CN108561098A - 一种集远程控制新型超大功率固井设备 - Google Patents
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Abstract
本发明涉及石油装备技术领域，具体地说，是一种集远程控制新型超大功率固井设备，包括装载系统和一副梁，副梁上由前往后依次连接液压系统、动力传动系统、计量罐、电气系统、气路系统、操控系统和混合系统，气路系统的下部设置柱塞泵，柱塞泵和高压排出系统连接；电气系统的下部设置一操控平台，操控系统位于操控平台上方，操控系统与远程控制系统连接。本发明满足了超深固井作业以及超高压气井作业对固井作业时高压力、大排量、长时间、持续不间断作业需要；占地面积小，管线连接简单，维修频率低。
Description
技术领域
本发明涉及石油装备技术领域，具体地说，是一种集远程控制新型超大功率固井设备。
背景技术
由于超深井及复杂地层固井作业出现的频次越来越多，尤其是超深固井作业以及超高压气井作业对固井作业时高压力、大排量、长时间、持续不间断作业需要，将助推大功率或者超大功率注水泥装备功率的快速发展。采用大功率电机，将逐步取代现有的单机或双机固井设备。目前作业现状：为同时满足高压力、大排量需求，用户采用多台双机双泵固井设备同时作业，具有占地面积大，管线连接复杂，维修频率高，操作人员多，单次作业成本高等特点。
发明内容
本发明为了克服上述技术问题的不足，提供了一种集远程控制新型超大功率固井设备，解决目前超深井及复杂地层固井作业提出的高压力、大排量、长时间、持续不间断作业需要，以达到满足作业工况需求，提高作业效率，节省作业成本的目的。
解决上述技术问题的技术方案如下：
一种集远程控制新型超大功率固井设备，包括装载系统和一副梁，所述的副梁与装载系统相连，所述的副梁上由前往后依次连接液压系统、动力传动系统、计量罐、低压管汇系统、操作平台及设置在操作平台上端的电气系统、气路系统、操控系统、柱塞泵、高压管汇和混合系统；所述的柱塞泵位于气路系统的下部，所述的柱塞泵的额定输入功率≥1200hp,所述的柱塞泵和高压排出系统连接，所述的气路系统上设置有旋塞阀，所述的旋塞阀是气路系统的总开关，所述的旋塞阀的下游端设置有过滤减压阀，过滤减压阀用于调节整个系统的工作压力和过滤进入系统的气体；
所述的操控系统位于操作平台上方，所述的操控系统与远程控制系统连接，所述的远程控制系统包括远程控制箱、第一云台、数据采集系统、笔记本电脑；
本发明的操作系统主要包括操作平台和仪表控制系统，操作平台是设备作业时操作人员进行设备操作的主要场所，以仪表箱为载体的仪表控制系统可在设备作业时实现实时监测和控制。
所述的动力传动系统包括发动机、变速箱总成、传动轴、扁担梁安装总成、进气和排气系统、冷却系统总成、燃油系统、加热系统和远程过滤器安装架，所述的传动轴位于变速箱总成和柱塞泵之间，所述的发动机和变速箱总成放置于扁担安装总成上，由扁担梁安装总成支撑，所述的进气系统和排气系统为发动机提供燃烧所需空气及废气热量排放，所述的远程过滤器安装架对进气空气过滤器进行支撑，所述的冷却系统总成为发动机、变速箱总成、液压系统和柱塞泵提供散热，所述的变速箱总成通过变换档位实现不同压力和排量的调节，发动机输出动力至变速箱总成，通过传动轴驱动柱塞泵；动力系统作为设备动力源，为设备上的工作部件提供动力。
所述的混合系统位于副梁的尾部，所述的混合系统实现水与灰的混合。
进一步地说，所述的装载系统为车载底盘、半挂车底盘或橇装底盘的任意一种，为设备提供作为设备的承载部件。
进一步地说，所述的柱塞泵为三缸柱塞泵。
