Hydraulic remote intelligent fracturing manifold system

Abstract

The utility model discloses a hydraulic remote intelligent fracturing manifold system, which belongs to the technical field of petroleum production, and is characterized in that a controller is matched with a hydraulic driving mode of a multi-union valve group to control the opening and closing actions of a hydraulic flat valve, a hydraulic plug valve and a control valve, so that the operation intensity of a traditional manual plug valve is reduced, the operation is convenient and safer, and the working efficiency is improved. The pressure sensor monitors the pressure on the high-pressure manifold assembly, the vibration sensor monitors the vibration on the high-pressure manifold assembly and the low-pressure manifold assembly, the bolt loosening sensor monitors the bolt loosening condition on the stud type five-way joint, the stud type four-way joint and the double-flange straight pipe, and the flow meter monitors the flow on the low-pressure manifold assembly; the pressure information, the vibration information, the bolt loosening information and the flow information are transmitted to the controller, and the controller controls the automatic grease injection assembly to automatically inject grease.

Description

Technical Field

[0001] This utility model belongs to the field of petroleum production technology, specifically relating to a hydraulically driven remote intelligent fracturing manifold system. Background Technology

[0002] During oil and gas well fracturing operations, the internal pressure of the high-pressure manifold can reach up to 140 MPa. The high-pressure fluid mixed with quartz sand erodes the inner wall of the pipeline at high speed and pressure. Coupled with equipment vibration during the operation, the manifold is at constant risk of unpredictable rupture. Furthermore, during the operation, the high-pressure fluid mixed with sand from the oil and gas well further erodes the inner wall of the pipeline at high speed and pressure, causing severe abrasion of the equipment and, in cases of large amounts of sand, clogging the pipeline.

[0003] However, the operation of gate valves, plug valves, and other valves in existing high-pressure manifolds is mostly done manually or hydraulically. Manual operation has the following drawbacks: it is very difficult, has a slow response time, and is labor-intensive; in high-pressure environments, leaks in the manifold pose a safety hazard to operators, endangering their lives. Hydraulic control valves have the following drawbacks: hydraulic regulating valves have low control accuracy and are easily affected by temperature; hydraulic systems require hydraulic power units, oil circuit systems, and control systems, resulting in higher costs.

[0004] Chinese patent CN218293513U, published on January 13, 2023, discloses a remote-controlled sand-proof high-pressure manifold, comprising two parallel high-pressure manifolds, a control box, and a remote control console. The two high-pressure manifolds have identical structures, including a single-line main manifold. Multiple branch manifolds are arranged perpendicularly to the main manifold on one side of its front end. A control valve assembly is located at the rear end of the main manifold. Each branch manifold includes a union flange and an electric plug valve arranged sequentially. The control valve assembly includes a first flange four-way valve, a first electric gate valve, a second electric gate valve, and a six-head diverter body connected sequentially. The first flange four-way valve... The upper port is equipped with a pressure sensor and a pressure gauge, which provide real-time feedback on the pipe pressure, enabling precise control of the well pressure. A first and second electric gate valve are connected in series, ensuring operational continuity even if one valve fails. The main manifold also features multiple filter pipes corresponding to branch manifolds, located at the rear end of each branch manifold. All electric gate valves and electric plug valves are electrically connected to a control box, which, along with the pressure sensor, is communicatively connected to a remote control console. The remote control console displays the real-time valve position status. During fracturing operations, leaks and fatigue fractures frequently occur in the fracturing well site piping and valves, posing significant safety risks. Utility Model Content

[0005] The purpose of this invention is to solve the problems of the prior art and provide a hydraulic remote intelligent fracturing manifold system. Through a controller and multi-valve assembly, the system uses a hydraulic drive to control the opening and closing of hydraulic flat valves, hydraulic plug valves, and control valves. This reduces the operational intensity of traditional manual plug valves, making operation more convenient and safer, and avoiding potential safety hazards. Pressure sensors monitor the pressure on the high-pressure manifold assembly, vibration sensors monitor the vibration on both the high-pressure and low-pressure manifold assemblies, bolt loosening sensors monitor the loosening of bolts on stud-type five-way valves, stud-type four-way valves, and double-flange straight pipes, and flow meters monitor the flow rate on the low-pressure manifold assembly. The pressure, vibration, bolt loosening, and flow rate information are transmitted to the controller, which then controls the automatic grease injection assembly to automatically inject grease.

