Patent Publication Number: US-2021172282-A1

Title: New ultra-high power cementing apparatus integrated with remote control

Description:
TECHNICAL FIELD 
     The present invention relates to the technical field of petroleum equipment, in particular to a new ultra-high power cementing apparatus integrated with remote control. 
     BACKGROUND 
     Because of the increasing frequency of cementing operations in ultra-deep wells and complex formation wells, and the requirement for high pressure, large displacement, long time and continuous operation during ultra-deep well and ultrahigh pressure gas well cementation, high-power or ultrahigh power cementing equipment is rapidly developing. High-power motors will gradually replace the existing single-machine or double-machine cementing equipment. In the prior art, to meet the requirement for high pressure and large displacement, multiple cementing equipment with double-machine and double-pump run at the same time, which has the disadvantages of large occupied area, complex pipeline connection, high maintenance frequency, large operator number and high single operation cost. 
     SUMMARY 
     In order to solve the above technical problems, the present invention provides a new ultra-high power cementing apparatus integrated with remote control, which meets the requirement for high pressure, large displacement, long time and continuous operation during cementing operations in ultra-deep well and complex formation well at present, so as to meet the requirements for operating conditions, improve operating efficiency and save operating cost. 
     The technical solution for solving the above technical problems is as follows: 
     A new ultra-high power cementing apparatus integrated with remote control, including a loading system and an auxiliary beam, the auxiliary beam is connected to the loading system, and the auxiliary beam is connected in sequence from front to back with a hydraulic system, a power and transmission system, a metering tank, a low-pressure manifold system, an operating platform, and an electrical system, an air path system, an operation and control system, a plunger pump, a high-pressure manifold and a mixing system which are arranged at an upper end of the operating platform; the plunger pump is located at a lower part of the air path system, a rated input power of the plunger pump is larger than or equal to 1200 horsepower, and the plunger pump is connected to a high-pressure discharge system; the air path system is provided with a plug valve, the plug valve is a main switch of the air path system, a downstream end of the plug valve is provided with a filtering pressure reducing valve, and the filtering pressure reducing valve is used for adjusting the working pressure of the whole air path system and filtering the gas entering the air path system. 
     The operation and control system is located on a top of the operating platform, the operation and control system is connected to a remote control system, and the remote control system comprises a remote control box, a first platform, a data acquisition system and a notebook computer. 
     An operating system of the present invention mainly includes the operating platform and an instrument control system, the operating platform is a main place for operators to operate the equipment, and the instrument control system with an instrument box as a carrier can realize real-time monitoring and control during operation. 
     The power and transmission system includes an engine, a gearbox assembly, a transmission shaft, a carrying pole beam mounting assembly, an air intake system, an air exhaust system, a cooling system assembly, a fuel system, a heating system and a remote filter mounting bracket; the transmission shaft is located between the gearbox assembly and the plunger pump, and the engine and the gearbox assembly are placed on and supported by the carrying pole beam mounting assembly; the air intake system provides the engine with air required for combustion and the air exhaust system realizes waste gas and heat emission, the remote filter mounting bracket supports an intake air filter, and the cooling system assembly is used for heat dissipation of the engine, the gearbox assembly, the hydraulic system and the plunger pump; the gearbox assembly realizes the adjustment of different pressures and displacements by changing gears, and the engine outputs power to the gearbox assembly and drives the plunger pump through the transmission shaft; and as a power source of the equipment, the power system provides power for the working parts on the equipment. 
     The mixing system is located at a tail of the auxiliary beam, and the mixing system realizes the mixing of water and cement. 
     Further, the loading system is any one of a vehicle chassis, a semi-trailer chassis or a skid-mounted chassis, and serves as a bearing component of the equipment. 
     Further, the plunger pump is a three-cylinder plunger pump. 
     Further, the high-pressure discharge system includes a mud discharge manifold and a high-pressure safety valve arranged on the mud discharge manifold. 
     Further, an upper part of the operating platform is further provided with a packing lubrication system. 
     Further, a lower part of the power and transmission system is further provided with a power end lubrication system for lubricating the plunger pump. 