进一步地说，所述的高压排出系统包括排出泥浆管汇和设置在排出泥浆管汇上的高压安全阀。
进一步地说，所述的操作平台的上部还设置有盘根润滑系统。
进一步地说，所述的动力传动系统下部还设置有动力端润滑系统用于驱动柱塞泵润滑。
进一步地说，所述的计量罐包括罐体，罐体的底部与清水管汇相连接，并由清水管汇供水，所述的清水管汇上设置有蝶阀，所述的罐体的底部还设置排出口，所述的罐体上还设置一液位尺和第二云台，所述的第二云台位于罐体顶部，罐体主要用于盛放和计量作业的清水，也可以用于部分药品的混配；所述的第二云台能够直观的观察罐内液位，防止溢罐，所述的排出口处的罐体内设置一过滤网，用于过滤杂质。
进一步地说，所述的低压管汇系统包括清水管汇和泥浆管汇，所述的泥浆管汇包括排出管汇和离心泵，所述的离心泵受气动执行器控制，所述的排出管汇上设置密度计管汇和蝶阀。清水管汇用于外接供水，向计量罐内输水以及给混合系统供水来混配泥浆等。泥浆管汇主要用于输送泥浆、测量泥浆流量及密度。
进一步地说，所述的副梁尾部还连接有上灰管汇。
进一步地说，所述的操控系统的下部设置有高压管汇。操控系统上集中安装有动力系统、混合系统等的主要控制部件和显示部件，以及电气系统的核心部件，是设备进行作业时的主要操作场所。本发明的操控系统以仪表箱为载体，主要包括仪表面板、仪表及控制元件等相关部件，通过这些仪表及控制元件实现对固井设备的监测和控制。仪表面板集中安装了设备工作所需的大部分阀件仪表。
本发明具有以下关键总成：
柱塞泵及高压排出系统：柱塞泵、旋塞阀、高压安全阀、排出管线等，将低压力的泥浆、钻井液、酸化、替浆液等流体转化成高压力的流体，通过变化柱塞直径获取不同压力和排量，实现液体的泵注，满足作业要求。
混浆系统：包含混浆罐、计量罐、低压管汇、高能混合器、搅拌器等，既可以采用手动混浆、单变量控制混浆、多变量全自动混浆系统，满足不同使用需求，也可以采用自动混合系统根据压力和排量要求自动控制发动机油门和变速箱挡位，彻底解放操作手。
远程控制系统：远程控制箱、云台、数据采集系统、笔记本电脑等，远程控制系统可使操作手远离操作的作业环境，在远处操作固井设备，远离噪音及高压区，可在远处通过摄像头观察固井设备上的作业情况，使操作手身临其境，达到所见即所得的操作体验。
液压、气路系统：主要包含液压泵、液压马达、液压油箱、液压阀件、润滑齿轮泵、干燥器、气瓶等，为设备离心泵、气动头、润滑等提供动力，保证设备正常工作。
电气系统主要作用：
a)控制发动机启动；
b)控制混浆系统；
c)给电气元件供电，确保作业时各指示灯显示，如触摸屏、仪表、闭锁指示灯、超压指示灯等；
d)给所有照明灯供电，以保证设备在夜间作业；
e)电源供电由电瓶完成。启动发动机之后发动机自带的发电机会给电瓶充电。设备上所有电气设备的电压均为24VDC。
气路系统有一旋塞阀是气路系统的总开关。其后连接的过滤减压阀不仅可以调节整个系统的工作压力还可以过滤进入系统的气体，保证气路元件的正常工作。其主要作用：
a)控制气动执行器开关；
b)控制气喇叭；
c)为盘根润滑系统提供气源；
d)为柴油喷洒油瓶提供气源。
液压系统采用开式/闭式系统设计，工作时液压系统的压力大小取决于外负载的大小，所以只要系统在低于设计压力下工作正常就说明液压系统运行正常。本设备发动机启动系统、离心泵马达驱动系统、混浆罐搅拌器马达驱动系统、下灰油缸驱动系统、液动旋塞阀驱动系统均采用液压驱动。液压系统所有液压元件均采用国际知名品牌，性能稳定可靠。
