CN-121976786-A - Wellhead component real-time monitoring and intelligent separation processing system and operation method

CN121976786ACN 121976786 ACN121976786 ACN 121976786ACN-121976786-A

Abstract

The invention discloses a wellhead component real-time monitoring and intelligent separation processing system which comprises a pipeline module, a sand removal module, a sand storage module, a valve module, a control module and a connection module. The pipeline module divides the independent lines of air intake, air exhaust, liquid discharge, sand discharge, flushing and bypass, the sand removal module comprises two groups of rotational flow sand removal units which are communicated with the sand storage module through switchable lines, and the sand storage module is provided with two groups of sand storage units which can work alternately. The control module integrates working condition recognition, monitoring acquisition, control decision, execution control and feedback units, and controls the valve module according to signals of sand, flow and pressure, so that selective communication and automatic switching of each line are realized. The system realizes dynamic matching and alternate operation of the rotational flow sand removal unit and the sand storage unit, keeps continuous sand removal during sand storage, sand discharge and flushing, reduces the risk of backflow series flow through a valve interlocking and unidirectional flow structure, and improves the continuity, stability and operation safety of a wellhead sand removal system through bypass self-adaptive switching.

Inventors

TANG YANG
LIN JUNZHE
ZHANG RUI
LAI WENXUAN
WANG JINZHONG
ZHANG WANCHUN
WANG GUORONG
LIU CHANG
Qi Changchao
LI ZELIANG
WU JIE

Assignees

西南石油大学

Dates

Publication Date: 20260505
Application Date: 20260326

Claims (10)