     Further, the metering tank includes a tank body, a clear water manifold is connected to a bottom of the tank body and the tank body is supplied with water by the clear water manifold, the clear water manifold is provided with a butterfly valve, and the bottom of the tank body is further provided with a discharge port; the tank body is further provided with a liquid level gauge and a second platform, the second platform is located at a top of the tank body, and the tank body is mainly used to contain and measure clean water for operation, and can also be used for mixing some chemical reagents; and the second platform can be used for observing a liquid level in the tank so as to prevent overflowing, and a filter screen is arranged inside the tank body at a position of the discharge port for filtering impurities. 
     Further, the low-pressure manifold system includes the clear water manifold and a mud manifold, the mud manifold includes a discharge manifold and a centrifugal pump, the centrifugal pump is controlled by a pneumatic actuator, and the discharge manifold is provided with a densimeter manifold and a butterfly valve. The clear water manifold is used for external water supply, water delivery to the metering tank and water supply to the mixing system to mix mud, etc. The mud manifold is mainly used for transporting mud and measuring the flow and density of mud. 
     Further, a cement adding manifold is further connected to the tail of the auxiliary beam. 
     Further, the high-pressure manifold is arranged at a lower part of the operation and control system. Main control components and display components of the power system and the mixing system, as well as core components of the electrical system, are integrated on the operation and control system, which is a main operation place for the equipment during operation. The operation and control system of the present invention uses the instrument box as the carrier, which mainly includes an instrument panel, instruments, control elements, etc., through which the cementing equipment can be monitored and controlled. The instrument panel is integrated with most valve instruments required for equipment operation. 
     The present invention has the following key assemblies: 
     Plunger pump and high-pressure discharge system: including the plunger pump, the plug valve, the high-pressure safety valve, a discharge pipeline, etc., which can convert low-pressure fluid such as mud, drilling fluid, acidizing fluid and slurry replacement, etc. into high-pressure fluid, and different pressures and displacements are obtained by changing plunger diameter, thus realizing liquid pumping and meeting operation requirements. 
     Mud mixing system: including a mud mixing tank, the metering tank, the low-pressure manifold, a high-energy mixer, an agitator, etc. A manual mud mixing system, a univariate controlled mud mixing system or a multivariate fully-automatic mud mixing system can be adopted to meet different requirements. Alternatively, an automatic mixing system can be used to automatically control an engine throttle and a gear of a gearbox according to pressure and displacement requirements, so as to completely liberate operators. 
     Remote control system: including the remote control box, the platform, the data acquisition system, the notebook computer, etc. The remote control system allows the operators to be away from the operating environment, and operate the cementing equipment at a distance, so as to keep away from noise and high pressure areas. The operation situation on the cementing equipment can be observed through a camera at a distance, so that the operators can be immersive and achieve the operation experience of what you see is what you get. 
     Hydraulic and air path system: mainly including a hydraulic pump, a hydraulic motor, a hydraulic oil tank, a hydraulic valve, a lubricating gear pump, a dryer, a air cylinder, etc., so as to provide power for the centrifugal pump, a pneumatic head and lubrication of the equipment to ensure normal operation of the equipment. 
     Main functions of the electrical system are: 
     (a) controlling the engine to start; 
     (b) controlling the mud mixing system; 
     (c) supplying power to electrical components to ensure that all indicator lights are on during operation, such as a touch screen, the instruments, a locking indicator light and an overpressure indicator light, etc; 
     (d) supplying power to all lighting lamps to ensure that the equipment can work at night; and 
     (e) realizing power supply by a storage battery. After the engine is started, a generator of the engine will charge the storage battery. The voltage of all electrical devices on the equipment is 24 VDC. 
     One plug valve of the air path system is the main switch of the air path system. The filtering pressure reducing valve connected afterwards can not only adjust the working pressure of the whole air path system, but also filter the gas entering the system to ensure the normal operation of air path components. Its main functions are: 
     (a) controlling on/off of the pneumatic actuator; 
     (b) controlling an air horn; 
     (c) providing air for the packing lubrication system; and 
     (d) providing air for a diesel spray bottle. 
