CN115310240B - Oil-gas fracturing pump equipment service life prediction method and device and nonvolatile storage medium - Google Patents
Oil-gas fracturing pump equipment service life prediction method and device and nonvolatile storage medium Download PDFInfo
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- CN115310240B CN115310240B CN202211237595.3A CN202211237595A CN115310240B CN 115310240 B CN115310240 B CN 115310240B CN 202211237595 A CN202211237595 A CN 202211237595A CN 115310240 B CN115310240 B CN 115310240B
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
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Abstract
The invention discloses a method and a device for predicting the service life of oil-gas fracturing pump equipment and a nonvolatile storage medium. Wherein, the method comprises the following steps: collecting at least one historical working condition of equipment and working time of the equipment under the at least one historical working condition respectively; acquiring at least one expected life of the equipment corresponding to at least one historical working condition according to the working time of the equipment under the at least one historical working condition respectively, wherein the at least one expected life represents the life of the equipment completely working under the corresponding historical working condition respectively; and predicting the residual life of the equipment according to the working time length under at least one historical working condition and at least one expected life corresponding to at least one historical working condition. The prediction device is used for realizing the service life prediction method. The non-volatile storage medium comprises a stored program, wherein the apparatus in which the non-volatile storage medium is controlled to perform the above-described method when the program is run. The invention solves the technical problem of inaccurate prediction of the residual life of the plunger pump.
Description
Technical Field
The invention relates to the field of oilfield fracturing, in particular to a method and a device for predicting the service life of oil-gas fracturing pump equipment and a nonvolatile storage medium.
Background
In the oilfield fracturing operation, industrial equipment required by fracturing is used as the core of the fracturing operation, and the stability and reliability of the industrial equipment play an important role in the success of the operation. For an operation team, the replacement cycle of equipment for fracturing operation is accurately grasped, the service time condition of the operation equipment is monitored in real time, and the scheduling of the whole operation equipment and the safety of the fracturing operation play an important role. For a diesel-driven fracturing device, an engine, a gearbox and a plunger pump are core components on the fracturing device; for electrically driven fracturing equipment, the motor and plunger pump are the core components. However, even if the fracturing equipment in the same batch has different loss schedules due to different working states of different equipment, the equipment with higher loss has potential safety hazards on the operation field when the equipment is kept in operation, and the equipment with lower loss is wasted when being replaced in the same batch with other fracturing equipment. It should be noted that the wear of the equipment, such as the plunger pump, may include various types, such as wear or corrosion, and the specific wear cause of the equipment depends on the working condition of the equipment.
For equipment of fracturing operation, no special control system is available for monitoring the real-time application condition of the fracturing equipment. In the related art, the replacement and management of the operation equipment either depend on the regular observation and uniform replacement of special personnel, which is very unfavorable for the safety and reliability of the equipment use, or a pre-trained machine learning model is needed to predict the service life of the fracturing equipment such as a high-pressure manifold, the prediction mode depends on the pre-constructed machine learning model, the use is very inconvenient, and the form and the result of the service life prediction depend on the construction mode of the pre-trained model, can not be changed at will, and are very inflexible.
In view of the above problems, no effective solution has been proposed.
Disclosure of Invention
The invention provides a method and a device for predicting the service life of oil-gas fracturing pump equipment and a nonvolatile storage medium, which at least solve the technical problem of inaccurate prediction of the residual service life of the fracturing equipment.
The invention provides a method for predicting the service life of oil-gas fracturing pump equipment, which comprises the following steps: collecting at least one historical working condition of equipment and working time of the equipment under the at least one historical working condition respectively; acquiring at least one expected life of the equipment corresponding to the at least one historical working condition according to the working time of the equipment under the at least one historical working condition respectively, wherein the at least one expected life represents the life of the equipment completely working under the corresponding historical working condition respectively; and predicting the residual life of the equipment according to the working time length under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition.
Optionally, the predicting the remaining life of the equipment according to the operating time under the at least one historical operating condition and at least one expected life corresponding to the at least one historical operating condition includes: determining at least one used life corresponding to the at least one historical working condition of the equipment according to the working time of the equipment under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition, wherein the at least one used life is the life respectively lost when the equipment is under the at least one historical working condition; determining a remaining lifetime of the device based on the at least one used lifetime.
Optionally, the determining, according to the operating duration of the device under the at least one historical operating condition and the at least one expected life corresponding to the at least one historical operating condition, at least one used life corresponding to the at least one historical operating condition includes: and comparing the working time of the equipment under each historical working condition of the at least one historical working condition with the expected life corresponding to each historical working condition to obtain the percentage of the used life of the equipment under each historical working condition of the at least one historical working condition, wherein the used life of the equipment comprises at least one percentage of the used life.
Optionally, said determining a remaining lifetime of said device according to said at least one used lifetime comprises: determining a remaining life percentage of the device based on the at least one used life percentage; obtaining the expected life corresponding to the current working condition of the equipment; and determining the residual life of the equipment under the current working condition according to the expected life corresponding to the current working condition and the residual life percentage.
Optionally, the apparatus comprises: a plunger pump; the at least one historical operating condition comprises: the plunger pump is located in at least one working pressure interval, and when the at least one working pressure interval comprises a plurality of intervals, the intervals are not overlapped with each other.
Optionally, the predicting the remaining life of the device according to the operating duration under the at least one historical operating condition and the at least one expected life corresponding to the at least one historical operating condition includes: when the plunger pumps are respectively in the at least one historical working condition, collecting the physical state of the fracturing fluid of the plunger pumps, wherein the physical state comprises any one of the following conditions: a standard state, a sand adding state and an acid adding state; and predicting the residual life of the equipment according to the working time under the at least one historical working condition, at least one expected life corresponding to the at least one historical working condition and the physical state of the fracturing fluid under the at least one historical working condition.