1. The wellhead component real-time monitoring and intelligent separation processing system is characterized by comprising a pipeline module (1), a sand removal module (2), a sand storage module (3), a valve module (4), a control module (5) and a connection module (6); The pipeline module (1) comprises an air inlet pipeline unit (101), an exhaust pipeline unit (102), a liquid discharge pipeline unit (103), a sand discharge pipeline unit (104), a flushing pipeline unit (105), a bypass pipeline unit (106), a rotational flow sand removal pipeline unit I (107) and a rotational flow sand removal pipeline unit II (108), wherein the sand removal module (2) is communicated with the air inlet pipeline (101) and the exhaust pipeline (102), and the sand removal module (2) is selectively communicated with the sand storage module (3) through a valve module (4); The sand storage module (3) is respectively communicated with the liquid discharge pipeline unit (103), the sand discharge pipeline unit (104) and the flushing pipeline unit (105), the control module (5) comprises a working condition identification unit (501), a monitoring acquisition unit (502), a control decision unit (503), an execution control unit (504) and a feedback unit (505), the monitoring acquisition unit (502) is electrically connected with the control decision unit (503), the control decision unit (503) is electrically connected with the execution control unit (504), the execution control unit (404) is connected with the valve module (4) to drive the valve to act, the feedback unit (505) is electrically connected with the control decision unit (503) to return a valve state signal, the valve module (4) is arranged on the pipeline module (1), and the connection module (6) is used for realizing the pipeline connection of the pipeline module (1) with the sand removal module (2) and the sand storage module (3).
2. The wellhead component real-time monitoring and intelligent separation processing system according to claim 1, wherein the sand removal module (2) consists of a first rotational flow sand removal unit (2-1), a second rotational flow sand removal unit (2-2) and a replaceable rotational flow sand removal unit (2-3), the first rotational flow sand removal unit (2-1) and the second rotational flow sand removal unit (2-2) are communicated with an air inlet pipeline unit (101) through an air inlet connection unit (601), and the first rotational flow sand removal unit (2-1) and the second rotational flow sand removal unit (2-2) are respectively communicated with a first sand storage unit (301) and a second sand storage unit (302) of the sand storage module (3) through a pipeline module (1) and a valve module (4); The sand storage module (3) consists of a first sand storage unit (301) and a second sand storage unit (302), wherein the first sand storage unit (301) and the second sand storage unit (302) are respectively communicated with the liquid discharge pipeline unit (103), the sand discharge pipeline unit (104) and the flushing pipeline unit (105); The valve module (4) comprises a valve unit I (4-1), a valve unit II (4-2), a valve unit III (4-3), a valve unit IV (4-4), a valve unit V (4-5), a valve unit VI (4-6), a valve unit VII (4-7), a valve unit VIII (4-8), a valve unit IX (4-9), a valve unit X (4-10), a flushing valve (4-11), a pipeline switching valve unit (4-12), a one-way circulation valve I (4-13) and a one-way circulation valve II (4-14); the monitoring and collecting unit (502) in the control module (5) comprises a sand-containing measuring instrument (5021), a fluid content monitoring module (5022) and a pressure monitoring module (5023), wherein the sand-containing measuring instrument (5021) is arranged on the air inlet pipeline unit (101) and the first sand storage unit (301) and the second sand storage unit (302), the fluid content monitoring module (5022) is arranged on the air inlet pipeline unit (101) and the exhaust pipeline unit (102), and the pressure monitoring module (5023) is arranged on an inlet pipe section and an outlet pipe section of the sand removal module (2); The monitoring acquisition unit (502) is electrically connected with the control decision unit (503), the working condition identification unit (501) is electrically connected with the control decision unit (504), the control decision unit (503) is electrically connected with the execution control unit (504), the execution control unit (506) is electrically connected with the valve module (4), the feedback unit (505) is electrically connected with the valve module (4) to acquire a valve opening and closing in-place signal, the feedback unit (505) is electrically connected with the control decision unit (503), and when preset conditions are met, a valve opening and closing in-place signal is sent out to output a next valve action control signal; The connecting module (6) is composed of an air inlet connecting unit (601), an air outlet connecting unit (602), a bottom flow port connecting unit I (603-1), a bottom flow port connecting unit II (603-2), a top flow port connecting unit I (604-1), a top flow port connecting unit II (604-2), a sand discharge connecting unit I (605), a sand discharge connecting unit II (606), a liquid discharge connecting unit I (607), a liquid discharge connecting unit II (608), an air inlet connecting unit II (609) and an air outlet connecting unit II (6010).
