed on the remote terminal.

[0066] As an alternative to the manifold, a plurality of functional skids can be provided to integrate the functions of the job, such as ball throwing, pressure relief, fluid one-way control (e.g., configuring a one-way valve), and main channel closing (e.g., configuring a master valve) to form a skid-mounted unit for easy on-site disassembly and assembly.

[0067] In the embodiments of the present application, the wellhead module includes a wellhead tree, a flow distribution manifold skid, and inter-skid connecting pipelines. The flow distribution manifold skid has two combined modes, i.e., a horizontal mode and a vertical mode. Remote control drivers are added to the valves, which can adopt electric, hydraulic, and pneumatic working modes, and have a separate manual emergency operating mechanism designed for emergency working conditions.

[0068] The control system can serve as a power unit and data transmission part of the wellhead module, which can provide a power source for the valves to achieve driving of the valves, and through sensors for pressure monitoring and valve position monitoring of the pipelines, automatic control of the driving is achieved, and through the electrical control unit, the valves can be operated according to the process flow.

[0069] Reference Figure 6 The valves in the manifold skid and the wellhead tree can adopt a driving device for remote control, which can adopt one or a combination of multiple driving modes, such as electric driving, hydraulic driving, pneumatic driving, and manual driving. For example, a hand-hydraulic integrated valve driver is adopted, which mainly includes a hydraulic cylinder, a control valve block, a manual oil pump, etc. The hydraulic cylinder directly drives the valve stem or other forms of driving rod through the contraction and extension of the piston rod, so as to control the opening of the valve; the control valve block can switch the path of the hydraulic oil flowing into the hydraulic cylinder, and prevent the pressure of the manual oil pump from being transmitted to the pump station or the pressure of the pump station from being transmitted to the manual oil pump; the manual oil pump is used to manually flow the hydraulic oil in the oil cylinder from the rodless chamber to the rod chamber or vice versa to drive the contraction or extension of the hydraulic cylinder.

[0070] The control closes the outlets of the manual oil pump, opens the oil path from the pump station to the oil cylinder, and the hydraulic oil can drive the hydraulic cylinder through the passage from the pump station to the oil cylinder. After closing the outlets of the hydraulic station, the inlet and outlet of the manual oil pump are opened, the hydraulic cylinder is driven by driving the manual oil pump, the hydraulic oil is controlled to flow from the rod chamber of the hydraulic cylinder to the rodless chamber through the manual oil pump, the hydraulic cylinder is retracted, or the hydraulic oil is controlled to flow from the rodless chamber of the hydraulic cylinder to the rod chamber through the manual oil pump, the hydraulic cylinder is extended, and the driving of the hydraulic cylinder is achieved.

[0071] Reference Figure 7 The driving mode of the valve: the power end + the connecting device + the structure form of the valve can adopt a manual + electric mode, a hydraulic cylinder + manual mode, or a hydraulic motor driving + manual integrated structure form to achieve remote control, and through pressure, flow, torque, etc. monitoring, the monitoring of the valve state and abnormal problems can be achieved.

[0072] The valve adopts a valve position monitoring mode, which can be in the form of distance measurement, displacement monitoring, electromagnetic proximity sensing, or a combination thereof, such as ultrasonic distance measurement and proximity switch form. Through ultrasonic distance measurement and electromagnetic induction principle, the valve position is monitored.

[0073] The angular travel valve position indicator (limit switch) is mainly composed of a stainless steel standard shaft, a cam, a micro switch, a wiring port, a die-cast aluminum shell, an indicator cover, a mounting bracket, etc. The standard shaft is connected to the plug valve hydraulic actuator to ensure that the standard shaft rotates coaxially with the plug valve. When the cam touches the micro switch, the micro switch is closed or opened, and the switch signal is transmitted externally. The indicator displays locally. The standard shaft drives the indicator cover to rotate, and the visual color change indicates the valve position switch condition.

[0074] Referring to Figure 8 and Figure 9 , the pipeline connection can be achieved by using a clamp, a flange, a yoke, or a screw thread, etc. The connection between the skids can be achieved by using a hard pipe and a soft pipe structure, and can be used in combination with one or more structure forms of a quick connection device and a pipe body.

[0075] The rotating flange can rotate and quickly dock with other flange structures. The retaining ring is a split structure and includes at least two petals, which are used in combination with the rotating flange to quickly connect the flange. The clamping ring is used to fold the split retaining ring together to ensure consistent installation. The quick-change connector body and the pipe body can be connected and locked by a thread, and high-pressure sealing can be achieved by a sealing ring. The sealing structure can be designed according to the actual situation, using a radial sealing or axial sealing structure, and the material can be non-metallic or metallic.