润滑系统采用柱塞泵动力端润滑和盘根润滑。动力端润滑由一套独立的系统组成，由台上变速箱侧取力驱动齿轮泵对柱塞泵动力端内各轴承、齿轮采用连续压油式强制润滑。齿轮泵将润滑油从油箱中吸入，再通过管路过滤器，经管线流至动力端后分为两路：一路进入主轴经主轴各孔润滑各滚动轴承和连杆的滑动轴承，另一路进入齿轮箱进行润滑，最后回到大泵润滑油箱。管路过滤器前面安装一个安全阀，可以调整整个润滑系统压力，当压力超过设定值时润滑油通过安全阀流回油箱。系统带自动冷却装置，靠发动机风扇制冷，当润滑油温达到设定温度后进入冷却器进行散热。盘根润滑可以采用润滑油脂对柱塞泵液力端盘根或离心泵盘根进行润滑，电动润滑装置将润滑油脂强制压入柱塞泵或离心泵盘根,为避免油脂浪费,电动润滑装置设置为间断运行,为盘根提供最合理的润滑油量,单向阀在此系统中起到防止润滑油脂反排的作用。此润滑液可以采用“气顶油”润滑方式。
柱塞泵系统主要实现不同柱塞、压力等获取最终客户需求的不同压力和排量，满足客户要求。
高压管汇系统是设备高压管件的统称，主要由2″旋塞阀、2″×1″旋塞阀、2″安全阀、压力传感器、整体式直管线、高压三通、高压弯头等组成。其主要实现连接柱塞泵及各个旋塞阀，将排出口延伸到合适的位置，便于外接井场，压力测量、管汇开关控制、泄压、超压保护等功能。
混合系统混合系统总成主要用于水泥浆的混配，主要包括混浆罐、喷射混合器、下灰阀、扩散箱、消泡剂容器、搅拌轴、上灰管汇等附件。其核心部件高能混合器是整个混浆系统总成中的核心部件，由清水管汇进入的清水和由下灰阀进入的水泥灰以及经过二次循环管汇循环的水泥浆在高能混合器中一同进行混合，是进行泥浆混配的主要部件。上灰管汇是为设备混浆系统提供干水泥灰的管路，包括连接管线、上灰胶管和控制蝶阀等。
本发明的有益效果是：
(1)满足了超深固井作业以及超高压气井作业对固井作业时高压力、大排量、长时间、持续不间断作业需要；
(2)节省设备作业空间，实现“小井场，大作业”，设备整体占地面积较小，相比多台常规固井车的排布，更有利于井场设备快速排布，提高现场作业效率；
(3)具有管线连接简单，维修频率低，需求操作人员数量少，单次作业成本低等特点；
(4)智能化设计，减少人工误操作，一键操作实现对发动机油门和变速箱挡位的自动控制，彻底解放操作手，向智慧油田迈进关键一步；
(5)安全高效，设备配备远程控制系统，使得操作手远离噪音与高压区，身临其境地完成操作，确保了设备和人员的双重安全。
下面结合附图和具体实施方式对本发明作进一步详细的说明。
附图说明
图1为本发明平面结构示意图；
图2为本发明的立体结构示意图；
图3为动力传动系统结构示意图；
图中：1为装载系统，2为液压系统，3为动力传动系统，4为电气系统，5 为气路系统，6为盘根润滑系统，7为操控系统，8为高压管汇，9为混合系统， 10为上灰管汇，11为排出泥浆管汇，12为操作平台，13为柱塞泵，14为清水管汇，15为计量罐，16为动力端润滑系统，17为副梁,18为传动轴，19为扁担梁安装总成，20为发动机，21为变速箱总成，22为进气系统，23为排气系统， 24为远程过滤器安装架，25为冷却系统总成。
具体实施方式
实施例1：
如图1-3所示：一种集远程控制新型超大功率固井设备，包括装载系统1 和一副梁17，副梁17与装载系统1相连，副梁17上由前往后依次连接液压系统2、动力传动系统3、计量罐15、低压管汇系统、操作平台12及设置在操作平台12上端的电气系统4、气路系统5、操控系统7、柱塞泵13、高压管汇8 和混合系统9；柱塞泵13位于气路系统5的下部，柱塞泵13的额定输入功率≥ 1200hp,柱塞泵13和高压排出系统连接，气路系统5上设置有旋塞阀，旋塞阀是气路系统的总开关，旋塞阀的下游端设置有过滤减压阀，过滤减压阀用于调节整个系统的工作压力和过滤进入系统的气体；