3. The wellhead component real-time monitoring and intelligent separation processing system according to claim 1, wherein the pipeline module (1), the sand removal module (2), the sand storage module (3), the valve module (4) and the control module (5) are communicated with each other to form a first operation line (7), a second operation line (8), a third operation line (9), a fourth operation line (10), a fifth operation line (11), a sixth operation line (12), a seventh operation line (13), an eighth operation line (14), a ninth operation line (15), a tenth operation line (16), an eleventh operation line (17) and a twelfth operation line (18); The first operation line (7) consists of an air inlet pipeline unit (101), an air inlet connection unit (601), a sand-containing measuring instrument (5021), a fluid content monitoring module (5022) and a valve unit I (4-1), the first operation line (7) is communicated with the first cyclone sand removal unit (2-1) through the air inlet connection unit (601), and the sand-containing measuring instrument (5021), the fluid content monitoring module (5022) and the valve unit I (4-1) are arranged on the air inlet pipeline unit (101); The second operation line (8) consists of an exhaust pipeline unit (102), an exhaust connection unit (602), a sand-containing measuring instrument (5021), a fluid content monitoring module (5022) and a valve unit II (4-2), the second operation line (8) is communicated with the first cyclone sand removal unit (2-1) through the exhaust connection unit (602), and the sand-containing measuring instrument (5021), the fluid content monitoring module (5022) and the valve unit II (4-2) are arranged on the exhaust pipeline unit (102); The third operation line (9) consists of a bottom flow port connecting unit I (603-1), a top flow port connecting unit I (604-1), a rotational flow sand removal pipeline unit I (107) and a valve unit III (4-3), wherein the first rotational flow sand removal unit (2-1) is communicated with the third operation line (9) through the bottom flow port connecting unit I (603), the first sand storage unit (301) is communicated with the third operation line (9) through the top flow port connecting unit I (604-1), and the valve unit III (4-3) is arranged on the rotational flow sand removal pipeline unit I (107); The fourth operation line (10) is composed of a bottom flow port connecting unit II (603-2), a top flow port connecting unit II (604-2), a rotational flow sand removal pipeline unit II (108) and a valve unit IV (4-4), the second rotational flow sand removal unit (2-2) is communicated with the fourth operation line (10) through the bottom flow port connecting unit II (603-2), the second sand storage unit (302) is communicated with the fourth operation line (10) through the top flow port connecting unit II (604-2), and the valve unit IV (4-4) is arranged on the rotational flow sand removal pipeline unit II (108); The fifth operation line (11) consists of a sand discharge connection unit I (605), a sand discharge pipeline unit (104) and a valve unit V (4-5), wherein the first sand storage unit (301) is communicated with the fifth operation line (11) through the sand discharge connection unit I (605), and the valve unit V (4-5) is arranged on the sand discharge pipeline unit (104); The sixth operation line (12) consists of a sand discharge connection unit II (606), a sand discharge pipeline unit (104) and a valve unit VI (4-6), the second sand storage unit (302) is communicated with the sixth operation line (12) through the sand discharge connection unit II (606), and the valve unit VI (4-6) is arranged on the sand discharge pipeline unit (104); the seventh operation line (13) consists of a liquid discharge connection unit I (607), a liquid discharge pipeline unit (103) and a valve unit VII (4-7), the first sand storage unit (301) is communicated with the seventh operation line (13) through the liquid discharge connection unit I (607), and the valve unit VII (4-7) is arranged on the liquid discharge pipeline unit (103); The eighth operation line (14) consists of a liquid discharge connection unit II (608), a liquid discharge pipeline unit (103) and a valve unit VIII (4-8), the second sand storage unit (302) is communicated with the eighth operation line (14) through the liquid discharge connection unit II (608), and the valve unit VIII (4-8) is arranged on the liquid discharge pipeline unit (103); The ninth operation line (15) is composed of an air inlet pipeline unit (101), an air inlet connection unit II (609), a sand-containing measuring instrument (5021), a fluid content monitoring module (5022) and a valve unit IX (4-9), the ninth operation line (15) is communicated with the second cyclone sand removal unit (2-2) through the air inlet connection unit II (609), and the sand-containing measuring instrument (5021), the fluid content monitoring module (5022) and the cyclone valve unit IX (4-9) are arranged on the air inlet pipeline unit (101); the tenth operation line (16) is composed of an exhaust pipeline unit (102), an exhaust connection unit II (6010), a sand-containing measuring instrument (5021), a fluid content monitoring module (5022) and a valve unit X (4-10), the tenth operation line (16) is communicated with the second cyclone sand removal unit (2-2) through the exhaust connection unit II (6010), and the sand-containing measuring instrument (5021), the fluid content monitoring module (5022) and the valve unit X (4-10) are arranged on the exhaust pipeline unit (102); the eleventh operation line (17) consists of a flushing pipeline unit (105) and flushing valves (4-11), the flushing pipeline unit (105) is respectively communicated with the sand removal module (2) and the sand storage module (3), and the flushing valves (4-11) are arranged on the flushing pipeline unit (105); The twelfth operation line (18) is composed of a bypass line unit (106) and a line switching valve unit (4-12), the bypass line unit (106) is respectively communicated with the air inlet line unit (101) and the air outlet line unit (102), and the line switching valve unit (4-12) is arranged on the bypass line unit (106).