     The hydraulic system is an open/close system, and the pressure of the hydraulic system during working depends on an external load, so as long as the system works normally below a design pressure, it means that the hydraulic system operates normally. An engine starting system, a motor drive system of a centrifugal pump, a motor drive system of a mud mixing tank agitator, a drive system of a cement discharging cylinder and a drive system of a hydraulic plug valve of the present equipment are all of a hydraulic drive type. All hydraulic components of the hydraulic system are from world-famous brands with stable and reliable performance. 
     A lubrication system adopts plunge pump power end lubrication and packing lubrication. Power end lubrication is composed of a set of independent systems. A gear pump is driven by the transmission side of an on-platform gearbox to apply continuous oil pressure forced lubrication to bearings and gears at a power end of the plunger pump. The gear pump sucks lubricating oil from the oil tank, the lubricating oil flows to the power end through a pipeline after passing through a pipeline filter, and then is divided into two paths: one path enters a main shaft to lubricate rolling bearings and sliding bearings of a connecting rod through holes of the main shaft, and the other path enters the gear box for lubrication, and finally the lubricating oil returns to a big pump lubricating oil tank. A safety valve is installed in front of the pipeline filter, which adjusts the pressure of the whole lubrication system. When pressure exceeds a set value, the lubricating oil flows back to the oil tank through the safety valve. The system is equipped with an automatic cooling device, which conducts cooling by means of an engine fan. When the temperature of the lubricating oil reaches a set temperature, the lubricating oil enters a cooler for heat dissipation. For packing lubrication, lubricating grease can be used to lubricate a plunge pump hydraulic end packing or centrifugal pump packing. An electric lubricating device forcibly presses the lubricating grease into the plunge pump or centrifugal pump packing. In order to avoid waste of the grease, the electric lubricating device is set to run intermittently to provide the most reasonable amount of lubricating oil for the packing. In this system, a one-way valve plays a role in preventing backflow of the lubricating grease. This lubricating fluid can use the “gas cap oil” lubrication method. 
     The plunger pump system mainly realizes different plungers, pressures, etc. to obtain different pressures and displacements required by end customers, so as to meet customer requirements. 
     The high-pressure manifold system is the general name of high-pressure pipe fittings of the equipment, which mainly consists of a 2″ plug valve, a 2″×1″ plug valve, a 2″ safety valve, a pressure sensor, an integral straight pipeline, a high-pressure tee, a high-pressure elbow, etc. The high-pressure manifold system mainly realizes the connection between the plunger pump and various plug valves, and extends the discharge port to a suitable position for external connection to a well site, and has other functions such as pressure measurement, manifold switch control, pressure relief and overpressure protection, etc. 
     The mixing system assembly is mainly used for mixing cement slurry, and mainly includes a mud mixing tank, a spray mixer, a cement discharge valve, a diffusion box, a defoamer container, a stirring shaft, a cement adding manifold, etc. A high-energy mixer is a core component of the whole mud mixing system assembly. Clear water entering from the clear water manifold, cement entering from the cement discharge valve and cement slurry circulating through a secondary circulation manifold are mixed in the high-energy mixer, which is a main component for mud mixing. The cement adding manifold is a pipeline which provides dry cement for the mud mixing system of the equipment, and includes a connecting pipeline, a cement adding hose and a control butterfly valve, etc. 
     The present invention has the beneficial effects that: 
     (1) the requirement for high pressure, large displacement, long time and continuous operation during ultra-deep well cementing operation and ultrahigh pressure gas well cementing operation is met; 
     (2) the operation space of the equipment is reduced so that complex operation can be conducted in a small well site, and the occupied area of the equipment is small, compared with the arrangement of multiple conventional cementing trucks, it is more conducive to the rapid arrangement of well site equipment and improves field operation efficiency; 
     (3) pipeline connection is easy, maintenance frequency is low, the number of required operators is small, and the cost of single operation is low; 
     (4) intelligent design reduces manual errors, one-touch operation realizes automatic control of the engine throttle and the gear of the gear box, and operators are completely liberated, marking a key step towards smart oilfield; and 
     (5) both safety and efficiency are guaranteed, and the equipment is equipped with the remote control system, which allows the operators to be away from noisy and high-pressure areas and complete operation in an immersive mode, thus ensuring the safety of both equipment and personnel. 