[0076] Referring to Figure 10 , the automatic control module is a key part of the automatic control of the manifold system, including a valve remote control device, a power unit, a pipeline system sensor (including a pressure sensor, a valve position sensor, a leakage detection sensor, a flow sensor, etc.), a video monitoring device, etc. The valve control mode can be remote operation, local automatic control, and local manual control. The automatic control module can control the valve control system to achieve body and remote control and integrated control of hydraulic plug valves and valve plate valves, and through valve position, pressure, video, etc. detection and feedback, the process is confirmed and abnormal alarm is given, and single valve action or multiple valve action is realized through the pre-set command, and is matched with the system operation process to reduce the risk and intensity of human operation.

[0077] The control system is configured separately from the power unit and the pipeline unit, and is independently formed into a skid, so that a total power unit can be set to distribute power to all control systems in the well site, realizing unified management of power. Alternatively, the control system can be integrated with the power unit and the pipeline unit, and a single or multiple wellheads can be controlled by one set of control system.

[0078] The control system includes hydraulic elements, electrical elements, control panels, video displays, etc., and is connected with a remote data center. The data transmission of the remote data center can be wireless or wired. The state display and control of the local and remote control panels are realized by controlling the camera to check the valve state.

[0079] Reference Figure 11 and Figure 12 The hydraulic operating handle can be visually confirmed to be consistent with the system flow switch state through various structural forms such as pneumatic lock, mechanical lock, and hydraulic lock. System safety setting: the valve position sensor can be used to detect the valve position state, and the valve state can be checked again through the control camera. The operation permission is set, and the password is input to operate. The priority is mainly local operation, and the remote control can issue a specified command, which can be executed locally. The valve action needs to detect the pipeline pressure value before it is operated. If the management pressure value is greater than the required set value, the operation is not allowed. Any command must be confirmed before it is issued, and the process requirements must be met.

[0080] Reference Figure 13 The valve can use wired monitoring or wireless monitoring, and different sensors are used for flat plate valves and plug valves. The plug valve uses a 90° development method, and a cam mechanism is used inside. When the rotation touches the fiber switch, the mechanical limit switch is used to actuate the ring, and a high-performance battery is used to supply power. The built-in Lora antenna realizes wireless signal transmission and is connected with the control system. The flat plate valve uses parallel movement, which can be distance measurement, displacement monitoring, electromagnetic proximity sensing, or a combination of these forms, such as ultrasonic ranging and proximity switch. According to the ultrasonic ranging and electromagnetic induction principle, the switch is triggered to actuate the switch and wake up. A high-performance battery and a super-low-power wireless state monitoring module are used to realize signal conversion, and a built-in antenna is used to realize signal transmission. At the same time, this wireless signal transmission method can also be transmitted through a wired method, and the power supply can also be used in a wired manner.

[0081] Reference Figure 14 Pipeline monitoring and early warning: valve positioning monitoring, pressure monitoring, visual confirmation, vibration monitoring, data integration and transmission, real-time monitoring of operation data records, automatic and digital management for users, confirmation and guarantee of pipeline state and abnormal problems, prevention of accidents, and safety of operation and personnel.

[0082] Reference Figure 16 , the intelligent control center is an independent software system, provides an interface for connecting with an intelligent decision system (a client), and the interface includes a control job flow instruction issued by the intelligent decision system, a feedback of a control job flow state, a feedback of a valve state or a pressure value state, a feedback of an abnormal processing state, etc. The hydraulic station is bound to a valve position, automatic grease injection maintenance of the valve, job process flow control arrangement, valve state abnormal processing, pressure abnormal processing, etc. are all completed in the manifold control center.

[0083] The control system edits a device, a manifold, a valve, and a wellhead connection distribution map; and edits communication parameters, hydraulic control, and grease injection control parameters of each valve. Configuration items include: ① binding of the hydraulic station and an IP address thereof; ② binding of a hydraulic valve connected to a hydraulic control port; ③ binding of the hydraulic valve connected to a grease injection port; ④ binding of a LoRa identification ID for monitoring the on-off state of the hydraulic valve; and configurable manifold types include: a hydraulic plug valve, a hydraulic flat plate valve, a large-diameter high-low pressure manifold skid, a wellhead tree, a shunt skid, and all device information in an oil and gas field operation process.

