DQYK-35BK型电动节流管汇控制箱使用说明书

DQYK35BK型电动节流管汇控制箱使用说明书沈阳鑫榆林石油机械有限公司一、用途：电动节流管汇控制箱是液动节流管汇上的控制装置，它可以远程控制液动节流阀的开启和关闭，并在控制箱上可以显示出系统压力、立管压力、套管压力、两个液动节流阀阀位开度、3路泥浆泵泵冲计数与累计数。由此来维持井底压力，是成功的控制井涌、井喷，实施油气井压力控制技术所必要的设备。电动节流管汇控制箱所用电器部份具有防爆性能，仪表的数字显示清晰，且具有自检功能，电传感器性能可靠、灵敏度高。二、主要技术指标：1、 1）防爆电机：电源电压：380VAC （三相四线制） 功 率：0.75KW 转 速：1450r/min 2）控制电源：220VAC （二线制）2、齿轮泵：排 量：5L/min额定压力：6MPa3、蓄能器：额定压力：10MPa 容 积：10L4、压力变送器：1）系统压力：量程：0 10MPa2）立管压力：量程：0 40MPa3) 套管压力：量程：0 40MPa 所有变送器输出信号为：420mA 5、电阀位变送器：量 程：0180度输出信号：420mA6、数字显示控制仪表：显示位数：4位精度：0.5%FS1字7、输出扭矩： 150Kgfm8、溢流阀调定为7.5MPa三、整机配备和工作原理：1、电动液控节流管汇控制箱是由控制箱、压力变感器、电阀位变送器、电缆、液压管线等组成。控制箱由防爆仪表箱、防爆电机、齿轮泵、蓄能器、溢流阀、截止阀、三位四通换向阀、手动试压泵、油箱、液压元件、电器控制元件、数字显示控制仪表等组成。2、 工作原理a) 液压工作原理见图一电动节流管汇控制箱它集电动、液压于一体，将外部电能转换成液压能量去控制液动节流阀的开启和关闭。启动防爆电机带动齿轮泵，高压液压油经单向阀，进入蓄能器，蓄能器随着液压油进入量增多而压力增高，当压力升至设定值后电机停止，扳动三位四通换向阀可达到控制节流阀开、关的目的。速度调节阀作用是调节液压油流量，控制液动节流阀开或关的速度。溢流阀是当控制电路出现故障，即系统油压升至超过设定最高压力电机仍未停止时，溢流阀打开，起着安全、保护作用。现场电源一旦中断，利用蓄能器所蓄的能量维持液动节流阀的 “开” “关” 一次。可利用“手动液压泵”（打印钢印标识号JK7.2.7.6.00）来维持控制箱操作所需的油压，向蓄能器补充能量，以备使用。液压工作原理图（图一）说明：1、电动泵：电源电压：380VAC功 率：0.75KW排 量：5L/min2、最高压力：8MPa3、 额定压力：6MPa4、 蓄能器：10MPa、10L5、 A1A5数字显示仪表B1B5变送器A1显示系统压力B1系统压力变送器A2显示套管压力B2套管压力变送器A3显示立管压力B3立管压力变送器A4显示节流阀1阀位开度B4节流阀1电阀位变送器A5显示节流阀2阀位开度B5节流阀2电阀位变送器b) 电控工作原理见图二、图三系统控制原理图（图二）控制箱电控工作由压力变送器、电阀位变送器、数字显示仪、交流接触器等元件组成，按系统控制原理图二，接上电源，仪表开始工作，显示仪随即可显示经变送器传送的数据。将“液压系统”开关旋至开位，则液压系统启动，电动泵工作，“系统压力”显示仪所显示的压力，如低于下限设定值，电机自动启动充压，当压力升至上限值时，交流接触器线圈失电脱落，电机停止，当压力降至下限值时，交流接触器得电吸合，电机启动。如此循环工作使系统压力得到所设定压力。数据采集原理图（图三）四、安装调试及使用： （图四）1、 液压系统调试：a) 系统排空：打开蓄能器截止阀（该阀属于常开阀，出厂时打开状态）打开系统泄荷阀 (该阀属于常闭阀，出厂时关闭状态)b) 液压泵调试：将系统泄荷阀关闭，启动液压泵，此时系统升压，见盘面上系统压力数字显示仪，当压力达到7MPa时，电动泵自行停止工作；如系统油压降至5MPa时，电动泵可自行启动补充压力，保持其额定工作压力状态。c) 溢流阀Y: 出厂时已调至7.5MPa面板显示及外部联接图（图五）1、电源进线口 2、传感器信号线入口3、液动节流阀1阀开接头（M221.5） 4、液动节流阀1阀关接头（M221.5）5、液动节流阀2阀开接头（M221.5） 6、液动节流阀2阀关接头（M221.5）7、数字显示仪：立管压力数字显示仪8、数字显示仪：套管压力数字显示仪9、数字显示仪：系统压力数字显示仪10、节流阀 1 阀位开度数字显示仪11、数字显示仪：节流阀 2 阀位开度数字显示仪12、液压系统启停按钮 13、液压系统停机指示灯 14、液压系统启动指示灯 15、防爆电机故障指示灯16、防爆电机工作指示灯17、三位四通手动换向阀118、三位四通手动换向阀219、调节阀：调节节流阀阀开、关速度20、泵冲计数器安装处2、控制箱右侧布置有：立管压力、套管压力、液动节流阀1阀位开度、液动节流阀2阀位开度及泵冲计数器接线口。外接电源进线口：380VAC 3、控制箱左侧布置有液压管线接口。4、向油箱加入经过140目/英寸以上的滤网过滤的液压油。5、接电源之前将电动节流管汇控制箱地线接好，以保护人身安全。将外接电源接好，动力电源为三相四线制的380VAC。控制电源为二线制的220VAC。防爆组合开关，插上插头后，旋转到“合”的位置，电源接通，旋转到“分”的位置，电源断开，敬请注意。6、电源正确连接后，按齿轮泵上方箭头方向，调试电机转向是否合适，如反向应立即停止，换向后再启动。7、打开泄荷阀，启动电动泵，空载运转，排除管路中的空气，连接节流阀液压管线。8、关闭泄荷阀，当系统油压升至设定值后，扳动三位四通换向阀手柄，使液动节流阀开、关两次，以排出液缸中空气。9、按标定的标识分别将立管压力变送器、套管压力变送器、液动节流阀1电阀位变送器、液动节流阀2电阀位变送器、泵冲计数器等一一对应相接。检查各线路、管线连接无误后，将盘面“液压系统”开关旋至开位，启动电动泵，同时调整电阀位变送器的位置，当液动节流阀的实际位置与阀位开度显示仪表一致，将电阀位变送器的位置固定。油压升至7MPa时自动停泵，如系统油压的压力降至5MPa，电动泵可自动启动，保持系统压力。上述调整完毕后即可投入运行，根据钻井工艺的要求，操纵三位四通换向阀控制液动节流阀的开启和关闭。从而继续平衡钻井工艺所需井底回压。五、保养及维修：1、注意观察控制箱内外各油路有无泄漏的地方，观察各电缆线有无破损的地方，如有应马上关闭外部电源及时检修。2、经常观察“液位计”油面的高低，少则加油，每半年更换油箱内的液压油一次，并同时清洗滤油器及油箱。3、每半年检查一次蓄能器充氮压力，预充氮气压为1.3MPa。4、故障指示：当此灯亮起时，代表电机出现故障。如：电机过载或电机实质性损坏等等，造成电机保护装置热过载继电器动作，从而使“电机故障”指示灯亮，此时应请电器专业人员进行维修。当故障解除后，电机保护装置热过载继电器自动复位，从而“电机故障”指示灯熄灭，系统恢复正常工作。六、DJFK6型角阀控制器 （图六）DJFK6型角阀控制器是孔板式液动节流阀上的专用变送器，它将节流阀的开度转换成420mA电信号输送给数字显示仪以显示阀的开度。（图六）七、CS20D型压力变送器CS20D型压力变送器是为监测石油钻井作业中立管、套管压力而配制的，它将立管、套管压力转换成420mA电信号输送给数字显示仪，以显示其实际压力。 压力变送器与数字显示仪在出厂前已整机匹配调定，正常情况下不用调整。 （图七）DQYK35BK Type Electric Throttle Manifold Control Box Instruction Manual Shenyang Xinyulin Petroleum Machinery Co., Ltd. Application The electric throttle manifold control box, designed for the control over hydrodynamic throttle manifold, is used for the remote control over the opening and closing of hydrodynamic throttle valves, and for the display of system pressure, rising pipe pressure , drive pipe pressure, valve opening position between two hydrodynamic throttle valves, the pump stroke count and accumulated number of three-way slurry pumps, thus the underground pressure will be better maintained, so it is essential for the control over kick and blowout and the implementation of gas well pressure control technology. The electric part of the electric throttle manifold control box is explosion-proof, in which the meters display figures clearly and have the function of self-inspection, and the electric sensors have a reliable performance and high sensibility. Main technical data：1. 1）Explosion-proof motor： Source voltage：380VAC (three-phase four-wire system）Power： 0.75KW Speed of rotation：1450r/min 2）Control power supply：220VAC（two-wire system）2. Gear pump：Output：5L/minRated pressure：6MPa3. Energy accumulator：Rated pressure：10MPa Volume：10L4. Pressure transmitter：1）System pressure：Range2) Rising pipe pressure： Range：0 40MPa3) Drive pipe pressure：Range：0 40MPaOutput signal of all transmitters：420mA 5. Electric valve position transmitter Range：0180Output signal：420mA6. Digital display control instrument：Number of digits displayed：4 Precision：0.5%FS1 character7. Output torque： 150Kgfm 8. The overflow valve is set to: 7.5MPa Complete disposition and working principle1. The electric throttle manifold control box consists of control box, pressure transmitter, electric valve position transmitter, cables and hydraulic lines, etc.The control box consists of explosion-proof instrument box, explosion-proof motor, gear pump, energy accumulator, overflow valve, break valve, three-position four-way hand-control directional valve, pressure testing hand pump, oil tank, hydraulic elements, electric control elements and digital display control instruments, etc.2. Working principlea) see Fig. 1 for the hydraulic working principleIntegrating electric drive and hydraulic pressure, the electric throttle manifold control box converts electric energy supplied into the hydraulic energy so as to control the opening/closing of the hydrodynamic throttle valve. Start the explosion-proof motor to drive the gear pump, thus the high-pressure hydraulic oil will be pumped, via a check valve, into the energy accumulator, the pressure in which will then get increased with the ingress of hydraulic oil. Stop the motor when the pressure reaches to the set value, at this time, the opening and closing of the throttle valve can be controlled through the three-position four-way directional valve. The speed regulating valve functions to regulate the flow rate of hydraulic oil and control the opening/closing speed of the hydrodynamic throttle valve. The overflow valve plays the role of safety and protection in case there is a failure occurred in the control circuit, that is, the motor does not to stop running when the oil pressure of the system rises up over the set maximum pressure. The energy accumulated in the energy accumulator can be supplied to the hydrodynamic