Optionally, the predicting the remaining life of the equipment according to the working time under the at least one historical operating condition, the at least one expected life corresponding to the at least one historical operating condition, and the physical state of the fracturing fluid under the at least one historical operating condition includes: when the physical state of the fracturing fluid is in an acid adding state, collecting the PH value of the fracturing fluid in each working condition of the at least one historical working condition; acquiring a pH value coefficient corresponding to the PH value of the fracturing fluid, and predicting the residual life according to the working time of the equipment under the at least one historical working condition, the at least one expected life and the pH value coefficient; when the physical state of the fracturing fluid is a sand adding state, collecting the sand density of the fracturing fluid in each working condition of the at least one historical working condition; and obtaining a sand density coefficient corresponding to the sand density of the fracturing fluid, and predicting the residual life according to the working duration of the equipment under the at least one historical working condition, the at least one expected life and the sand density coefficient.
The invention also provides a device for predicting the service life of the oil-gas fracturing pump equipment, which comprises: the acquisition module is used for acquiring at least one historical working condition of equipment and the working time of the equipment under the at least one historical working condition respectively; the acquisition module is used for acquiring at least one expected life of the equipment corresponding to the at least one historical working condition according to the working time of the equipment under the at least one historical working condition respectively, wherein the at least one expected life represents the life of the equipment completely working under the corresponding historical working condition respectively; and the prediction module is used for predicting the residual life of the equipment according to the working time under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition.
The invention also provides a nonvolatile storage medium which comprises a stored program, wherein when the program runs, the equipment where the nonvolatile storage medium is located is controlled to execute any one of the methods for predicting the service life of the oil-gas fracturing pump equipment.
The invention also provides computer equipment which comprises a memory and a processor, wherein the memory is used for storing programs, the processor is used for operating the programs stored by the memory, and the program is operated to execute any one of the oil and gas fracturing pump equipment life prediction methods.
The method adopts a segmented estimation mode, and comprises the steps of collecting a plurality of historical working conditions of the equipment and working time of the equipment under the plurality of historical working conditions respectively; acquiring a plurality of expected lives of the equipment corresponding to a plurality of historical working conditions according to the working time of the equipment under the plurality of historical working conditions respectively, wherein the plurality of expected lives respectively represent the lives of the equipment which completely works under the corresponding historical working conditions; the residual service life of the equipment is predicted according to the working time under the plurality of historical working conditions and the plurality of expected service lives corresponding to the plurality of historical working conditions, and the purpose of reasonably estimating the loss degree of the operating equipment is achieved, so that the technical effect of improving the prediction accuracy of the residual service life of the oil-gas fracturing pump operating equipment is achieved, and the technical problem that the prediction of the residual service life of the fracturing equipment is inaccurate is solved.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the invention without limiting the invention. In the drawings:
FIG. 1 shows a hardware block diagram of a computer terminal for implementing a method for predicting the life of oil and gas fracturing pump equipment;
FIG. 2 is a schematic flow chart of a method for predicting the service life of oil and gas fracturing pump equipment provided according to an embodiment of the invention;
FIG. 3 is a schematic flow diagram of a plunger pump life warning provided in accordance with an alternative embodiment of the present invention;
FIG. 4 is a structural block diagram of a life prediction device for oil and gas fracturing pump equipment provided according to an embodiment of the invention.
Detailed Description
In order to make the technical solutions of the present invention better understood, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and claims of the present invention and in the drawings described above are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used is interchangeable under appropriate circumstances such that the embodiments of the invention described herein are capable of operation in other sequences than those illustrated or described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed, but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
In accordance with an embodiment of the present invention, there is provided an embodiment of a method for device life prediction, it being noted that the steps illustrated in the flowchart of the figure may be performed in a computer system such as a set of computer-executable instructions and that, although a logical order is illustrated in the flowchart, in some cases the steps illustrated or described may be performed in an order different than that presented herein.
The method provided by the first embodiment of the present application may be executed in a mobile terminal, a computer terminal, or a similar computing device. Fig. 1 shows a hardware structure block diagram of a computer terminal for implementing a life prediction method of oil and gas fracturing pump equipment. As shown in fig. 1, the computer terminal 10 may include one or more processors (shown in the figures as 102a, 102b, \8230;, 102 n) which may include, but are not limited to, a processing device such as a microprocessor MCU or a programmable logic device FPGA, or the like, a memory 104 for storing data. Besides, the method can also comprise the following steps: a display, an input/output interface (I/O interface), a Universal Serial BUS (USB) port (which may be included as one of the ports of the BUS), a network interface, a power source, and/or a camera. It will be understood by those skilled in the art that the structure shown in fig. 1 is only an illustration and is not intended to limit the structure of the electronic device. For example, the computer terminal 10 may also include more or fewer components than shown in FIG. 1, or have a different configuration than shown in FIG. 1.
It should be noted that the one or more processors and/or other data processing circuitry described above may be referred to generally herein as "data processing circuitry". The data processing circuitry may be embodied in whole or in part in software, hardware, firmware, or any combination thereof. Further, the data processing circuit may be a single stand-alone processing module, or incorporated in whole or in part into any of the other elements in the computer terminal 10. As referred to in the embodiments of the application, the data processing circuit acts as a processor control (e.g. selection of variable resistance termination paths connected to the interface).
The memory 104 may be used to store software programs and modules of application software, such as program instructions/data storage devices corresponding to the device life prediction method in the embodiment of the present invention, and the processor executes various functional applications and data processing by running the software programs and modules stored in the memory 104, that is, implements the device life prediction method of the application program. The memory 104 may include high speed random access memory, and may also include non-volatile memory, such as one or more magnetic storage devices, flash memory, or other non-volatile solid-state memory. In some examples, the memory 104 may further include memory remotely located from the processor, which may be connected to the computer terminal 10 over a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The display may be, for example, a touch screen type Liquid Crystal Display (LCD) that may enable a user to interact with the user interface of the computer terminal 10.