[0084] Functions implemented: configuration of parameters such as a hydraulic station name, an IP address, and a communication protocol; configuration of a PLC valve state, an on-off control channel address; a grease injection related channel; and a pressure monitoring related channel.

[0085] Configuration functions: configuration of a fracturing job process corresponding valve opening sequence and state; including pressure testing, back pressure, well opening, pump injection, well closing, and other process related valve operations. Process setting preview is supported. In manual mode, a preset process can be selected for execution; in automatic mode, only a job process issued by a decision command center is received; a valve on-off state is dynamically displayed during process execution, and in automatic mode, the state is reported to the decision command center; a single valve can be manually double-clicked for emergency control. The system displays a record of the number of layers, operation time, and statistical display of each wellhead operation in the platform; saves and queries device operation data such as instruments, sand mixing, and fracturing; associates job data with maintenance; provides maintenance plans and reminders; displays grease injection history information and job information of a certain module unit, so that an operator can determine whether grease injection is needed. Manifold, wellhead, and other maintenance records.

[0086] The intelligent pipe gathering control system software is based on a Windows system, conforms to the operation habits of most users, is developed using a Microsoft C# programming language, and has guaranteed program reliability and stability. The software interface is developed using a Winform UI framework and DevExpress controls, has an elegant interface, and uses a widely used Sqlite database to store data, ensuring data safety and reliability. A SqlSugar open source ORM framework is used for database access, and the data access efficiency is high. A S7.NetPlus communication library based on a Siemens S7 protocol is used for PLC communication, supports data batch reading and writing, and is stable and reliable. The MQTT protocol widely used in the Internet of Things field is used for message communication with the self-developed intelligent fracturing system, and the system is integrated and extensible.

[0087] Reference Figure 17 Pipe leakage detection: The seal of high-pressure fluid pipeline transportation is between pipe connections, such as flange and flange connections, flange and cross connections, n-butt connections, clamp connections, etc. During the operation process, the general leakage is first micro-permeation, and then the micro-permeation is not easy to observe. Fluid will continue to flow along the leakage channel, and high-pressure fluid will cause erosion and increase the crack after a period of time. With the increase of the seal crack, the fluid is ejected at the crack due to the pressure difference, and the turbulent flow is formed. The medium in the turbulent flow and the medium sealing surface produce impact and friction, causing large-flow leakage. Once leakage occurs during the operation process, it will directly affect the operation process, cause economic losses to the site construction, and also have safety risks.

[0088] Working principle of pipe leakage device: A face seal groove is opened on the standard flange, a leakage channel is opened on the outer diameter of the flange, and a pressure transmitter is installed for detection. Once the fluid in the channel leaks or leaks, the leakage sealing ring will seal the leakage pressure in the leakage channel, and the pressure transmitter will report the abnormal data of the channel leakage to the control system, so as to avoid further expansion of the loss and improve the safety performance. The patent device can transmit the leakage point signal to the instrument through the data line, and the instrument can display the leakage on the screen of the intelligent control system and timely alarm to remind the customer to check the leakage and solve the problem. The patent device can be set at all connection points in the high-pressure pipe gathering system, and the wiring box can be configured according to the field layout for data transmission.

[0089] Reference Figures 18 to 21, based on the added sensors, data collectors, edge calculators, 4G gateways, failure mechanisms and machine learning algorithms, to realize the operation time monitoring, fatigue damage monitoring and leakage monitoring of the high-pressure manifold system. High-pressure manifold failure monitoring can accurately count and record the service time of the pipeline, reduce manual labor time, improve work efficiency, and can identify and warn of pipeline loosening, fatigue cracks and leakage in advance. Signal monitoring and early warning combined with intelligent manifold control system can identify abnormal signals beyond the range, thereby warning and intervening in the failure of the manifold, to avoid major accidents.

[0090] In summary, the intelligent and automated control high-pressure manifold system in the embodiments of the present application integrates intelligent control systems, automation and digital management, modular platform design of the manifold system, intelligent decision-making and standard data models.

[0091] The intelligent control system integrates sensors, safe operation and data centers, expands information transmission and data integration between local and remote locations, and provides flexible data displays on the data panel to display real-time data at the well site, control center or any location. Remote valve control can be achieved through the HDC control unit. Remote operation, monitoring and process confirmation can be achieved to improve the safety and efficiency of the entire well site operation.