4. A wellhead component real-time monitoring and intelligent separation processing system is characterized in that a one-way circulation valve I (4-13) is arranged on a third operation line (9) and matched with a valve unit III (4-3), a one-way circulation valve II (4-14) is arranged on a fourth operation line (10) and matched with a valve unit IV (4-4), the one-way circulation valve I (4-13) and the one-way circulation valve II (4-14) limit medium to circulate only along the direction from a cyclone sand removal unit (2) to a corresponding sand storage unit (3), the valve unit III (4-3) and the valve unit IV (4-4) form an interlocking switching structure, only one of the third operation line (9) and the fourth operation line (10) is in a communicating state at any moment under the condition, and when the third operation line (9) and the fourth operation line (10) are controlled to be switched, a control line is output according to the sequence of opening the corresponding valve of the target operation line and then closing the corresponding valve under the control signal.
5. The wellhead component real-time monitoring and intelligent separation processing system according to claim 2, wherein the sand-containing measuring instrument (5021) is respectively arranged on the first sand storage unit (301) and the second sand storage unit (302), the execution control unit (504) is electrically connected with the valve unit III (4-3) and the valve unit IV (4-4) so as to control the valve unit III (4-3) and the valve unit IV (4-4) to switch when the sand-containing measuring instrument (5021) of the first sand storage unit (301) or the second sand storage unit (302) detects that the sand-containing state reaches or approaches to a preset threshold value, the feedback unit (505) detects a valve opening and closing feedback signal, and the execution control unit (504) outputs a next valve action signal after receiving the valve opening and closing feedback signal.
6. A wellhead component real-time monitoring and intelligent separation processing system according to claim 2, wherein the pipeline switching valve unit (4-12) is arranged on a bypass pipeline unit (106), the bypass pipeline unit (106) is communicated with the air inlet pipeline unit (101) and the exhaust pipeline unit (102), the execution control unit (504) is electrically connected with the pipeline switching valve unit (4-12), and controls to close valves on the air inlet pipeline unit (101), the exhaust pipeline unit (102), the liquid discharge pipeline unit (103), the sand discharge pipeline unit (104), the flushing pipeline unit (105), the rotational flow sand removal pipeline unit I (107) and the rotational flow sand removal pipeline unit II (108) when the sand content of the mixed gas is monitored to be lower than a preset threshold value, and the control module (5) enables the gas to bypass the sand removal module (2) to flow to a downstream pipeline through the bypass pipeline unit (106).
7. The wellhead component real-time monitoring and intelligent separation processing system according to claim 1, wherein the monitoring and collecting unit (502) comprises sand-containing measuring instruments (5021) respectively arranged on the first sand storage unit (301) and the second sand storage unit (302), the sand-containing measuring instruments (5021) are respectively and electrically connected with control decision units (503) of the control module (5), the control decision units (503) are respectively and electrically connected with valve units III (4-3) and IV (4-4) of a third operation line and a fourth operation line, and when the sand-containing measuring instruments (5021) corresponding to the first sand storage unit or the second sand storage unit output abnormal signals, the communication between the rotational flow sand removal unit and the other sand storage unit is realized through valve switching of the corresponding operation line.
8. The wellhead component real-time monitoring and intelligent separation processing system according to claim 1, wherein the working condition identification unit (501) is used for measuring the sand content, the water content, the oil content and the gas content in the fluid in real time based on a sand content measuring instrument (5021) and a fluid content monitoring module (5022) on an air inlet pipeline unit (101), when the measured sand content is lower than a preset threshold value, a bypass operation line (106) is controlled to be opened and an operation line corresponding to a sand removal module (2) is controlled to be closed, and when the sand content or the particle size change exceeds the preset threshold value, the control decision unit (503) outputs a replacement instruction when the sand content or the particle size change is detected to exceed the preset threshold value, and the single cyclone sand removal cylinder operation is replaced by the double cyclone sand removal cylinder alternate operation.
9. The wellhead component real-time monitoring and intelligent separation processing system according to claim 1, wherein when the wellhead component real-time monitoring and intelligent separation processing system is in a production working condition, the control decision unit (503) judges that the sand storage module (3) is abnormal based on a signal of the sand-containing measuring instrument (5021), and outputs an abnormal working condition control instruction, the valve module (4) is controlled to switch the third operating circuit (9) and the fourth operating circuit (10) firstly, and then the eleventh operating circuit (17) is controlled to be started so as to flush the sand storage module (3).