[0006] This utility model is achieved through the following technical solution:

[0007] A hydraulically operated remote intelligent fracturing manifold system includes a high-pressure manifold assembly, a low-pressure manifold assembly, and a base for mounting the high-pressure and low-pressure manifold assemblies. The high-pressure manifold assembly includes a set of studded bottom-joints symmetrically arranged on both sides, with several studded four-way joints between them. Adjacent studded four-way joints are connected by double-flange straight pipes, and studded bottom-joints are connected to adjacent studded four-way joints by double-flange straight pipes. Each studded four-way joint and each studded bottom-joint joint has a hydraulic flat valve connected to both ends. Each hydraulic flat valve also has a... One end of each is connected to a first union flange that mates with the high-pressure suction port of the pump truck. A pressure sensor and a hydraulic stopcock valve are installed on the top of the first stud-type five-way valve. The hydraulic stopcock valve is connected to the automatic grease injection assembly. A flow meter is installed on the low-pressure manifold assembly. Vibration sensors are installed at both ends of the high-pressure manifold assembly and the low-pressure manifold assembly. Bolt loosening sensors are installed on the bolts on the stud-type five-way valve, stud-type four-way valve, and double-flange straight pipe. The bolt loosening sensors, vibration sensors, pressure sensors, flow meters, and hydraulic flat valves are connected to the controller.

[0008] Preferably, the base is further provided with a limiting component for fixing the high-pressure manifold assembly. The limiting component includes a set of limiting rings respectively disposed on the upper sides of both ends of the hydraulic flat valve. One end of the limiting ring is hinged to a connecting rod fixedly connected to the base, and the other end of the limiting ring is provided with a protrusion. A steel wire rope is fixedly disposed on one end of the protrusion. The lower end of the steel wire rope passes through the base and extends to the bottom of the base and is wound around a winding shaft. An adjusting seat is fixedly connected to one end of the winding shaft. Fixed seats are also threaded at equal intervals on the outer side of the winding shaft. A protective plate is fixedly connected to the outer side of the winding shaft to protect the steel wire rope wound around the outer side of the winding shaft.

[0009] 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.

[0010] Preferably, the low-pressure manifold is provided with an input end and an output end at both ends. The input end includes a welded female union that mates with one end of the low-pressure manifold. A male plug and a control valve are provided inside the welded female union. The output end includes a flange that mates with the other end of the low-pressure manifold. A flange plug is provided inside the flange. The control valve is connected to a controller.

[0011] Preferably, the low-pressure manifold is made of stainless steel pipe, and the control valve is a stainless steel manual acid-resistant butterfly valve.

[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, each first union flange is provided with a first plug at the end away from the hydraulic flat valve.

[0015] Preferably, the top flange mating surfaces of both stud-type bottom brackets are fitted with second union flanges.

[0016] Preferably, a second plug is provided inside the end of the second union flange.

[0017] Preferably, the base includes a base plate, and a support frame for supporting the high-pressure manifold assembly is fixedly connected to the middle of the base plate. The low-pressure manifold assembly is disposed in the middle of the support frame, and the high-pressure manifold assembly and the low-pressure manifold assembly are relatively independent and separate.