throttle valve for its opening/closing for once in case of a failure of the site power supply. The “hydraulic hand pump” (embossing seal ID No.: JK7.2.7.6.00) is available to maintain the oil pressure necessary for the operation of the control box and supplement energy to the energy accumulator for the future use. Hydraulic schematic diagram (Fig.1)Instructions：1. Motor pump：Power supply voltage：380VACPower：0.75KWOutput：5L/min2. Max. pressure：8MPa3. Rated pressure：6MPa4. Energy accumulator：10MPa.10L5. A1A5 digital indicator A1indicating system pressure A2indicating drive pipe pressure A3indicating rising pipe pressure A4indicating the valve opening position of throttle valve1A5indicating the valve opening position of throttle valve2B1B5 transmitterB1system pressure transmitterB2drive pipe pressure transmitterB3rising pipe pressure transmitterB4electric valve position transmitter of throttle valve 1B5electric valve position transmitter of throttle valve 2b) See Fig. 2 and Fig.3 for the electric control principle System control schematic diagram (Fig.2)The electric control part of the control box consists of such elements as transmitter, electric valve position transmitter, digital indicator, AC contactor, etc. The meters will begin to work with the power supply being connected according to the system control principle diagram (Fig.2), and the indicators will soon indicate the data transmitted over by the transmitter. Turn the Hydraulic System switch to the position of Opening to start the hydraulic system, and then the motor pump will begin to work. If the pressure indicated in the System Pressure indicator is lower than the lower limit value, the motor will start automatically for a pressure supplementation. When the pressure rises up to the upper limit value, the AC contactor coil will lose power supply and fall off, which will cause a stop of the motor; when the pressure drops down to the lower limit value, the AC contactor will be electrified and attracted, which will cause a restarting of the motor. It is just through such a circulating operation that the system pressure rises up to the set value. Data acquisition schematic diagram (Fig. 3) Installation, trial run and use （Fig 4）1. Trial run of hydraulic systema) System exhausting: Open the break valve for energy accumulator (this valve is of a normally open valve, and at the state of opening when leaving the factory)Open the system release valve (this valve is of a normally closed valve, and at the state of closing when leaving the factory). b) Trial run of the power-driven pump: Startup the power-driven pump with the system release valve closed. At this time, the system pressure rises （see the system pressure digital indicator on the panel）, and the power-driven pump will come to a stop automatically when the pressure reaches 7MPa and restart automatically to maintain the system pressure when the system oil pressure drops down to 5MPa to keep it in the state of rated working pressure. c) Overflow valve Y: has been regulated to 7.5MPa when leaving the factory. Panel display and external connection diagram (Fig 5)1. Power line entrance 2. Sensor signal line entrance3. Valve opening joint of hydrodynamic throttle valve 1（M221.5）4. Valve