操控系统7位于操作平台12上方，操控系统7与远程控制系统连接，远程控制系统包括远程控制箱、第一云台、数据采集系统、笔记本电脑(图中无示出)；
动力传动系统3包括发动机20、变速箱总成21、传动轴18、扁担梁安装总成19、进气系统22和排气系统23、冷却系统总成25、燃油系统、加热系统和远程过滤器安装架24，传动轴18位于变速箱总成21和柱塞泵13之间，发动机 20和变速箱总成21放置于扁担梁安装总成19上，由扁担梁安装总成19支撑，进气系统22和排气系统23为发动机20提供燃烧所需空气及废气热量排放，远程过滤器安装架24对进气空气过滤器进行支撑，冷却系统总成25为发动机20、变速箱总成21、液压系统2和柱塞泵13提供散热，变速箱总成21通过变换档位实现不同压力和排量的调节，发动机20输出动力至变速箱总成21，通过传动轴18驱动柱塞泵13；
混合系统9位于副梁17的尾部，混合系统9实现水与灰的混合。
装载系统1为车载底盘。
柱塞泵13为三缸柱塞泵。
高压排出系统包括排出泥浆管汇11和设置在排出泥浆管汇11上的高压安全阀。
操作平台12的上部还设置有盘根润滑系统6。
动力传动系统3下部还设置有动力端润滑系统16用于驱动柱塞泵13润滑。
计量罐15包括罐体，罐体的底部与清水管汇14相连接，并由清水管汇14 供水，清水管汇14上设置有蝶阀，罐体的底部还设置排出口，罐体上还设置一液位尺和第二云台，第二云台位于罐体顶部，排出口处的罐体内设置一过滤网。
低压管汇系统包括清水管汇14和泥浆管汇，泥浆管汇包括排出管汇和离心泵，离心泵受气动执行器控制，排出管汇上设置密度计管汇和蝶阀。
副梁17尾部还连接有上灰管汇10。
操控系统7的下部设置有高压管汇8。
实施例2：
一种集远程控制新型超大功率固井设备，包括装载系统1和一副梁17，副梁17与装载系统1相连，副梁17上由前往后依次连接液压系统2、动力传动系统3、计量罐15、低压管汇系统、操作平台12及设置在操作平台12上端的电气系统4、气路系统5、操控系统7、柱塞泵13、高压管汇8和混合系统9；柱塞泵13位于气路系统5的下部，柱塞泵13的额定输入功率≥1200hp,柱塞泵13 和高压排出系统连接，气路系统5上设置有旋塞阀，旋塞阀是气路系统的总开关，旋塞阀的下游端设置有过滤减压阀，过滤减压阀用于调节整个系统的工作压力和过滤进入系统的气体；
操控系统7位于操作平台12上方，操控系统7与远程控制系统连接，远程控制系统包括远程控制箱、第一云台、数据采集系统、笔记本电脑(图中无示出)；
动力传动系统3包括发动机20、变速箱总成21、传动轴18、扁担梁安装总成19、进气系统22和排气系统23、冷却系统总成25、燃油系统、加热系统和远程过滤器安装架24，传动轴18位于变速箱总成21和柱塞泵13之间，发动机 20和变速箱总成21放置于扁担梁安装总成19上，由扁担梁安装总成19支撑，进气系统22和排气系统23为发动机20提供燃烧所需空气及废气热量排放，远程过滤器安装架24对进气空气过滤器进行支撑，冷却系统总成25为发动机20、变速箱总成21、液压系统2和柱塞泵13提供散热，变速箱总成21通过变换档位实现不同压力和排量的调节，发动机20输出动力至变速箱总成21，通过传动轴18驱动柱塞泵13；
混合系统9位于副梁17的尾部，混合系统9实现水与灰的混合。
装载系统1为半挂车底盘。
柱塞泵13为三缸柱塞泵。
高压排出系统包括排出泥浆管汇11和设置在排出泥浆管汇11上的高压安全阀。
操作平台12的上部还设置有盘根润滑系统6。