[0018] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0019] I. This utility model provides a hydraulically driven remote intelligent fracturing manifold system. Through a controller and multi-valve assembly, the system uses a hydraulic drive to control the opening and closing of hydraulic flat valves, hydraulic plug valves, and control valves. This reduces the operational intensity of traditional manual plug valves, making operation more convenient and safer, and avoiding potential safety hazards. Pressure sensors monitor the pressure on the high-pressure manifold assembly, vibration sensors monitor the vibration on both the high-pressure and low-pressure manifold assemblies, bolt loosening sensors monitor the loosening of bolts on stud-type five-way valves, stud-type four-way valves, and double-flange straight pipes, and flow meters monitor the flow rate on the low-pressure manifold assembly. The pressure, vibration, bolt loosening, and flow rate information are transmitted to the controller, which then controls the automatic grease injection assembly to automatically inject grease.

[0020] II. The present invention provides a hydraulic remote intelligent fracturing manifold system, wherein the high-pressure manifold assembly and the low-pressure manifold assembly are integral structures and are installed via a base, eliminating the need for a valve lifting support frame and avoiding difficulties in adjusting the valve support frame. Attached Figure Description

[0021] Figure 1 This is the front view of the present invention;

[0022] Figure 2 This is a top view of the present invention;

[0023] Figure 3 This is a side view of the present invention;

[0024] Figure 4 This is a schematic diagram of the limiting component in this utility model.

[0025] The components include: 1. Studded four-way valve; 2. Studded five-way valve; 3. Hydraulic flat valve; 4. First union flange; 5. Double flange straight pipe; 6. Stud nut; 7. Low-pressure manifold; 8. Base plate; 9. Welded union; 10. Output end; 11. Input end; 12. Support frame; 13. Mounting plate; 14. Limit ring; 15. Protrusion; 16. Wire rope; 17. Winding shaft; 18. Protective plate; 19. Fixed seat. Detailed Implementation

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

[0027] Example 1

[0028] like Figures 1-4As shown, this embodiment provides a hydraulically operated remote intelligent fracturing manifold system, including a high-pressure manifold assembly, a low-pressure manifold assembly, and a base for mounting the high-pressure and low-pressure manifold assemblies. The high-pressure manifold assembly includes a set of studded bottom kilometres 2 symmetrically arranged on both sides, with several studded four-way kilometres 1 arranged between the two sides of the studded bottom kilometres 2. A double-flange straight pipe 5 connects adjacent studded four-way kilometres 1, and a double-flange straight pipe 5 connects the studded bottom kilometres 2 to adjacent studded four-way kilometres 1. Each studded four-way 1 and studded bottom kilometres 2 has a hydraulic flat valve 3 connected to both ends. The other end of the pressure plate valve 3 is connected to the first union flange 4 that matches the high-pressure suction port of the pump truck. The top of the first stud-type five-way 2 is equipped with a pressure sensor and a hydraulic plug valve. The hydraulic plug valve is connected to the automatic grease injection assembly. The low-pressure manifold 7 assembly is equipped with a flow meter. Vibration sensors are installed at both ends of the high-pressure manifold assembly and the low-pressure manifold assembly. Bolt loosening sensors are installed on the bolts on the stud-type five-way 2, the stud-type four-way 1, and the double-flange straight pipe 5. The bolt loosening sensors, vibration sensors, pressure sensors, flow meters, and hydraulic plate valve 3 are connected to the controller.