     The present invention will be further described below with reference to the accompanying drawings and specific embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram of a plane structure of the present invention; 
         FIG. 2  is a schematic diagram of a three-dimensional structure of the present invention; and 
         FIG. 3  is a schematic structural diagram of a power and transmission system. 
     
    
    
     In the drawings:  1 : loading system,  2 : hydraulic system,  3 : power and transmission system,  4 : electrical system,  5 : air path system,  6 : packing lubrication system,  7 : operation and control system,  8 : high-pressure manifold,  9 : mixing system,  10 : cement adding manifold,  11 : mud discharge manifold,  12 : operating platform,  13 : plunger pump,  14 : clear water manifold,  15 : metering tank,  16 : power end lubrication system,  17 : auxiliary beam,  18 : transmission shaft,  19 : carrying pole beam mounting assembly,  20 : engine,  21 : gearbox assembly,  22 : air intake system,  23 : air exhaust system,  24 : remote filter mounting bracket,  25 : cooling system assembly. 
     DETAILED DESCRIPTION 
     Embodiment 1 
     As illustrated in  FIGS. 1-3 , a new ultra-high power cementing apparatus integrated with remote control includes a loading system  1  and an auxiliary beam  17 , the auxiliary beam  17  is connected to the loading system  1 , and the auxiliary beam  17  is connected in sequence from front to back with a hydraulic system  2 , a power and transmission system  3 , a metering tank  15 , a low-pressure manifold system, an operating platform  12 , and those arranged at an upper end of the operating platform  12  that are an electrical system  4 , an air path system  5 , an operation and control system  7 , a plunger pump  13 , a high-pressure manifold  8  and a mixing system  9 ; the plunger pump  13  is located at a lower part of the air path system  5 , the rated input power of the plunger pump  13  is larger than or equal to 1200 horsepower, and the plunger pump  13  is connected to a high-pressure discharge system; the air path system  5  is provided with a plug valve, the plug valve is a main switch of the air path system, a downstream end of the plug valve is provided with a filtering pressure reducing valve, and the filtering pressure reducing valve is used for adjusting the working pressure of the whole air path system and filtering the gas entering the air path system. 
     The operation and control system  7  is located on a top of the operating platform  12 , the operation and control system  7  is connected to a remote control system, and the remote control system includes a remote control box, a first platform, a data acquisition system and a notebook computer (not illustrated in the figure). 
     The power and transmission system  3  includes an engine  20 , a gearbox assembly  21 , a transmission shaft  18 , a carrying pole beam mounting assembly  19 , an air intake system  22 , an air exhaust system  23 , a cooling system assembly  25 , a fuel system, a heating system and a remote filter mounting bracket  24 ; the transmission shaft  18  is located between the gearbox assembly  21  and the plunger pump  13 , and the engine  20  and the gearbox assembly  21  are placed on and supported by the carrying pole beam mounting assembly  19 ; the air intake system  22  provides the engine  20  with air required for combustion and the air exhaust system  23  realizes waste gas and heat emission, the remote filter mounting bracket  24  supports an intake air filter, and the cooling system assembly  25  is used for heat dissipation of the engine  20 , the gearbox assembly  21 , the hydraulic system  2  and the plunger pump  13 ; the gearbox assembly  21  realizes the adjustment of pressures and displacements by changing gears, and the engine  20  outputs power to the gearbox assembly  21  and drives the plunger pump  13  through the transmission shaft  18 . 
     The mixing system  9  is located at a tail of the auxiliary beam  17 , and the mixing system  9  realizes the mixing of water and cement. 
     The loading system  1  is a vehicle chassis. 
     The plunger pump  13  is a three-cylinder plunger pump. 
     The high-pressure discharge system includes a mud discharge manifold  11  and a high-pressure safety valve arranged on the mud discharge manifold  11 . 
     An upper part of the operating platform  12  is further provided with a packing lubrication system  6 . 
     A lower part of the power and transmission system  3  is further provided with a power end lubrication system for lubricating the plunger pump  13 . 
     The metering tank  15  includes a tank body, a clear water manifold  14  is connected to a bottom of the tank body and the tank body is supplied with water by the clear water manifold  14 , the clear water manifold  14  is provided with a butterfly valve, and the bottom of the tank body is further provided with a discharge port; and the tank body is further provided with a liquid level gauge and a second platform, the second platform is located at a top of the tank body, and a filter screen is arranged inside the tank body at a position of the discharge port. 