[0092] Automation and digital management: valve positioning monitoring, pressure monitoring, hydraulic locking, remote control and video monitoring system integration, real-time monitoring and operation data recording, providing confirmation and assurance of the actual position of the valve and abnormal problems. Avoid manual data, solve the problem of on-site operation data model storage and manual input. No need to enter the red area for verification to ensure operation and personnel safety.

[0093] Modular platform design of the manifold system: The system is divided into high and low pressure skids, shunt skids, multifunctional skids and wellheads, and the flexible pipe and quick connection device are used to realize the rapid installation of each module. The valve is driven by remote control. Automatic grease injection system, and installation of valve position sensor, pressure sensor to realize automatic control and monitoring. Realize the rapid field layout of the system, reduce NPT, reduce labor intensity. Convenient and efficient maintenance, reduce loss cost, improve product service life.

[0094] Intelligent decision-making and standard data model: operation data sharing with the intelligent decision-making system ensures seamless integration of data transmission and intelligent decision-making between systems, improves data accuracy, and realizes data-driven analysis and decision-making. Based on the SOP data-driven logic of the customer, control and locking are realized to reduce the risk of human error, thereby improving the efficiency of on-site operations and reducing operating costs.

[0095] In the embodiments of the present application, the control system can remotely operate, monitor the operation and confirm the process, thereby improving the safety and efficiency of the entire well site operation; the high-low pressure manifold skid is provided with a high pressure, a low pressure and a control system part, can realize independent control or combined control, and can realize local automatic grease injection of the valve by integrating the grease injection unit on the skid frame; the shunt manifold skid module can adopt various structural forms of vertical or horizontal type, and realize the integration of pipelines on the skid frame; the control system can realize independent control of the wellhead or use multiple control modules in series for the platform well; the wellhead valve adopts automatic grease injection, can realize remote, quantitative and automatic grease injection maintenance function, and transfer data with the data center to realize maintenance reminder; the control system can realize monitoring of the high pressure manifold operation process through various models such as pressure, displacement, flow and video monitoring, real-time feedback of whether the pipeline has pressure, whether the pipeline leaks and the valve switch state information during operation, realize the confirmation and reminder function before process operation; the control system can realize valve position, pressure signal monitoring and feedback, local viewing and remote control panel screen display; the pressure and displacement monitoring mode can be wired or wireless transmission mode, through high-performance battery and ultra-low power wireless state monitoring module, realize signal conversion, and through the built-in antenna, realize signal transmission. At the same time, the wireless signal transmission mode can also realize transmission through wire, and the power supply can also adopt wired mode; the valve switch stroke can be monitored by remote video through mechanical lock, including color differentiation, as an auxiliary checking means for valve position detection.

[0096] In addition, the embodiment of the application provides a flexible data display for displaying real-time data of a well site, a control center or any position; the data display is configured with a data storage and recording function, realizes digital conversion, avoids manual data, solves the problems of on-site operation data model storage and manual input, modularizes and platformizes the arrangement of the well site, divides the system into a high-pressure skid, a shunt skid, a multifunctional skid and a wellhead, realizes rapid installation of each module through flexible pipes and quick connecting devices, adopts a remote control system for the valve, and can have various combined control modes such as electric control, hydraulic control and pneumatic control, to realize remote control and monitoring; the valve position sensor can adopt forms or combinations such as distance measurement, displacement monitoring and electromagnetic proximity sensing, such as ultrasonic distance measurement and proximity switch, to trigger the switch action through the principle of ultrasonic distance measurement and electromagnetic induction; the high-pressure process can be safely locked, unlocked and operated in an emergency (emergency unlocking of a single valve). The hydraulic control unit in the patent is provided with a hydraulic locking function, mechanical locking or electric, pneumatic and hydraulic locking, to realize locking of the valve state and confirmation before the process; the flat plate is provided with a hydraulic operation handle, so that visual confirmation can be performed and the system process switch state is consistent; the explosion-proof motor pump set adopts two groups of electric hydraulic pumps for pressure boosting, is provided with a UPS (4 hours) and a manual pump, and the hydraulic control system needs to ensure that there is no pressure leakage when power is lost; the prefabricated instruction realizes implementation of multiple instructions of a fracturing plan, sequential opening and closing of multiple valves of the fracturing, and other instructions during the process; the pipeline pressure value needs to be detected before the valve is operated, and the operation is not allowed if the management pressure value is greater than the required set value; the program needs to be confirmed before any instruction is issued, to meet the process requirements; the screen display interface is optimized to display the fracturing operation valve state and the operation process; the electrical control is modularized. The valve, pressure monitoring and control means can be transplanted to high-pressure and low-pressure manifolds; the software control logic and method can be flexibly configured and edited, the operation process pipeline is displayed, the operation state and data are displayed, and automatic data storage and recording are also included; the process locking function logic controls the locking according to the priority of the on-site operation and the manual unlocking function; the control valve opening and closing correspond to the PLC address reading of the current valve state PLC address; the fracturing operation process is configured to correspond to the valve opening sequence and state, including pressure test, back pressure, wellhead opening, pump injection, wellhead closing and other process associated valve operations, to support process setting preview.

