Design of automatic control system for underground hydraulic fracturing in coal mine
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摘要: 分析指出目前煤矿井下水力压裂技术面临压裂泵输出压力和流量无法快速精确调节、远程安全监控效果及自动化水平有待提高等难题。设计了一种煤矿井下水力压裂自动控制系统。根据煤矿井下水力压裂工艺及系统构成，明确了控制系统关键技术为高压大流量压裂泵输出流量和压力的快速精确调节，远程高可靠性安全、高速实时监控，一键启停及图形化分析等。以KXH12本安型控制器为核心，搭配变频器、组合开关、监控主机、电动开度球阀等设备，以及光纤加CAN总线的双线冗余通信方案，研发了控制系统硬件，并编制了压裂泵控制器、水箱控制器及中央控制器软件，实现了压裂系统快速变流量注水、稳定保压及远程高速实时监控和报警等功能。在煤矿现场对水力压裂自动控制系统进行工业性试验，结果表明该系统压力控制精度为0.1 MPa，流量控制精度为0.1 m3/h，在连续完成14次压裂过程中，每次煤岩层开裂后均能实现较好的保压效果，且操作简单，安全性高，满足煤矿井下水力压裂工艺要求。Abstract: The analysis points out that the current hydraulic pressure technology in coal mines faces challenges such as the inability to quickly and accurately adjust the output pressure and flow rate of fracturing pumps, the need to improve the remote safety monitoring effect, and the level of automation. An underground hydraulic fracturing automatic control system in coal mine has been designed. Based on the hydraulic fracturing technology and system composition in coal mines, it is clear that the key technologies of the control system include rapid and precise adjustment of the output flow and pressure of high-pressure and high flow fracturing pumps, remote high reliability and safety, high-speed real-time monitoring, one click start stop, and graphical analysis. Based on the KXH12 intrinsic safety controller as the core, combined with frequency converters, combination switches, monitoring hosts, electric valves and other equipment, as well as a dual line redundant communication scheme with fiber optic and CAN bus, the control system hardware has been developed. The fracturing pump controller, water tank controller, and central controller software have been developed. It achieves functions such as fast variable flow water injection, stable pressure maintenance, remote high-speed real-time monitoring and alarm of the fracturing system. Industrial tests are conducted on the hydraulic fracturing automatic control system at the coal mine site, and the results show that the pressure control precision of the system is 0.1 MPa, and the flow control precision is 0.1 m3/h. During 14 consecutive fracturing processes, good pressure retention effects are achieved after each coal layer crack. The operation is simple with high safety, meeting the requirements of hydraulic fracturing technology in coal mines underground.
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图 1 煤矿井下水力压裂系统架构
Figure 1. Architecture of underground hydraulic fracturing system in coal mine
图 2 煤矿井下水力压裂自动控制系统功能架构
Figure 2. Functional architecture of hydraulic fracturing automatic control system in underground coal mine
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