In the oilfield fracturing operation, the fracturing equipment is the core of the fracturing operation, and for the diesel drive fracturing equipment, an engine, a gearbox and a plunger pump are core components on the fracturing equipment; for electrically driven fracturing equipment, the motor and plunger pump are the core components. In the related art, a method for accurately monitoring and maintaining fracturing equipment is lacked, and the state of the equipment can be judged only by directly observing field workers, or the fracturing equipment in the same batch is uniformly replaced after the equipment is used for a long time. However, even if the fracturing equipment in the same batch has different loss schedules due to different working states of different equipment, the equipment with higher loss has potential safety hazards on the operation field when the equipment is kept in operation, and the equipment with lower loss is wasted when being replaced in the same batch with other fracturing equipment. It should be noted that the wear of the equipment, such as the plunger pump, may include various types, such as wear or corrosion, and the specific wear cause of the equipment depends on the working condition of the equipment.
Fig. 2 is a schematic flow chart of the method for predicting the service life of the oil and gas fracturing pump equipment, which is provided by the embodiment of the invention, and the method for predicting the service life of the equipment can be used for accurately predicting the residual service life of each construction equipment on a fracturing site and providing a basis for equipment operation and maintenance for site workers. As shown in fig. 2, the method comprises the steps of:
step S202, at least one historical working condition of the equipment and the working time of the equipment under the at least one historical working condition are collected. It should be noted that the equipment described in the method may be oil and gas fracturing pump equipment used for oil field fracturing operation, or may be a specific component of the oil and gas fracturing pump equipment, for example, a component on the oil and gas fracturing pump equipment, which is in direct contact with the environment, or a component which is in direct contact with a substance which is liable to cause the loss of the oil and gas fracturing pump equipment, and when such a component is lost, it may be considered that the life loss of the oil and gas fracturing pump equipment itself occurs.
The historical working condition can be a working condition which is experienced by the equipment in the using process, the equipment is lost in the historical working condition, and the residual service life of the equipment is reduced, so that the residual service life of the equipment can be more accurately predicted by observing the historical working condition of the equipment. In addition, the historical working conditions of the equipment can be divided in various ways. For example, the factors which are easy to cause the equipment loss can be analyzed, and then the working conditions which the equipment can face are distinguished according to the influence of the factors on the equipment loss, and the working conditions are divided into a plurality of historical working conditions.
Optionally, the type of each operating condition in the at least one historical operating condition may be divided according to a pressure environment in which the equipment is located, if an upper limit of a pressure that the equipment can withstand is 137 mpa, a pressure interval range from 0 to 137 mpa may be divided into a plurality of sub-intervals, each sub-interval corresponds to one operating condition, for example, a total pressure interval is divided into 5 sub-intervals, so that 5 operating conditions may be obtained, where the units are [0, 27.4 ], [27.4, 54.8 ], [54.8, 82.2 ], [82.2, 109.6 ], [109.6, 137], and are all mpa, respectively, and therefore the type of the at least one historical operating condition in which the equipment is located may be determined by determining which interval of the five sub-intervals is matched with.
For another example, the operating condition types of the historical operating conditions may be divided according to the water horsepower of the equipment during operation, and when the water horsepower of the equipment is at the upper limit of 2500 hp, the range of the water horsepower interval from 0 to 2500 hp may be divided into a plurality of sub-intervals, each sub-interval corresponds to one operating condition, and the type of each historical operating condition in at least one historical operating condition of the equipment is determined by which sub-interval the value of the water horsepower in the historical operating condition falls in.
For example, the operating condition types of the historical operating conditions can be divided according to the connecting rod load of the equipment during operation, the total operating condition interval of the equipment can be set to be 0-100% of the rated connecting rod load of the equipment, then the total interval is divided into a plurality of sub-intervals, the operating time of the equipment in each sub-interval is recorded, and at least one historical operating condition of the equipment and the operating time of the equipment under each historical operating condition can be obtained.
Optionally, the equipment may be under the same operating condition for multiple times at different times, and then the operating durations of the equipment under the same operating condition for multiple times may be added to obtain a total operating duration of the equipment under the historical operating condition, and the remaining life of the equipment may be predicted according to the total operating duration.
As an alternative embodiment, the apparatus may comprise a plunger pump, and the at least one historical operating condition may comprise at least one operating pressure interval in which the plunger pump is operating, and when the at least one operating pressure interval comprises a plurality of intervals, the plurality of intervals do not overlap with each other. When the historical working condition of the plunger pump is a plurality of working conditions, a plurality of working pressure intervals in which the plunger pump is respectively located under the plurality of historical working conditions need to be determined.
On the oil field fracturing equipment, a plunger pump is used as a component of the fracturing equipment, belongs to a core part with short service life relative to an engine, a gearbox, a motor and the like, and mainly comprises a power end, a hydraulic end, a lubricating system, a valve seat, a valve and other vulnerable parts in the pump. The valve and the valve seat of the plunger pump belong to conventional wearing parts, several layers of general fracturing operation need to be replaced, the hydraulic end belongs to unconventional wearing parts, and the service life of the hydraulic end is different in hundreds of hours according to different operation working conditions. It will be understood by those skilled in the art that the description of the life of the plunger pump generally refers to the life of the hydraulic end of the plunger pump, and the factors affecting the life of the hydraulic end are mainly the working pressure carried by the hydraulic end during working, and also include other factors such as the physical state of the fracturing fluid. The operating pressure at the hydraulic end of the plunger pump may be measured by a pressure sensor located on the pump above the fluid level.