[0029] Example 2

[0030] This embodiment provides a hydraulically driven remote intelligent fracturing manifold system, including a high-pressure manifold assembly, a low-pressure manifold assembly, and a base for mounting the high-pressure and low-pressure manifold assemblies. The high-pressure manifold assembly includes a set of studded bottom kilometres 2 symmetrically arranged on both sides, with several studded four-way kilometres 1 arranged between the two sides of the studded bottom kilometres 2. A double-flange straight pipe 5 connects adjacent studded four-way kilometres 1, and a double-flange straight pipe 5 connects the studded bottom kilometres 2 to adjacent studded four-way kilometres 1. Each studded four-way 1 and studded bottom kilometre 2 has a hydraulic flat valve 3 connected to both ends, and each hydraulic flat valve 3... The other end of each flat plate valve 3 is connected to a first union flange 4 that mates with the high-pressure suction port of the pump truck. A pressure sensor and a hydraulic plug valve are installed on the top of the first stud-type five-way valve 2. The hydraulic plug valve is connected to an automatic grease injection assembly. A flow meter is installed on the low-pressure manifold 7 assembly. Vibration sensors are installed at both ends of the high-pressure and low-pressure manifold assemblies. Bolt loosening sensors are installed on the bolts of the stud-type five-way valve 2, stud-type four-way valve 1, and double-flange straight pipe 5. The bolt loosening sensors, vibration sensors, pressure sensors, flow meters, and hydraulic flat plate valves 3 are connected to a controller. Several hydraulic flat plate valves 3 are connected to multi-valve assemblies via pipelines. These multi-valve assemblies are connected to the hydraulic system and the controller. Several hydraulic plug valves are also connected to multi-valve assemblies via pipelines. These multi-valve assemblies are connected to the hydraulic system and the controller. The hydraulic system includes a hydraulic power unit, which is connected to the hydraulic flat plate valves 3, hydraulic plug valves, and hydraulic gate valves. The stud-type five-way 2, stud-type four-way 1, and double-flange straight pipe 5 are connected by bolts and stud nuts 6.

[0031] The base is also equipped with a limiting component for fixing the high-pressure manifold assembly. The limiting component includes a set of limiting rings 14 respectively set on the upper sides of both ends of the hydraulic flat valve 3. One end of the limiting ring 14 is hinged to a connecting rod fixedly connected to the base. The other end of the limiting ring 14 is provided with a protrusion 15. A steel wire rope 16 is fixedly installed at one end of the protrusion 15. The lower end of the steel wire rope 16 passes through the base and extends to the bottom of the base and is wound with a winding shaft 17. One end of the winding shaft 17 is fixedly connected to an adjusting seat. Fixed seats 19 are also threaded at equal intervals on the outside of the winding shaft 17. A protective plate 18 is fixedly connected to the outside of the winding shaft 17 to protect the steel wire rope 16 wound on the outside of the winding shaft 17.

[0032] The low-pressure manifold assembly includes a low-pressure manifold 7, and several docking ports are provided on both sides of the low-pressure manifold 7. Each docking port is connected to a weld union 9, and one end of the weld union 9 is connected to the low-pressure suction port of the fracturing pump truck.

[0033] The low-pressure manifold 7 is provided with an input end 11 and an output end 10 at its two ends. The input end 11 includes a welded female union that mates with one end of the low-pressure manifold 7. A male plug and a control valve are provided inside the welded female union. The output end 10 includes a flange that mates with the other end of the low-pressure manifold 7. A flange plug is provided inside the flange. The control valve is connected to a controller.

[0034] The low-pressure manifold 7 is made of stainless steel pipe, and the control valve is a stainless steel manual acid-resistant butterfly valve.

[0035] The automatic grease injection assembly is connected to the corresponding hydraulic plug valve through a corresponding lubrication line. The hydraulic plug valve is connected to the top of the stud-type five-way valve 2 through a union flange. The hydraulic plug valve is connected to the controller.

[0036] The stud-type five-way valve 2 is also equipped with a safety valve at its top.

[0037] Each of the first union flanges 4 has a first plug at the end furthest from the hydraulic flat valve 3.

[0038] Among them, the top flange mating surfaces of the two stud-type bottom brackets 2 are both fitted with second union flanges.

[0039] The second union flange has a second plug inside its end.

[0040] The base includes a base plate 8, and a support frame 12 for supporting the high-pressure manifold assembly is fixedly connected to the middle of the base plate 8. The low-pressure manifold assembly 7 is located in the middle of the support frame 12, and the high-pressure manifold assembly and the low-pressure manifold assembly 7 are relatively independent and separate.