动力传动系统3下部还设置有动力端润滑系统16用于驱动柱塞泵13润滑。
计量罐15包括罐体，罐体的底部与清水管汇14相连接，并由清水管汇14 供水，清水管汇14上设置有蝶阀，罐体的底部还设置排出口，罐体上还设置一液位尺和第二云台，第二云台位于罐体顶部，排出口处的罐体内设置一过滤网。
低压管汇系统包括清水管汇14和泥浆管汇，泥浆管汇包括排出管汇和离心泵，离心泵受气动执行器控制，排出管汇上设置密度计管汇和蝶阀。
副梁17尾部还连接有上灰管汇10。
操控系统7的下部设置有高压管汇8。
实施例3：
一种集远程控制新型超大功率固井设备，包括装载系统1和一副梁17，副梁17与装载系统1相连，副梁17上由前往后依次连接液压系统2、动力传动系统3、计量罐15、低压管汇系统、操作平台12及设置在操作平台12上端的电气系统4、气路系统5、操控系统7、柱塞泵13、高压管汇8和混合系统9；柱塞泵13位于气路系统5的下部，柱塞泵13的额定输入功率≥1200hp,柱塞泵13 和高压排出系统连接，气路系统5上设置有旋塞阀，旋塞阀是气路系统的总开关，旋塞阀的下游端设置有过滤减压阀，过滤减压阀用于调节整个系统的工作压力和过滤进入系统的气体；
操控系统7位于操作平台12上方，操控系统7与远程控制系统连接，远程控制系统包括远程控制箱、第一云台、数据采集系统、笔记本电脑(图中无示出)；
动力传动系统3包括发动机20、变速箱总成21、传动轴18、扁担梁安装总成19、进气系统22和排气系统23、冷却系统总成25、燃油系统、加热系统和远程过滤器安装架24，传动轴18位于变速箱总成21和柱塞泵13之间，发动机 20和变速箱总成21放置于扁担梁安装总成19上，由扁担梁安装总成19支撑，进气系统22和排气系统23为发动机20提供燃烧所需空气及废气热量排放，远程过滤器安装架24对进气空气过滤器进行支撑，冷却系统总成25为发动机20、变速箱总成21、液压系统2和柱塞泵13提供散热，变速箱总成21通过变换档位实现不同压力和排量的调节，发动机20输出动力至变速箱总成21，通过传动轴18驱动柱塞泵13；
混合系统9位于副梁17的尾部，混合系统9实现水与灰的混合。
装载系统1为橇装底盘。
柱塞泵13为三缸柱塞泵。
高压排出系统包括排出泥浆管汇11和设置在排出泥浆管汇11上的高压安全阀。
操作平台12的上部还设置有盘根润滑系统6。
动力传动系统3下部还设置有动力端润滑系统16用于驱动柱塞泵13润滑。
计量罐15包括罐体，罐体的底部与清水管汇14相连接，并由清水管汇14 供水，清水管汇14上设置有蝶阀，罐体的底部还设置排出口，罐体上还设置一液位尺和第二云台，第二云台位于罐体顶部，排出口处的罐体内设置一过滤网。
低压管汇系统包括清水管汇14和泥浆管汇，泥浆管汇包括排出管汇和离心泵，离心泵受气动执行器控制，排出管汇上设置密度计管汇和蝶阀。
副梁17尾部还连接有上灰管汇10。
操控系统7的下部设置有高压管汇8。
以上所述，仅是本发明的较佳实施例，并非对本发明做任何形式上的限制，凡是依据本发明的技术实质上对以上实施例所作的任何简单修改、等同变化，均落入本发明的保护范围之内。
Claims (10)
1.一种集远程控制新型超大功率固井设备，其特征在于，包括装载系统和一副梁，所述的副梁与装载系统相连，所述的副梁上由前往后依次连接液压系统、动力传动系统、计量罐、低压管汇系统、操作平台及设置在操作平台上端的电气系统、气路系统、操控系统、柱塞泵、高压管汇和混合系统；所述的柱塞泵位于气路系统的下部，所述的柱塞泵的额定输入功率≥1200hp,所述的柱塞泵和高压排出系统连接，所述的气路系统上设置有旋塞阀，所述的旋塞阀是气路系统的总开关，所述的旋塞阀的下游端设置有过滤减压阀，过滤减压阀用于调节整个系统的工作压力和过滤进入系统的气体；