Optionally, when the operation pressure interval of the plunger pump is divided, different operation pressure interval division schemes may be adopted according to the influence of the operation pressure of the plunger pump on the service life of the plunger pump. Specifically, the rated working pressure of the plunger pump is determined to be a Pa, and then the pressure interval of 0 to a Pa is divided into a plurality of working pressure intervals with equal length, for example, into 8 or 10 working pressure intervals with equal length, and the interval length of each interval is a/8 or a/10.
Alternatively, the operation pressure interval may be divided into a plurality of intervals with different lengths according to the nonlinear condition of the loss change rate of the plunger pump under different operation pressures, for example, the rated operation pressure of the plunger pump is a Pa, and if it is found through experiments that the service life loss speed of the plunger pump under a specific model or working environment is not greatly different when the operation pressure is below 0.5A, at this time, [0, 0.5A ] may be divided into one operation pressure interval, and under the operation pressure condition of 0.5 to 1a, the loss of the service life of the plunger pump under different working conditions may be more finely divided, for example, the operation pressure range of 0.5 to 1a is divided into 5 operation pressure intervals, and each interval has a length of 0.1A.
Step S204, at least one expected life corresponding to at least one historical working condition of the equipment is obtained according to the working time of the equipment under the at least one historical working condition, wherein the at least one expected life represents the life of the equipment which completely works under the corresponding historical working condition.
It should be noted that the expected life of the device under different historical operating conditions may be obtained in advance through experiments or simulation and stored for calling. For example, when the device is a plunger pump, a plurality of brand-new experimental plunger pumps of the same brand and the same model of the plunger pump can be obtained to perform a service life experiment, the experimental plunger pumps are respectively placed in working environments corresponding to different historical working conditions, the working conditions of the experimental plunger pumps are kept unchanged, operation is performed until the loss degree of the experimental plunger pumps reaches the safety standard or below, the experimental plunger pumps need to be replaced, the working time of the experimental plunger pumps is recorded at the moment, and the expected service lives of the experimental plunger pumps under the historical working conditions can be obtained. Equipment that operates for longer periods of time under more severe operating conditions with greater equipment wear and tear is clearly expected to have a shorter remaining life. Based on the steps, a mode of combining the residual life prediction of the equipment with the historical working state of the equipment is provided, and the prediction accuracy is improved.
As an alternative embodiment, the remaining life of the device may be predicted according to the operating time of the at least one historical operating condition and the at least one expected life corresponding to the at least one historical operating condition in the following manner: determining at least one used life corresponding to at least one historical working condition of the equipment according to the working duration of the equipment under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition, wherein the at least one used life is the life respectively lost when the equipment is under the at least one historical working condition; based on the at least one used lifetime, a remaining lifetime of the device is determined.
Optionally, when the historical operating conditions where the device is located include a plurality of operating conditions, a plurality of operating durations under the plurality of historical operating conditions are recorded, and a plurality of used lives corresponding to the plurality of historical operating conditions may be determined according to a plurality of expected lives corresponding to the plurality of historical operating conditions, respectively. The optional embodiment provides a scheme for estimating the residual life of the equipment by predicting the used life of the equipment in different working conditions in a segmented manner. It can be understood that even if the operating time of the equipment is the same under different working conditions, the same operating time of the equipment under different working conditions may consume the used life of the equipment with different lengths due to different loss rates of the equipment under different working conditions. Specifically, a plurality of used lives of the equipment under different historical working conditions can be predicted in a segmented mode, then the plurality of used lives are summed algebraically to obtain the overall used life of the equipment, and then the overall used life is subtracted from the overall life of the equipment to obtain the remaining life of the equipment.
As an alternative embodiment, when determining at least one used life of the device according to the operating time of the device under at least one historical operating condition and at least one expected life corresponding to at least one historical operating condition respectively, the following manners may be adopted: and comparing the working time of the equipment under each historical working condition in the at least one historical working condition with the expected life corresponding to each historical working condition to obtain the used life percentage of the equipment under each historical working condition in the at least one historical working condition, wherein the used life of the equipment comprises the used life percentage.
The loss state of the equipment can be clearly and accurately expressed by adopting the life percentage, and the problem that the loss degree of the equipment under different historical working conditions cannot be accurately expressed due to the fact that the same working time generates different degrees of loss on the equipment when the equipment is under different historical working conditions is solved.
And step S206, predicting the residual life of the equipment according to the working time length under at least one historical working condition and at least one expected life corresponding to at least one historical working condition.
It will be appreciated that if the equipment is frequently in poor operation and is operated for a longer period of time in poor operation, the equipment will have a faster loss of life and a lower residual life. Through the prediction of the residual service life of the equipment, the operator can be helped to accurately master the loss degree of each equipment and the safety of continuous operation.
As an alternative embodiment, the remaining life of the device may be determined according to the following method: determining the remaining life percentage of the equipment according to the used life percentage of the equipment; acquiring the expected life corresponding to the current working condition of the equipment; and determining the residual life of the equipment under the current working condition according to the expected life and the residual life percentage corresponding to the current working condition. In the optional embodiment, the current working condition state of the equipment is introduced into the estimation of the residual life, so that the residual life of the equipment in the current working condition state can be accurately estimated, the phenomenon that the loss degree of the equipment in the future is overestimated or underestimated due to the fact that the working condition of the equipment is not considered is avoided, and the accuracy of the predicted theoretical residual life is improved.
Through the steps, a scheme for predicting the service life of the equipment is provided. The method for estimating the loss life in a segmented mode based on the historical working conditions of the equipment achieves the purpose of reasonably estimating the loss degree of the operating equipment, achieves the technical effect of improving the accuracy of predicting the residual life of the operating equipment, and further solves the technical problem that the residual life of the plunger pump is not accurately predicted.