closing joint of hydrodynamic throttle valve 1（M221.5）5. Valve opening joint of hydrodynamic throttle valve 2（M221.5）6. Valve closing joint of hydrodynamic throttle valve 2（M221.5）7. Digital Indicator: rising pipe pressure digital indicator8. Digital Indicator: drive pipe pressure digital indicator9. Digital indicator: system pressure digital indicator 10. Valve opening position digital indicator for throttle valve 1 11.Digital Indicator：valve opening position digital indicator for throttle valve 2 12. Hydraulic system start/stop button13. Hydraulic system stop indicator light14. Hydraulic system starting indicator light15. Explosion-proof motor fault indicator light16. Explosion-proof motor working indicator light17. Three-position four-way hand-control directional valve 118. Three- position four-way hand-control directional valve 219. Regulating valve: designed for the regulation of opening /closing speed of the throttle valve20. Installation position of the pump stroke counter 2. On the right side of the control box such interfaces as rising pipe pressure, drive pipe pressure, the valve position opening angle of hydrodynamic throttle valve 1, the valve opening position of hydrodynamic throttle valve 2 and pump stroke counter are arranged. The external power line entrance: 380V AC.3. On the left side of the control box, hydraulic pipe interfaces are arranged. 4. Fill the oil tank with hydraulic oil filtered by a filter screen of 140 meshes /inch or above. 5. Before connection to the power supply, the electric throttle manifold control box must be properly earthed for the protection of personal safety. Make good connection with the external power supply, which is of a 380V three-phase four-wire system AC power supply. The control power supply is of a 220V two-wire system AC power supply. Note: insert the plug of the combined explosion-proof switch in and turn to the position of Closing, the power supply is switched on; turn to the position of Opening, the power supply is switched off. 6. Adjust the direction of rotation of the motor according to the arrow instruction above the gear pump after the power supply is properly connected. Stop the motor instantly in case of a reverse rotation, and restart the motor after a change in direction. 7. Start the motor pump and run it without load with the release valve open to exhaust the air in the pipes, and then connect the throttle valve hydraulic pipes.8. When the system oil pressure rises up to the set value, operate the handle of the three-position four-way directional valve with the release valve closed to close and open the hydrodynamic throttle valve twice to exhaust the air in the hydraulic cylinder. 9. Connect the rising pipe pressure transmitter, drive pipe pressure transmitter, electric valve position transmitter of hydrodynamic throttle valve 1 and electric valve position transmitter of hydrodynamic throttle valve 2 and pump stroke counter to their corresponding positions.Turn the “hydraulic system” switch on the panel to the position of Opening to start the motor pump after various lines and pipes are connected and checked without fault, at the same time, adjust the position of the electric valve position transmitter. Fix the