[0041] Example 3

[0042] The difference between this embodiment and embodiment 2 is that the diameter of the double-flange straight pipe 5 is 180mm, and each high-pressure manifold assembly is connected by a 7 1 / 16 x 20K L=1.5m double-flange straight pipe 5. A 7 1 / 16" x 20K (2) - 3 1 / 16" x 20K (6) fracturing octagon assembly is installed at the front end of the high-pressure manifold assembly. The fracturing octagon assembly includes a 7 1 / 16" 20K blind flange and 6 3 1 / 16" 20K union flanges with blind plugs. The main channel is 7 1 / 16" 20K, comprising three studded bottom brackets 2 of 7 1 / 16" x 20K (2) - 3 1 / 16" x 20K (3), and two 7 1 / 16" x 20K double flange straight pipes 5 (L=2640mm), resulting in a spacing of approximately 3.1 meters between the high-pressure inlet ends; the top of the first studded bottom bracket 2 is equipped with a 3 1 / 16" x 20K - 2" FIG2002 union flange and a pressure sensor; the top of the second studded bottom bracket 2 is connected to a 3 1 / 16" x 20K Union flange of FIG2002F and two 2" x 20K FIG2002FM hydraulic plug valves connected in series, with the plug valve ends blocked by blind plugs; the top of the last studded bottom bracket 2 is connected to a safety valve connected by a 3 1 / 16" x 20K flange. Each studded four-way 1 on the main channel is supported by a fixed bracket.

[0043] During use: Pressure information, vibration information, bolt loosening information, and flow information are compared with the preset values ​​in the controller. When a parameter is abnormal, the controller controls the hydraulic flat valve to remotely close it, avoiding further damage caused by failure to close in time due to abnormal working conditions.

[0044] Compared with the prior art, this utility model has the following advantages and beneficial effects:

[0045] I. This utility model provides a hydraulic remote intelligent fracturing manifold system. Through a controller and a multi-valve assembly, the system uses a hydraulic drive to control the opening and closing of the hydraulic flat valve 3, hydraulic plug valve, and control valve. This reduces the operational intensity of traditional manual plug valves, making operation more convenient and safer, and avoiding potential safety hazards. Pressure sensors monitor the pressure on the high-pressure manifold assembly, vibration sensors monitor the vibration on the high-pressure and low-pressure manifold 7 assemblies, bolt loosening sensors monitor the loosening of bolts on the stud-type five-way 2, stud-type four-way 1, and double-flange straight pipe 5, and a flow meter monitors the flow rate on the low-pressure manifold 7 assembly. The pressure, vibration, bolt loosening, and flow rate information are transmitted to the controller, which then controls the automatic grease injection assembly to automatically inject grease.

[0046] II. The present invention provides a hydraulic remote intelligent fracturing manifold system, wherein the high-pressure manifold assembly and the low-pressure manifold 7 assembly are integral structures and are installed via a base, eliminating the need for the valve lifting support frame 12 and avoiding the difficulty in adjusting the valve support frame 12.

[0047] The above description is merely a preferred embodiment of the present utility model and is not intended to limit the present utility model in any way. Any simple modifications or equivalent changes made to the above embodiments based on the technical essence of the present utility model shall fall within the protection scope of the present utility model.