As an alternative embodiment, when predicting the remaining life of the device, the following steps may be further included: when the plunger pump is respectively in at least one historical working condition, the physical state of the fracturing fluid of the plunger pump is collected, wherein the physical state comprises any one of the following conditions: a standard state, a sand adding state and an acid adding state; and predicting the residual life of the equipment according to the working duration under at least one historical working condition, at least one expected life corresponding to at least one historical working condition and the physical state of the fracturing fluid under at least one historical working condition.
The plunger pump finishes fracturing operation by pumping fracturing fluid into underground, so that the hydraulic end of the plunger pump can be contacted with the fracturing fluid for a long time, and the property of the fracturing fluid affects the loss of the hydraulic end of the plunger pump. For example, when acid is added to the fracturing fluid, the fracturing fluid can corrode the plunger pump; after sand is added into the fracturing fluid, the fracturing fluid can cause more serious abrasion to the plunger pump; when the physical state of the fracturing fluid is a standard state, the fracturing fluid can be defaulted without generating extra loss on the plunger pump, and at the moment, only the loss influence of the working pressure interval where the plunger pump is located on the plunger pump needs to be considered. Therefore, the optional embodiment can further refine the estimation of the service life loss of the plunger pump under different historical working conditions by recording the physical state of the fracturing fluid pumped by the plunger pump under different historical working conditions, and improve the accuracy of the prediction of the residual service life of the plunger pump.
Alternatively, in the case that the apparatus is a plunger pump, the combination of the type of the plunger pump and the physical state of the fracturing fluid can be divided into the following four cases: a stainless steel pump head for carrying out acidizing and fracturing operations; a stainless steel pump head for sand fracturing operation; a carbon steel pump head for carrying out acidizing and fracturing operations; and (5) carrying out sand fracturing operation on the carbon steel pump head. Obviously, for different plunger pump types and fracturing fluid physical state combinations, the plunger pumps are different in wear degree under the same working pressure, so that when the used service life of the plunger pumps is estimated, the working pressure intervals of the plunger pumps are divided into different sections, the expected service lives of the plunger pumps in the working pressure intervals are different, and repeated measurement is needed.
As an alternative example, the remaining life of the equipment may be predicted by taking into account the physical state of the fracturing fluid by: when the physical state of the fracturing fluid is an acid adding state, collecting the PH value of the fracturing fluid in each working condition of at least one historical working condition; acquiring a pH value coefficient corresponding to the PH value of the fracturing fluid, and predicting the residual life according to the working time of the equipment under at least one historical working condition, at least one expected life and the pH value coefficient; when the physical state of the fracturing fluid is a sand adding state, collecting the sand density of the fracturing fluid in each working condition of at least one historical working condition; and obtaining a sand density coefficient corresponding to the sand density of the fracturing fluid, and predicting the residual life according to the working time of the equipment under at least one historical working condition, at least one expected life and the sand density coefficient.
It can be understood that the lower the PH of the fracturing fluid, the stronger the corrosive effect of the fracturing fluid on the plunger pump; the larger the sand content of the fracturing fluid, i.e. the sand density, the stronger the abrasion effect of the fracturing fluid on the plunger pump. The service life loss of the plunger pump is accelerated by the factors, so that the corresponding relation between the service life loss speed and the physical state of the fracturing fluid can be established through the pH value coefficient or the sand density coefficient. For example, the PH coefficient may be proportional to the inverse of the PH value of the fracturing fluid, and as the PH value of the fracturing fluid decreases, the PH coefficient increases, and then when the used life of the plunger pump for pumping the acidic fracturing fluid is calculated, the used life of the plunger pump under the historical operating condition may be obtained by multiplying the used life of the plunger pump, which is calculated according to the historical operating condition and the operating duration of the historical operating condition, by the PH coefficient greater than 1, and the used life of the plunger pump under the historical operating condition may be calculated in the same manner, that is, the remaining life may be predicted more accurately.
It should be noted that for simplicity of description, the above-mentioned method embodiments are shown as a series of combinations of acts, but those skilled in the art will recognize that the present invention is not limited by the order of acts, as some steps may occur in other orders or concurrently in accordance with the invention. Further, those skilled in the art should also appreciate that the embodiments described in the specification are preferred embodiments and that the acts and modules referred to are not necessarily required by the invention.
Through the description of the foregoing embodiments, it is clear to those skilled in the art that the device life prediction method according to the foregoing embodiments may be implemented by software plus a necessary general hardware platform, and certainly may also be implemented by hardware, but the former is a better implementation in many cases. Based on such understanding, the technical solutions of the present invention or portions thereof contributing to the prior art may be embodied in the form of a software product, which is stored in a storage medium (such as ROM/RAM, magnetic disk, optical disk) and includes several instructions for enabling a terminal device (which may be a mobile phone, a computer, a server, or a network device, etc.) to execute the method of the embodiments of the present invention.