     The low-pressure manifold system includes the clear water manifold  14  and a mud manifold, wherein the mud manifold includes a discharge manifold and a centrifugal pump, the centrifugal pump is controlled by a pneumatic actuator, and the discharge manifold is provided with a densimeter manifold and a butterfly valve. 
     A cement adding manifold  10  is further connected to a tail of the auxiliary beam  17 . 
     The high-pressure manifold  8  is arranged at a lower part of the operation and control system  7 . 
     Embodiment 2 
     A new ultra-high power cementing apparatus integrated with remote control, including a loading system  1  and an auxiliary beam  17 , the auxiliary beam  17  is connected to the loading system  1 , and the auxiliary beam  17  is connected in sequence from front to back with a hydraulic system  2 , a power and transmission system  3 , a metering tank  15 , a low-pressure manifold system, an operating platform  12 , and those arranged at an upper end of the operating platform  12  that are an electrical system  4 , an air path system  5 , an operation and control system  7 , a plunger pump  13 , a high-pressure manifold  8  and a mixing system  9 ; the plunger pump  13  is located at a lower part of the air path system  5 , the rated input power of the plunger pump  13  is larger than or equal to 1200 horsepower, and the plunger pump  13  is connected to a high-pressure discharge system; the air path system  5  is provided with a plug valve, the plug valve is a main switch of the air path system, a downstream end of the plug valve is provided with a filtering pressure reducing valve, and the filtering pressure reducing valve is used for adjusting the working pressure of the whole air path system and filtering the gas entering the air path system. 
     The operation and control system  7  is located on a top of the operating platform  12 , the operation and control system  7  is connected to a remote control system, and the remote control system includes a remote control box, a first platform, a data acquisition system and a notebook computer (not illustrated in the figure). 
     The power and transmission system  3  includes an engine  20 , a gearbox assembly  21 , a transmission shaft  18 , a carrying pole beam mounting assembly  19 , an air intake system  22 , an air exhaust system  23 , a cooling system assembly  25 , a fuel system, a heating system and a remote filter mounting bracket  24 ; the transmission shaft  18  is located between the gearbox assembly  21  and the plunger pump  13 , and the engine  20  and the gearbox assembly  21  are placed on and supported by the carrying pole beam mounting assembly  19 ; the air intake system  22  provides the engine  20  with air required for combustion and the air exhaust system  23  realizes waste gas and heat emission, the remote filter mounting bracket  24  supports an intake air filter, and the cooling system assembly  25  is used for heat dissipation of the engine  20 , the gearbox assembly  21 , the hydraulic system  2  and the plunger pump  13 ; the gearbox assembly  21  realizes the adjustment of pressures and displacements by changing gears, and the engine  20  outputs power to the gearbox assembly  21  and drives the plunger pump  13  through the transmission shaft  18 . 
     The mixing system  9  is located at a tail of the auxiliary beam  17 , and the mixing system  9  realizes the mixing of water and cement. 
     The loading system  1  is a semi-trailer chassis. 
     The plunger pump  13  is a three-cylinder plunger pump. 
     The high-pressure discharge system includes a discharge mud manifold  11  and a high-pressure safety valve arranged on the discharge mud manifold  11 . 
     An upper part of the operating platform  12  is further provided with a packing lubrication system  6 . 
     A lower part of the power and transmission system  3  is further provided with a power end lubrication system  16  for lubricating the plunger pump  13 . 
     The metering tank  15  includes a tank body, a clear water manifold  14  is connected to a bottom of the tank body and the tank body is supplied with water by the clear water manifold  14 , the clear water manifold  14  is provided with a butterfly valve, and the bottom of the tank body is further provided with a discharge port; and the tank body is further provided with a liquid level gauge and a second platform, the second platform is located at a top of the tank body, and a filter screen is arranged inside the tank body at a position of the discharge port. 
     The low-pressure manifold system includes the clear water manifold  14  and a mud manifold, wherein the mud manifold includes a discharge manifold and a centrifugal pump, the centrifugal pump is controlled by a pneumatic actuator, and the discharge manifold is provided with a densimeter manifold and a butterfly valve. 