[0097] In the embodiments of the present application, the wellhead Christmas tree part: through the configuration of hand and liquid integrated, electric drive, hydraulic and other different forms of automatic control flat valve to realize the automatic control and data feedback of operation process, solve the well site problem of manual operation and confirmation; the wellhead Christmas tree and well control connection or transportation manifold connection adopts quick connection device, realizes quick connection in the process of disassembly and assembly operation, improves efficiency and reduces artificial time waste; the wellhead Christmas tree part is provided with a valve position sensor on the valve, and pressure sensors are arranged on the main pipeline, the flowback pipeline and the connection position, through real-time data feedback, the monitoring and early warning of operation process are realized; the shunt manifold skid and the wellhead tree are connected by flexible manifold or large diameter manifold, realizing the quick connection between the wellhead and the shunt skid; the shunt manifold skid can adopt vertical or horizontal structure form, through modular design, realizing the quick arrangement of wellhead; the shunt manifold skid adopts double automatic control valve driving mode, and one valve is also provided with a manual operating mechanism, realizing automatic control under the premise of ensuring operation safety; the shunt manifold skid is connected with pumping and blowout manifold, realizing the modularization of operation process, and is also provided with valve position monitoring and pressure monitoring, realizing centralized management of data transmission and control; the high and low pressure manifold skid integrates high pressure manifold, low pressure manifold, control module, grease injection module and the like, adopts modular centralized management, realizing the quick arrangement of well site; the module design of high and low pressure manifold skid can realize multiple layout modes of high pressure on the top, high pressure on the bottom, two low pressure manifolds or one low pressure manifold, adapting to different well site operation requirements; the high and low pressure manifold skid device adopts multiple high pressure interface modes, and the low pressure interface is 1 / 4 of the high pressure interface.5-2 times, meeting diverse operational needs; the high and low pressure manifold skid integrates multiple monitoring and data transmission methods such as pressure monitoring, valve position monitoring, and grease injection monitoring, achieving automated control, data monitoring, and early warning for the high-pressure manifold skid; a multi-functional skid section can be selectively configured, integrating pumping, backflow, pressure relief, and pipeline shut-off functions into one unit, achieving modular functionality and facilitating on-site installation; the multi-functional skid is equipped with a remote ball-throwing device, enabling remote detection and control, meeting the requirements for temporary plugging agent / ball dispensing during operations; the main pipeline can be equipped with large-diameter flat valves and plug valves for pipeline shut-off; flat valve structures include manual / hydraulic, hydraulic, and electric types. The system offers a variety of control valve structures, including actuated and pneumatic, providing diverse options. Valve open / close status can be integrated with remote valve position indication and local display, with the display method including proximity switches, magnetostrictive systems, ultrasonic sensors, lasers, and more. Connection options include clamp connections (metal + non-metal sealing design), quick-tightening mechanisms, flexible tube quick-connect designs, and union flange + swivel flange structures. The automatic grease injection system includes a grease injection unit, power unit, control unit, and other accessories. The system's operating principle and logic enable local + remote control, real-time air path monitoring, and display of grease volume and cumulative metering. The system features one-button operation on the control panel and PAD or other display devices; an automatic grease injection system with early warning functions, including maintenance cycle reminders, low liquid level alarms, and electric heating; for high-pressure sealing grease, a high-pressure grease injection unit encompassing a storage unit or a grease supply unit can be used; the hydraulic control system integrates sensor devices, the hydraulic control system itself, the control section, and the display functions of the control interface; pipeline leak monitoring methods include manual inspection, hardware detection, and software monitoring, combined with readily available materials on site, and real-time leak detection based on flange leak principles using sensor-based early warning; position sensors monitor flange positions, including valve position monitoring and control handle operation. The system implements the transmission function of valve positions and operating methods; hydraulic electrical components include relays, transformers, circuit breakers, and corresponding input / output lines and communication components; the hydraulic system includes accumulators, directional valves, safety valves, backup power supplies, manual pumps, etc. Hydraulic pipelines are uniquely identified through color coding, numerical marking, quick-connect couplings, and the physical address binding function of electrical components; the software's control logic and methods allow for flexible interface configuration and editing, display of pipelines in the work process, and simultaneous display of work status and data, including automatic data storage and recording; the process locking function logic controls locking and unlocking based on the priority of on-site operations.