Fig. 3 is a schematic flow chart of the plunger pump life warning provided according to an alternative embodiment of the present invention, and as shown in fig. 3, the monitoring of the used life of the plunger pump and the prediction of the remaining life of the plunger pump and the alarm can be implemented by the following steps:
(1) Firstly, the expected life and the working duration of the plunger pump under different working conditions under the condition that the fracturing fluid is in an acid adding state can be obtained:
obtaining the expected service life of the plunger pump in each working pressure interval when the plunger pump is in acidizing operation as follows:
the pressure is 0 to P 1 Time, life is T 1 ；
Pressure of P 1 ~P 2 Time, life is T 2 ；
Pressure of P 2 ~P 3 Time, life is T 3 ；
……
Pressure of P (n-1) ~P rate Life time T at rated pressure n 。
And/or the presence of a gas in the gas,
when the plunger pump is in sand adding operation, the expected service life of the plunger pump in each operation pressure interval is obtained as follows:
pressure of 0 to P' 1 Life is T' 1 ;
Pressure is P' 1 ~P' 2 In time, the lifetime is T' 2 ；
Pressure is P' 2 ~P' 3 In time, the lifetime is T' 3 ；
……
Pressure is P' (n-1) ~P rate Life time of T' n 。
(2) The method comprises the following steps of (1) acquiring the working time lengths of the plunger pump in a plurality of historical working conditions in an acidizing environment and a sanding environment as follows (if the plunger pump is only in the acidizing environment or the sanding environment in the whole process, the working time lengths corresponding to the historical working conditions in one environment can be acquired):
in the acidizing environment, the working time of the collecting plunger pump under each historical working condition is as follows:
pressure 0 to P 1 Interval, already operating time T s1 ;
Pressure P 1 ~P 2 Interval, already operating time T s2 ；
Pressure P 2 ~P 3 Interval, already operating time T s3 ；
……
Pressure of P (n-1) ~P rate (rated pressure), already operating time T sn 。
In a sand adding environment, the working time of the plunger pump under each historical working condition is collected as follows:
when the plunger pump is in the sand adding mode, the working time is as follows:
pressure 0 to P' 1 Interval, already operating time T j1 ;
Pressure P' 1 ~P' 2 Interval, already operating time T j2 ；
Pressure P' 2 ~P' 3 Interval, already operating time T j3 ；
……
Under pressure of P' (n-1) ~P' rate (rated pressure) interval, the working time is T jn 。
(3.1) the used life of the plunger pump is calculated as follows. Wherein, for the used lifetime in the acidizing environment, the following formula is used for calculating:
wherein the calculated value of the used life
In the following percentage,
for the duration of the operation of the plunger pump in an acidizing environment under various historical conditions,
the expected life of the plunger pump in the acidizing environment under various historical conditions is disclosed. Calculation of a value of assumed used life
Is 80% meaning that the plunger pump has been running for 80% of its life and may continue to run for 20% of its time. According to the current pressure operation interval, the remaining working time of the plunger pump in the current pressure interval can be calculated by combining the remaining 20% of the service life with the expected service life of the plunger pump under the current working condition.
(3.2) similarly, when the sand adding operation is carried out, the service life of the plunger pump is calculated in the following mode:
wherein, the calculated value of the used service life of the plunger pump in the sand adding environment
In the following percentage,
for the working time of the plunger pump in various historical working conditions in a sand adding environment,
the expected life of the plunger pump in a sand adding environment under various historical working conditions is disclosed. Assuming that the calculated used life is 80%, it means that the plunger pump has been operated to 80% of its life, and can be continued to operate for 20% of the time. According to the current pressure operation interval, the remaining operating time in the current pressure interval can be calculated through the remaining 20% of the life.
(3.3) when the sand adding and acidizing working environments exist at the same time, the step (3.1) and the step (3.2) can be respectively executed, and then the used service lives calculated under the two environments are algebraically summed to obtain the total used service life of the plunger pump.
It should be noted that the used life and the expected life of the above-listed plunger pumps in each interval are a statistical average, and the individual plunger pumps may be damaged when the used life is greater than 100% or less than 100%, which is theoretically normal, and meanwhile, the selection of the pressure interval may affect the final predicted result, and the finer the working pressure interval is, the more accurate the predicted life calculation value is.
Optionally, when the used life of the plunger pump is calculated, the influence of the acidification environment and the sand adding environment on the equipment loss degree can be introduced by adding a pH value coefficient and a sand density coefficient into a formula, for example, the following formula:
wherein, K is a conventional coefficient,
the pH value coefficient represents the influence of different pH values of the fracturing fluid on the service life of the plunger pump, when the fracturing fluid is neutral, the value is 1, and the value is larger along with the deviation of the pH value from 7;
the working pressure coefficient is an influence of the plunger pump on the service life of the plunger pump under the working pressures corresponding to different historical working conditions, and the higher the working pressure is, the larger the value is;
the sand density coefficient is a sand density coefficient which represents the influence of different sand densities on the service life of the plunger pump, if the plunger pump is in non-sand-adding operation, the value is 1, the value is gradually increased along with the increase of the sand density, optionally, sand is used as a propping agent and can be replaced by other types of propping agents, n is the number of subareas of the operation pressure in the historical working condition of the plunger pump,
for the life expectancy of the plunger pump in the kth pressure interval,
the working time of the plunger pump in the k-th pressure interval in the historical working condition is shown.
(4) Based on the steps, the residual service life of the plunger pump is calculated, and when the residual service life is close to 0 or is called as a negative value, alarm information can be sent out to inform field workers that the equipment is damaged and needs to be replaced.
According to an embodiment of the present invention, there is further provided an oil and gas fracturing pump equipment life prediction apparatus 40 for implementing the oil and gas fracturing pump equipment life prediction method, fig. 4 is a structural block diagram of the oil and gas fracturing pump equipment life prediction apparatus provided according to the embodiment of the present invention, and as shown in fig. 4, the oil and gas fracturing pump equipment life prediction apparatus 40 includes: an acquisition module 42, an acquisition module 44, and a prediction module 46, which are described below with respect to the hydrocarbon fracturing pump equipment life prediction device 40.
The acquisition module 42 is configured to acquire at least one historical operating condition of the equipment and operating durations of the equipment under the at least one historical operating condition;
an obtaining module 44, connected to the acquiring module 42, configured to obtain at least one expected life of the device corresponding to at least one historical operating condition according to the operating time of the device under the at least one historical operating condition, where the at least one expected life represents a life of the device when the device completely operates under the corresponding historical operating condition;
and a prediction module 46, coupled to the obtaining module 44, for predicting a remaining life of the equipment based on the operating time at the at least one historical operating condition and the at least one expected life corresponding to the at least one historical operating condition.