10. A method for operating a wellhead component real-time monitoring and intelligent separation processing system is characterized in that the wellhead component real-time monitoring and intelligent separation processing system according to any one of claims 1-9 is adopted, and comprises the following steps: I. Continuous operation method of single cyclone sand removal cylinder S101, enabling a gas-liquid-solid mixture to enter a first rotational flow sand removal unit (2-1) through a first operation line (7), forming centrifugal rotational flow in the first rotational flow sand removal unit (2-1) to realize separation of a gas phase and a liquid-solid phase, discharging the separated gas to an exhaust pipeline unit (102) through a second operation line (8), enabling the liquid-solid phase to enter a first sand storage unit (301) through a third operation line (9), discharging the liquid phase entering the first sand storage unit (301) through a seventh operation line (13), and depositing the solid phase in the first sand storage unit (301) and discharging the solid phase through a corresponding sand discharge line; S102, when the sand-containing measuring instrument (5021) monitors that the sand storage amount in the first sand storage unit (301) is close to a preset threshold value, controlling the liquid-solid phase flow to be switched to the second sand storage unit (302) through the first sand storage unit (301) so that the second sand storage unit (302) takes over the first sand storage unit (301) to receive and store liquid-solid phase, after switching, executing flushing operation on the first sand storage unit (301) which is out of operation, discharging the flushed liquid-solid mixture through a corresponding discharge line, entering a liquid-solid phase of the second sand storage unit (302), discharging the liquid phase through an eighth operation line (14), and discharging the solid phase through a sixth operation line (12); S103, when the sand storage amount in the second sand storage unit (302) is monitored by the sand-containing measuring instrument (5021) to reach or be close to a preset threshold value, controlling the liquid-solid phase flow to be switched back to the first sand storage unit (301) through the second sand storage unit (302), enabling the first sand storage unit (301) to replace the second sand storage unit (302) again, and executing flushing operation on the second sand storage unit (302) to realize continuous sand removal operation of the single cyclone sand removal cylinder under the mining working condition; II. Alternate operation method of double-cyclone sand removal cylinder S201, enabling a gas-liquid-solid mixture to enter a first cyclone sand removal unit (2-1) in a working state through a first operation line (7) to form centrifugal strong cyclone separation liquid-solid phase and gas phase, enabling separated gas to flow out to an exhaust pipeline unit (102) through a second operation line (8), enabling separated liquid-solid phase to enter a first sand storage unit (301) through a third operation line (9), and enabling liquid phase to be discharged through a seventh operation line (13); S202, when a sand-containing measuring instrument (5021) and a fluid content monitoring module (5022) monitor that the solid-phase concentration, the particle size or the gas production in the gas-liquid-solid mixture reaches a preset switching condition, the first cyclone sand removal unit (2-1) is led to exit a main separation working condition, the second cyclone sand removal unit (2-2) is put into operation, the cyclone sand removal units are switched according to the monitoring result, S203, after the cyclone sand removal units are switched, the gas-liquid-solid mixture enters a second cyclone sand removal unit (2-2) in a working state through a ninth operation line (15) to be separated, the separated gas is discharged through a tenth operation line (16), the separated liquid-solid phase enters a second sand storage unit (302) through a fourth operation line (10), the liquid phase is discharged through an eighth operation line (14), and the solid phase is discharged through a sixth operation line (12), so that the alternate operation of the double cyclone sand removal cylinders under the extraction working condition is realized, and the sand removal requirements under different sand-containing working conditions are met; III bypass mode of operation S301, when the working condition identification unit (501) detects that the sand content of an incoming flow medium is lower than a preset threshold value or is in a working condition without sand removal based on a sand-containing measuring instrument (5021) and a fluid content monitoring module (5022) on the air inlet pipeline unit (101), the decision unit (503) is controlled to output a bypass operation instruction, the execution control unit (504) is controlled to open a pipeline switching valve unit (4-12) on a twelfth operation line (18), and the air inlet pipeline unit (101), the air outlet pipeline unit (102), the liquid discharge pipeline unit (103), the sand discharge pipeline unit (104), the flushing pipeline unit (105), the rotational flow sand removal pipeline unit I (107) and related valves on the rotational flow sand removal pipeline unit II (108) are controlled to be closed, so that the incoming flow medium is conveyed to a downstream pipeline by bypassing the sand removal module (2) through the bypass pipeline unit (106).