[0098] Therefore, in the embodiments of the present application, the intelligent and automated control high-pressure manifold system can integrate data into a unified instrument, provide valuable suggestions for operations, connect system services, digitize work processes, and increase operation process control, realize standard data models of field control and hydraulic interlocking through intelligent decision systems and data-driven logic control, thereby reducing the operation and labor intensity of operation personnel, improving the operation efficiency of the well site, reducing the operating cost, and ensuring the safety and sustainability of the well site operation.

[0099] The embodiments of the present application are described above in combination with the drawings, but the present application is not limited to the specific embodiments described above, which are only illustrative but not restrictive, and those of ordinary skill in the art can make many forms under the inspiration of the present application without departing from the scope of the present application and the scope protected by the claims.

Claims

1. A high pressure manifold system controlled intelligently and automatically, characterized by, The high-pressure manifold system comprises a control system, an intelligent control center, a grease injection system, a manifold system and a wellhead module; The manifold system is connected with the wellhead module and used for conveying pressure liquid to the wellhead module; The grease injection system is used for injecting grease to valves respectively arranged in the manifold system and the wellhead module; The control system is respectively signal connected with the grease injection system, the manifold system and the wellhead module; The intelligent control center is signal connected with the control system.

2. The high pressure manifold system of claim 1, wherein, The grease injection system comprises a power module, a pumping module, a distribution module and a control module; The power module is drivingly connected with the pumping module, the pumping module is connected with the distribution module, and the pumping module pumps sealing grease to the distribution module by driving of the power module; The control module is respectively signal connected with the power module, the pumping module and the distribution module.

3. The high pressure manifold system of claim 2, wherein, The power module comprises an air compressor, an air tank and a pneumatic booster pump, the distribution module comprises a power cylinder, and the pumping module comprises a grease injection pump; An air outlet of the air compressor is communicated with the air tank, an air outlet of the air tank is communicated with the pneumatic booster pump, an air outlet of the pneumatic booster pump is communicated with an air inlet of the power cylinder, and an air outlet of the power cylinder is communicated with the grease injection pump; Under the action of the air compressor, the air in the air tank enters the pneumatic booster pump, is conveyed to the power cylinder by the pneumatic booster pump, and is pressed into the grease injection pump by the power cylinder, so as to inject grease to the valve by the grease injection pump.

4. The high pressure manifold system of claim 1, wherein, The control system is used for monitoring the operation of the manifold system and the wellhead module by at least one of pressure, displacement, flow and displacement monitoring.

5. The high pressure manifold system of claim 1, wherein, The manifold system and the wellhead module each comprise a driving device, the driving device is drivingly connected with a corresponding valve to drive the valve to move and adjust the opening degree of the valve, and the driving device comprises one of an electric driving element, a hydraulic driving element and a pneumatic driving element.

6. The high pressure manifold system of claim 1, wherein, The manifold system comprises a pipeline and a leakage detection device; An interface region of the pipeline is provided with a leakage passage; The leakage detection device comprises a pressure transmitter, an instrument and a power supply, the pressure transmitter is arranged at the leakage passage and signal connected with the instrument, and the power supply is respectively connected with the pressure transmitter and the instrument to supply power for the pressure transmitter and the instrument.

7. The high pressure manifold system of claim 1, wherein, A valve position monitoring element is arranged at the valve, and the valve position monitoring element is used for monitoring the position of the valve by at least one of distance measurement, displacement monitoring and electromagnetic proximity sensing.

8. The high pressure manifold system of claim 1, wherein, A sealing grease detection element is further arranged at the valve, and the sealing grease detection element is used for detecting at least one of the injection pressure and the injection amount of the valve.

9. The high pressure manifold system of claim 1, wherein, The manifold system comprises a pipeline, a quick-change connector body, a flange, a split type retaining ring and a spring clamping ring; One end of the quick-change connector body is detachably connected with the pipeline; The split type retaining ring is connected between the other end of the quick-change connector body and the flange, and the spring clamping ring is connected with the split type retaining ring and used for folding the split type retaining ring.

10. The high pressure manifold system of claim 1, wherein, The valve can include a flat valve, a plug valve, a check valve, or a relief valve.

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