所述的操控系统位于操作平台上方，所述的操控系统与远程控制系统连接，所述的远程控制系统包括远程控制箱、第一云台、数据采集系统、笔记本电脑；
所述的动力传动系统包括发动机、变速箱总成、传动轴、扁担梁安装总成、进气和排气系统、冷却系统总成、燃油系统、加热系统和远程过滤器安装架，所述的传动轴位于变速箱总成和柱塞泵之间，所述的发动机和变速箱总成放置于扁担安装总成上，由扁担梁安装总成支撑，所述的进气系统和排气系统为发动机提供燃烧所需空气及废气热量排放，所述的远程过滤器安装架对进气空气过滤器进行支撑，所述的冷却系统总成为发动机、变速箱总成、液压系统和柱塞泵提供散热，所述的变速箱总成通过变换档位实现不同压力和排量的调节，发动机输出动力至变速箱总成，通过传动轴驱动柱塞泵；
所述的混合系统位于副梁的尾部，所述的混合系统实现水与灰的混合。
2.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的装载系统为车载底盘、半挂车底盘或橇装底盘的任意一种。
3.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的柱塞泵为三缸柱塞泵。
4.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的高压排出系统包括排出泥浆管汇和设置在排出泥浆管汇上的高压安全阀。
5.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的操作平台的上部还设置有盘根润滑系统。
6.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的动力传动系统下部还设置有动力端润滑系统用于驱动柱塞泵润滑。
7.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的计量罐包括罐体，罐体的底部与清水管汇相连接，并由清水管汇供水，所述的清水管汇上设置有蝶阀，所述的罐体的底部还设置排出口，所述的罐体上还设置一液位尺和第二云台，所述的第二云台位于罐体顶部，所述的排出口处的罐体内设置一过滤网。
8.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的低压管汇系统包括清水管汇和泥浆管汇，所述的泥浆管汇包括排出管汇和离心泵，所述的离心泵受气动执行器控制，所述的排出管汇上设置密度计管汇和蝶阀。
9.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的副梁尾部还连接有上灰管汇。
10.根据权利要求1所述的集远程控制新型超大功率固井设备，其特征在于，所述的操控系统的下部设置有高压管汇。
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| US11732563B2 (en) | 2021-05-24 | 2023-08-22 | Bj Energy Solutions, Llc | Hydraulic fracturing pumps to enhance flow of fracturing fluid into wellheads and related methods |
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