position of the electric valve position transmitter when the actual position of the hydraulic throttle valve is in conformity with that displayed on the valve opening position indicator. The pump will come to a stop when the oil pressure rises up to 7MPa and restart automatically to maintain the system pressure when the system oil pressure drops down to 5MPa. Go into operation when the above regulation completes. According to the requirement for drilling process, the opening/ closing of the hydrodynamic throttle valve can be controlled by operating the three-position four-way directional valve, thus the balance of underground back pressure necessary for drilling process will be continued. Maintenance and repair1. Check all the oil ways inside and outside the control box for oil leak; check all the electric cables for damage, if any, switch off the external power supply instantly for a timely examination and repair.2. Observe the oil level of the liquid level meter at intervals, refill it in case of a shortage; change hydraulic oil in the oil tank at interval of half a year, simultaneously, clean the oil filter and oil tank. 3. Check the energy accumulator at interval of half a year for the pressure of nitrogen charged. The pressure of nitrogen pre-charged is 1.3MPa.4. Failure indication: a lightening of this light is a sign of failure in motor. For example, an overloading on or real damage in motor will cause the action of the thermal overloading relay, which serves as a motor protection device, and the action will cause the lightening of the “motor failure” indicator light. In that case, electric professionals should be invited for repair. When the failure is remedied, the thermal overloading relay will reset automatically. Thus the “motor failure” indicator light will go out and the system will work normally again.The DJFK6 angle valve controller （Fig. 6） DJFK6 angle valve controller is specially designed for the orifice plate hydrodynamic throttle valve, transfers the opening position of the throttle valve into 420mA electric signals and transmits them to the digital indicator to indicate the opening position of the valve. （图六）. CS20D pressure transmitter The CS20D pressure transmitter, designed for monitoring the pressure of stand pipes and casing pipes used for petroleum drilling operations, transfers the pressure of stand pipes and casing pipes into 420mA electric signals and transmits them to the digital indicator to display its actual pressure. The pressure transmitter and digital indicator have been properly adjusted as a part of the whole unit before leaving the factory, and any readjustment is unnecessary under normal conditions. （Fig. 7）沈阳鑫榆林石油机械有限公司Shenyang Xinyulin Petroleum Machinery Co., Ltd.地 址：沈阳市沈北新区夏花湖街1号Address: No.1 Xiahuahu Street， Shenbeixin District, Shenyang电 话（传真）：024-Telephone（Fax）: 024-邮 编：Postcode: 装 箱 清 单Packing list序号S/N产 品 名 称Name of product产 品 型 号Model of product单 位Unit数 量Quantity1压力变送器pressure transmitterCS20D（2”1502）台Set22压力变送器转接头Pressure transmitter adapterNPT 3/42”1502套Set23角阀控制器angle valve controllerDJFK6台Set14橡胶管线Rubber pipeline815m 根Piece25卡 套Spacing collarJYK-04.01个Piece56螺 母NutJYK-04.02个Piece57GB1235-76“0”型圈GB1235-76“0”sealring222.4个Piece48GB3452.1-9