Description

Wellhead component real-time monitoring and intelligent separation processing system and operation method Technical Field The invention belongs to the technical field of intelligent energy equipment, and particularly relates to a wellhead component real-time monitoring and intelligent separation processing system and an operation method. Background Along with the long-term operation of the high-sand-content oil gas well and the gas storage, the working condition shows the characteristics of large fluctuation of gas production, frequent change of sand concentration, alternate operation of gas injection working condition and gas production working condition, and the like. The high sand-containing medium component is easy to cause erosion, abrasion and blockage to subsequent pipelines and equipment in the wellhead treatment process, so that the arrangement of a separation sand-removing treatment device at the wellhead has become a conventional technical means. However, the conventional wellhead separation sand removal technology has the following main problems: The existing wellhead sand removal system is mainly configured by taking a single rotational flow sand removal unit or a local sand removal unit as a core, the system structure and the operation flow are usually fixed, functional pipelines such as air inlet, air exhaust and sand discharge are lack of independent division and unified coordination, the linkage degree between the system and the integral working condition of the wellhead is low, the starting and stopping of the sand removal device and the flow switching mainly depend on manual experience or fixed operation parameters, the wellhead produced flow, sand concentration or fluid composition change is difficult to respond in time, the integral response of the system is lagged, and the sand removal continuity and adaptability are insufficient. Meanwhile, most of sand storage units of the existing wellhead rotational flow sand removal system are of a single-tank structure or a simple serial structure, and sand removal operation depends on manual or fixed timing strategies. When the sand storage amount is excessively fast or the sand discharge is not timely, the problems of full sand, blocked bottom flow or reduced separation efficiency are easy to occur, so that the stable operation of the cyclone sand removal unit is influenced, the wellhead treatment system is forced to stop for treatment, and the requirement of wellhead continuous production is difficult to meet. In the existing wellhead sand removal system, the problems of underflow backflow, pressure fluctuation, medium backflow and the like often exist in the sand storage unit switching, sand discharge or flushing process, short-time series flow, false communication or cutoff easily occur due to the lack of a backflow prevention and valve interlocking structure under the multi-branch switching scene, so that the cyclone sand removal unit is unstable in operation, and even safety risks such as equipment impact, valve damage or sand removal efficiency reduction are caused. The running mode of the existing wellhead sand removal system is generally single, parameter setting is carried out aiming at specific design working conditions, and dynamic identification and self-adaptive adjustment capacity based on real-time monitoring signals are lacked. When the sand-containing characteristic, flow rate or phase proportion of the incoming flow of the wellhead fluctuates, the system cannot automatically recognize the working condition change and match the corresponding operation mode, manual intervention or reconfiguration of the system is often required, dynamic matching and self-adaptive operation between the sand removing unit and the sand storage unit are difficult to realize, and the sand-containing concentration of the incoming flow medium can be in a lower level or stage-descending state under partial wellhead production working conditions. Under such working conditions, if the cyclone sand removal module is still maintained in a working state, not only pressure drop and energy consumption of the system can be increased, but also equipment abrasion can be aggravated. The existing wellhead sand removal system generally lacks an operation strategy capable of automatically judging whether a sand removal module needs to be put into according to a real-time sand-containing state, and is difficult to realize flow optimization under a low-sand-containing working condition. When sand removal is not needed or the sand content is lower than the safety threshold value, the system still runs along the original sand removal path, so that the running efficiency is reduced, and unnecessary equipment burden is increased. The prior art lacks flexible operation path selection capability under different sand-containing level conditions, and is difficult to realize self-adaptive control of flow switching and bypass operation according to the sand-containing state, so