Claims

1. A hydraulically driven, remotely controlled, intelligent fracturing manifold system, characterized in that: The system includes a high-pressure manifold assembly, a low-pressure manifold assembly, and a base for mounting the high-pressure and low-pressure manifold assemblies. The high-pressure manifold assembly includes a set of studded bottom kilometres (2) arranged symmetrically on both sides. Several studded four-way kilometres (1) are arranged between the two studded bottom kilometres (2). A double-flange straight pipe (5) connects adjacent studded four-way kilometres (1). A double-flange straight pipe (5) connects the studded bottom kilometres (2) to adjacent studded four-way kilometres (1). Each studded four-way kilometre (1) and each studded bottom kilometre (2) has a hydraulic flat valve (3) connected to both sides of its mating ends. The other end is connected to the first union flange (4) that matches the high pressure suction port of the pump truck. The top of the first stud-type five-way (2) is equipped with a pressure sensor and a hydraulic plug valve. The hydraulic plug valve is connected to the automatic grease injection assembly. The low pressure manifold assembly is equipped with a flow meter. Both ends of the high pressure manifold assembly and the low pressure manifold assembly are equipped with vibration sensors. The bolts on the stud-type five-way (2), stud-type four-way (1) and double flange straight pipe (5) are equipped with bolt loosening sensors. The bolt loosening sensors, vibration sensors, pressure sensors, flow meters and hydraulic flat valve (3) are connected to the controller.

2. The hydraulically operated remote intelligent fracturing manifold system according to claim 1, characterized in that: The base is also provided with a limiting component for fixing the high-pressure manifold assembly. The limiting component includes a set of limiting rings (14) respectively set on the upper side of both ends of the hydraulic flat valve (3). One end of the limiting ring (14) is hinged to a connecting rod fixedly connected to the base. The other end of the limiting ring (14) is provided with a protrusion (15). One end of the protrusion (15) is fixedly provided with a steel wire rope (16). The lower end of the steel wire rope (16) extends through the base to the bottom of the base and is wound with a winding shaft (17). One end of the winding shaft (17) is fixedly connected with an adjusting seat. The outer side of the winding shaft (17) is also threaded with a fixed seat (19) at equal intervals. The outer side of the winding shaft (17) is fixedly connected with a protective plate (18) to protect the steel wire rope (16) wound on the outer side of the winding shaft (17).

3. The hydraulically driven remote intelligent fracturing manifold system according to claim 2, characterized in that: The low-pressure manifold assembly includes a low-pressure manifold (7), and several docking ports are provided on both sides of the low-pressure manifold (7). Each docking port is connected to a weld union (9), and one end of the weld union (9) is connected to the low-pressure inlet of the fracturing pump truck.

4. The hydraulically operated remote intelligent fracturing manifold system according to claim 3, characterized in that: The low-pressure manifold (7) is provided with an input end (11) and an output end (10) at its two ends. The input end (11) includes a welded female union that mates with one end of the low-pressure manifold (7). A male plug and a control valve are provided inside the welded female union. The output end (10) includes a flange that mates with the other end of the low-pressure manifold (7). A flange plug is provided inside the flange. The control valve is connected to a controller.

5. The hydraulically operated remote intelligent fracturing manifold system according to claim 4, characterized in that: The low-pressure manifold (7) is made of stainless steel pipe, and the control valve is a stainless steel manual acid-resistant butterfly valve.

6. The hydraulically operated remote intelligent fracturing manifold system according to claim 5, 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 (2) through a union flange. The hydraulic plug valve is connected to the controller.

7. The hydraulically operated remote intelligent fracturing manifold system according to claim 6, characterized in that: The stud-type five-way valve (2) is also equipped with a safety valve at the top.

8. The hydraulically operated remote intelligent fracturing manifold system according to claim 7, characterized in that: Each first union flange (4) is provided with a first plug at the end away from the hydraulic flat valve (3).

9. A hydraulically operated remote intelligent fracturing manifold system according to claim 8, characterized in that: The top flange mating surfaces of the stud-type bottom brackets (2) on both sides are fitted with second union flanges.

10. A hydraulically operated remote intelligent fracturing manifold system according to claim 9, characterized in that: A second plug is provided inside the end of the second union flange.

11. A hydraulically operated remote intelligent fracturing manifold system according to claim 10, characterized in that: The base includes a base plate (8), and a support frame (12) for supporting the high-pressure manifold assembly is fixedly connected to the middle of the base plate (8). The low-pressure manifold assembly is located in the middle of the support frame (12), and the high-pressure manifold assembly and the low-pressure manifold assembly are set up independently.

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