It should be noted here that the acquiring module 42, the obtaining module 44 and the predicting module 46 correspond to steps S202 to S206 in the embodiment, and the three modules are the same as the corresponding steps in the implementation example and the application scenario, but are not limited to the disclosure in the embodiment. It should be noted that the above modules as a part of the apparatus may be run in the computer terminal 10 provided in the embodiment.
An embodiment of the present invention may provide a computer device, and optionally, in this embodiment, the computer device may be located in at least one network device of a plurality of network devices of a computer network. The computer device includes a memory and a processor.
The memory may be configured to store software programs and modules, such as program instructions/modules corresponding to the device life prediction method and apparatus in the embodiments of the present invention, and the processor executes various functional applications and data processing by running the software programs and modules stored in the memory, so as to implement the device life prediction method. The memory may include high speed random access memory, and may also include non-volatile memory, such as one or more magnetic storage devices, flash memory, or other non-volatile solid-state memory. In some examples, the memory may further include memory located remotely from the processor, and these remote memories may be connected to the computer terminal through a network. Examples of such networks include, but are not limited to, the internet, intranets, local area networks, mobile communication networks, and combinations thereof.
The processor can call the information and application program stored in the memory through the transmission device to execute the following steps: collecting at least one historical working condition of equipment and working time of the equipment under the at least one historical working condition respectively; acquiring at least one expected life of the equipment corresponding to at least one historical working condition according to the working duration of the equipment under the at least one historical working condition, wherein the at least one expected life represents the life of the equipment which completely works under the corresponding historical working condition; and predicting the residual life of the equipment according to the working time length under at least one historical working condition and at least one expected life corresponding to at least one historical working condition.
The embodiment of the invention provides a scheme for predicting the service life of equipment. The method for estimating the loss service life by sections based on the historical working conditions of the equipment achieves the purpose of reasonably estimating the loss degree of the operation equipment, achieves the technical effect of improving the accuracy of predicting the residual service life of the operation equipment, and further solves the technical problem that the residual service life of the plunger pump is inaccurate to predict.
Those skilled in the art will appreciate that all or part of the steps in the methods of the above embodiments may be implemented by a program instructing hardware associated with the terminal device, where the program may be stored in a non-volatile storage medium, and the storage medium may include: flash disks, read-Only memories (ROMs), random Access Memories (RAMs), magnetic or optical disks, and the like.
Embodiments of the present invention also provide a non-volatile storage medium. Optionally, in this embodiment, the nonvolatile storage medium may be configured to store the program codes executed by the device life prediction method provided in the foregoing embodiment.
Optionally, in this embodiment, the nonvolatile storage medium may be located in any one of a group of computer terminals in a computer network, or in any one of a group of mobile terminals.
Optionally, in this embodiment, the non-volatile storage medium is configured to store program code for performing the following steps: collecting at least one historical working condition of equipment and working time of the equipment under the at least one historical working condition respectively; acquiring at least one expected life of the equipment corresponding to at least one historical working condition according to the working time of the equipment under the at least one historical working condition respectively, wherein the at least one expected life represents the life of the equipment completely working under the corresponding historical working condition respectively; and predicting the residual life of the equipment according to the working time length under at least one historical working condition and at least one expected life corresponding to at least one historical working condition.
The embodiment of the invention provides a scheme for predicting the service life of equipment. The method for estimating the loss service life by sections based on the historical working conditions of the equipment achieves the purpose of reasonably estimating the loss degree of the operation equipment, achieves the technical effect of improving the accuracy of predicting the residual service life of the operation equipment, and further solves the technical problem that the residual service life of the plunger pump is inaccurate to predict.
The above-mentioned serial numbers of the embodiments of the present invention are only for description, and do not represent the advantages and disadvantages of the embodiments.
In the above embodiments of the present invention, the description of each embodiment has its own emphasis, and reference may be made to the related description of other embodiments for parts that are not described in detail in a certain embodiment.
In the embodiments provided in the present application, it should be understood that the disclosed technology can be implemented in other ways. The above-described embodiments of the apparatus are merely illustrative, and for example, a division of a unit may be a division of a logic function, and an actual implementation may have another division, for example, a plurality of units or components may be combined or may be integrated into another system, or some features may be omitted, or may not be executed. In addition, the shown or discussed mutual coupling or direct coupling or communication connection may be an indirect coupling or communication connection through some interfaces, units or modules, and may be in an electrical or other form.
The units described as separate parts may or may not be physically separate, and parts displayed as units may or may not be physical units, may be located in one position, or may be distributed on a plurality of units. Some or all of the units can be selected according to actual needs to achieve the purpose of the solution of the embodiment.
In addition, functional units in the embodiments of the present invention may be integrated into one processing unit, or each unit may exist alone physically, or two or more units are integrated into one unit. The integrated unit may be implemented in the form of hardware, or may also be implemented in the form of a software functional unit.
The integrated unit, if implemented in the form of a software functional unit and sold or used as a stand-alone product, may be stored in a non-volatile memory storage medium. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a removable hard disk, a magnetic disk, or an optical disk, and various media capable of storing program codes.
The foregoing is only a preferred embodiment of the present invention, and it should be noted that it is obvious to those skilled in the art that various modifications and improvements can be made without departing from the principle of the present invention, and these modifications and improvements should also be considered as the protection scope of the present invention.