     A cement adding manifold  10  is further connected to a tail of the auxiliary beam  17 . 
     The high-pressure manifold  8  is arranged at a lower part of the operation and control system  7 . 
     Embodiment 3 
     A new ultra-high power cementing apparatus integrated with remote control, including a loading system  1  and an auxiliary beam  17 , the auxiliary beam  17  is connected to the loading system  1 , and the auxiliary beam  17  is connected in sequence from front to back with a hydraulic system  2 , a power and transmission system  3 , a metering tank  15 , a low-pressure manifold system, an operating platform  12 , and those arranged at an upper end of the operating platform  12  that are an electrical system  4 , an air path system  5 , an operation and control system  7 , a plunger pump  13 , a high-pressure manifold  8  and a mixing system  9 ; the plunger pump  13  is located at a lower part of the air path system  5 , the rated input power of the plunger pump  13  is larger than or equal to 1200 horsepower, and the plunger pump  13  is connected to a high-pressure discharge system; the air path system  5  is provided with a plug valve, the plug valve is a main switch of the air path system, a downstream end of the plug valve is provided with a filtering pressure reducing valve, and the filtering pressure reducing valve is used for adjusting the working pressure of the whole air path system and filtering the gas entering the air path system. 
     The operation and control system  7  is located on a top of the operating platform  12 , the operation and control system  7  is connected to a remote control system, and the remote control system includes a remote control box, a first platform, a data acquisition system and a notebook computer (not illustrated in the figure). 
     The power and transmission system  3  includes an engine  20 , a gearbox assembly  21 , a transmission shaft  18 , a carrying pole beam mounting assembly  19 , an air intake system  22 , an air exhaust system  23 , a cooling system assembly  25 , a fuel system, a heating system and a remote filter mounting bracket  24 ; the transmission shaft  18  is located between the gearbox assembly  21  and the plunger pump  13 , and the engine  20  and the gearbox assembly  21  are placed on and supported by the carrying pole beam mounting assembly  19 ; the air intake system  22  provides the engine  20  with air required for combustion and the air exhaust system  23  realizes waste gas and heat emission, the remote filter mounting bracket  24  supports an intake air filter, and the cooling system assembly  25  is used for heat dissipation of the engine  20 , the gearbox assembly  21 , the hydraulic system  2  and the plunger pump  13 ; the gearbox assembly  21  realizes the adjustment of pressures and displacements by changing gears, and the engine  20  outputs power to the gearbox assembly  21  and drives the plunger pump  13  through the transmission shaft  18 . 
     The mixing system  9  is located at a tail of the auxiliary beam  17 , and the mixing system  9  realizes the mixing of water and cement. 
     The loading system  1  is a skid-mounted chassis. 
     The plunger pump  13  is a three-cylinder plunger pump. 
     The high-pressure discharge system includes a discharge mud manifold  11  and a high-pressure safety valve arranged on the discharge mud manifold  11 . 
     An upper part of the operating platform  12  is further provided with a packing lubrication system  6 . 
     A lower part of the power and transmission system  3  is further provided with a power end lubrication system  16  for lubricating the plunger pump  13 . 
     The metering tank  15  includes a tank body, a clear water manifold  14  is connected to a bottom of the tank body and the tank body is supplied with water by the clear water manifold  14 , the clear water manifold  14  is provided with a butterfly valve, and the bottom of the tank body is further provided with a discharge port; and the tank body is further provided with a liquid level gauge and a second platform, the second platform is located at a top of the tank body, and a filter screen is arranged inside the tank body at a position of the discharge port. 
     The low-pressure manifold system includes the clear water manifold  14  and a mud manifold, wherein the mud manifold includes a discharge manifold and a centrifugal pump, the centrifugal pump is controlled by a pneumatic actuator, and the discharge manifold is provided with a densimeter manifold and a butterfly valve. 
     A cement adding manifold  10  is further connected to a tail of the auxiliary beam  17 . 
     The high-pressure manifold  8  is arranged at a lower part of the operation and control system  7 . 
     The above are only preferred embodiments of the present invention, and does not limit the present invention in any form. Any simple modifications and equivalent changes made to the above embodiments according to the technology of the present invention fall within the protection scope of the present invention.