Claims (8)
1. A method for predicting the service life of oil and gas fracturing pump equipment is characterized by comprising the following steps:
collecting at least one historical working condition of equipment and working time of the equipment under the at least one historical working condition respectively;
obtaining at least one expected life of the equipment corresponding to the at least one historical working condition according to the working duration of the equipment under the at least one historical working condition, wherein the at least one expected life represents the life of the equipment which completely works under the corresponding historical working condition;
predicting the residual life of the equipment according to the working duration under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition;
predicting the remaining life of the equipment according to the working time under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition, wherein the predicting comprises the following steps: determining at least one used life corresponding to the at least one historical working condition of the equipment according to the working time of the equipment under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition, wherein the at least one used life is the life respectively lost when the equipment is under the at least one historical working condition; determining a remaining lifetime of the device based on the at least one used lifetime;
wherein the determining at least one used life of the equipment corresponding to the at least one historical operating condition according to the operating time of the equipment under the at least one historical operating condition and the at least one expected life corresponding to the at least one historical operating condition respectively comprises:
and comparing the working time of the equipment under each historical working condition in the at least one historical working condition with the expected life corresponding to each historical working condition to obtain the percentage of the used life of the equipment under each historical working condition in the at least one historical working condition, wherein the used life of the equipment comprises at least one percentage of the used life.
2. The method of claim 1, wherein determining the remaining lifetime of the device based on the at least one used lifetime comprises:
determining a remaining life percentage of the device based on the at least one used life percentage;
acquiring the expected life corresponding to the current working condition of the equipment;
and determining the residual life of the equipment under the current working condition according to the expected life corresponding to the current working condition and the residual life percentage.
3. The method according to any one of claims 1 to 2, characterized in that the device comprises: a plunger pump; the at least one historical operating condition comprises: the plunger pump is located in at least one working pressure interval, and when the at least one working pressure interval comprises a plurality of intervals, the intervals are not overlapped with each other.
4. The method of claim 3, wherein predicting the remaining life of the equipment based on the length of operation under the at least one historical operating condition and the at least one expected life corresponding to the at least one historical operating condition comprises:
when the plunger pumps are respectively in the at least one historical working condition, collecting the physical state of the fracturing fluid of the plunger pumps, wherein the physical state comprises any one of the following conditions: a standard state, a sand adding state and an acid adding state;
and predicting the residual life of the equipment according to the working time under the at least one historical working condition, at least one expected life corresponding to the at least one historical working condition and the physical state of the fracturing fluid under the at least one historical working condition.
5. The method of claim 4, wherein predicting the remaining life of the equipment based on the length of operation at the at least one historical operating condition, the at least one expected life for the at least one historical operating condition, and the physical state of the fracturing fluid at the at least one historical operating condition comprises:
when the physical state of the fracturing fluid is an acid adding state, collecting the PH value of the fracturing fluid in each working condition of the at least one historical working condition;
acquiring a pH value coefficient corresponding to the PH value of the fracturing fluid, and predicting the residual life according to the working duration of the equipment under the at least one historical working condition, the at least one expected life and the pH value coefficient;
collecting the sand density of the fracturing fluid in each working condition of the at least one historical working condition when the physical state of the fracturing fluid is a sand adding state;
and obtaining a sand density coefficient corresponding to the sand density of the fracturing fluid, and predicting the residual life according to the working duration of the equipment under the at least one historical working condition, the at least one expected life and the sand density coefficient.
6. A prediction device for implementing the method for predicting the life of an oil and gas fracturing pump device as claimed in any one of claims 1 to 5, comprising:
the acquisition module is used for acquiring at least one historical working condition of equipment and the working time of the equipment under the at least one historical working condition respectively;
the obtaining module is used for obtaining at least one expected life of the equipment corresponding to the at least one historical working condition according to the working duration of the equipment under the at least one historical working condition, wherein the at least one expected life represents the life of the equipment which completely works under the corresponding historical working condition;
the prediction module is used for predicting the residual life of the equipment according to the working duration under the at least one historical working condition and at least one expected life corresponding to the at least one historical working condition;
the prediction module is further configured to determine at least one used life of the equipment corresponding to the at least one historical operating condition according to the operating time of the equipment under the at least one historical operating condition and at least one expected life corresponding to the at least one historical operating condition, respectively, where the at least one used life is a life that the equipment loses when the equipment is under the at least one historical operating condition, respectively; determining a remaining lifetime of the device based on the at least one used lifetime;
the prediction module is further configured to compare the operating time of the equipment under each of the at least one historical operating condition with the expected life corresponding to each historical operating condition to obtain a used life percentage of the equipment under each of the at least one historical operating condition, where the used life of the equipment includes at least one used life percentage.
7. A non-volatile storage medium, comprising a stored program, wherein the program, when executed, controls a device in which the non-volatile storage medium is located to perform the method of predicting the life of a hydrocarbon fracturing pump device as claimed in any one of claims 1 to 5.
8. A computer apparatus comprising a memory for storing a program and a processor for executing the program stored by the memory, wherein the program when executed performs the hydrocarbon fracturing pump apparatus life prediction method of any one of claims 1 to 5.
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| CN202211237595.3A CN115310240B (en) | 2022-10-11 | 2022-10-11 | Oil-gas fracturing pump equipment service life prediction method and device and nonvolatile storage medium |
| PCT/CN2022/130019 WO2024077685A1 (en) | 2022-10-11 | 2022-11-04 | Service life prediction method and apparatus for oil and gas fracturing pump device, and non-volatile storage medium |
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| CN111222203B (en) * | 2018-11-08 | 2024-05-10 | 上海仪电（集团）有限公司中央研究院 | Bearing service life model creation and prediction method thereof |
| CN109784574A (en) * | 2019-01-24 | 2019-05-21 | 新奥数能科技有限公司 | The prediction technique and device of equipment state, storage medium, electronic device |
| CN109931254B (en) * | 2019-02-28 | 2020-10-02 | 四机赛瓦石油钻采设备有限公司 | Fracturing pump maintenance rule setting system capable of continuously changing working conditions |
| CN110378052B (en) * | 2019-07-25 | 2020-11-06 | 北京航空航天大学 | Equipment residual life prediction method considering future working conditions based on cyclic neural network |
| CN113378286B (en) * | 2020-03-10 | 2023-09-15 | 上海杰之能软件科技有限公司 | Fatigue life prediction method, storage medium and terminal |
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