An adaptive drilling fluid intelligent blending device and a method of using the same

Abstract

The application discloses a self-adaptive drilling fluid intelligent blending device and a use method thereof, belongs to the technical field of shale gas exploitation auxiliary devices, and comprises an original drilling fluid circulating system, a sensor group, a controller, a blending execution group and the drilling fluid circulating system; the sensor group comprises a density sensor, a viscosity sensor, a pH value sensor and a temperature sensor; the controller comprises a digital-analog conversion module, an algorithm module and a communication module; and the blending execution group comprises a metering pump, a stirring device, a feeding pipeline and a valve.

Description

Technical Field

[0001] This invention relates to the field of shale gas extraction auxiliary equipment technology, specifically to an adaptive drilling fluid intelligent mixing device and its usage method. Background Technology

[0002] When extracting shale gas, drilling fluids are used in conjunction with drilling rigs. Traditional drilling fluid blending methods suffer from the following problems: 1. Blending relies heavily on manual experience and simple measuring tools, making it difficult to accurately control various parameters of the drilling fluid; 2. When encountering formation changes or unexpected situations during drilling, existing blending technologies often cannot detect and respond quickly enough. This may lead to the drilling fluid performance not adapting to changes in operating conditions in a timely manner, increasing drilling risks. The long response feedback path makes it easy to miss the optimal adjustment opportunity, causing drilling accidents or reducing drilling speed; 3. Existing blending methods are based on preset fixed formulas and processes, and cannot adaptively adjust according to real-time drilling conditions and formation characteristics. This makes it impossible for the drilling fluid to maintain optimal performance in the face of complex and changing underground environments, and it is also impossible to automatically optimize the drilling fluid formula according to different drilling depths, formation pressures, rock types, and other factors, limiting the flexibility and adaptability of drilling operations; 4. Existing drilling fluid blending systems lack sufficient analysis and utilization of historical and real-time monitoring data (the application of historical data is lacking in the handover documents). These data contain a wealth of information that can be used to optimize allocation strategies and predict performance changes, but they are often overlooked or not effectively mined. The lack of big data integration and analysis capabilities makes it impossible to summarize patterns and discover potential problems from a large amount of drilling fluid allocation data, making it difficult to achieve intelligent decision support. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide an adaptive drilling fluid intelligent mixing device to solve the various problems existing in the mixing of drilling fluid.

[0004] To address the above problems, the present invention provides the following technical solution:

[0005] An adaptive drilling fluid intelligent mixing device; it includes the original drilling fluid circulation system; it also includes a sensor group, a controller, a mixing execution group and the drilling fluid circulation system;

[0006] The sensor group includes a density sensor, a viscosity sensor, a pH sensor, and a temperature sensor;

[0007] The controller includes a digital-to-analog / analog-to-digital conversion module; an algorithm module; and a communication module.

[0008] The mixing and execution unit includes a metering pump, a mixing device, a feeding pipeline, and valves; the metering pump is used to quantitatively add the specified raw materials to the mixing device; the mixing device is used to fully mix the drilling fluid; the feeding pipeline is used to provide different raw materials; the valves are installed on the feeding pipeline, and the valves' actions are controlled by a controller, which can control the opening and closing of the feeding pipeline;

[0009] The density sensor is installed on the main pipeline of the drilling fluid circulation system near the drilling fluid outlet, and it is connected to the controller via a wire.

[0010] The viscosity sensor is installed inside the drilling fluid mixing tank near the mixing blades and is connected to the controller via a wired connection.

[0011] The pH sensor is installed in the drilling fluid storage tank and interacts with the controller wirelessly.

[0012] There are no fewer than three temperature sensors, and these temperature sensors are respectively installed at the wellhead, the drilling fluid outlet, and the drilling fluid mixing tank of the drilling fluid circulation system;

[0013] The method of using this intelligent drilling fluid mixing device includes the following steps:

[0014] S1. The controller collects signals from the density sensor, viscosity sensor, pH sensor, and temperature sensor at a certain frequency; processes the signals through the digital-to-analog / analog-to-digital converter module; and inputs the processed signals into the algorithm module.

[0015] S2. The algorithm module outputs different control commands to the dispatch execution group through the communication module based on the following different conditions:

[0016] When the density sensor transmits a signal indicating that the density of the drilling fluid supplied to the drilling fluid circulation system is outside the range of 1.0~2.5 g / cm³, the corresponding control output will be activated to increase the amount of material or diluent used.

[0017] When the viscosity sensor transmits a signal indicating that the current drilling fluid viscosity is outside the range of 5 to 100 mPa·s, the corresponding control output will be executed to add or reduce the treatment agent.

[0018] When the pH sensor transmits a signal indicating that the pH value of the drilling fluid stored in the drilling fluid storage tank is outside the range of 6.5 to 9.0, the corresponding control output will be executed to add or reduce the acid-base regulator.

[0019] When any temperature sensor uploads a signal indicating that the current drilling fluid temperature is outside the range of 5~80℃, the corresponding control output is dispatched to start the cooling or heating device.

[0020] Preferably, the density sensor, viscosity sensor, pH sensor, and temperature sensor output signals to the controller once per minute.

[0021] Preferably, the sensor group also includes a gas chromatograph and a liquid chromatograph; the gas chromatograph and the liquid chromatograph are also connected to the controller via data cables;

[0022] The sampling points of both the gas chromatograph and the liquid chromatograph are installed near the drilling fluid sample collection port, and both are connected to the controller via a data cable.

[0023] Gas chromatographs are used to vaporize and separate samples using chromatographic columns, and to detect the composition and content of organic compounds, transmitting the data to the controller.

[0024] Liquid chromatographs are used to sample, separate, and detect water-soluble components, and transmit the results to the controller.

[0025] Furthermore, an alarm is issued when the signal uploaded by the liquid chromatograph shows that the deviation of the water-soluble component content in the current drilling fluid is greater than 5%.

[0026] Preferably, it also includes an analytical testing laboratory; the analytical testing laboratory is equipped with an atomic absorption spectrometer, an infrared spectrometer, and a X-ray fluorescence spectrometer; all three are connected to the controller via data cables;

[0027] Atomic absorption spectrometers are used to determine the content of metallic elements and transmit the data to a controller.

[0028] Infrared spectrometers are used to determine molecular structure and chemical composition and transmit this information to the controller.

[0029] X-ray fluorescence spectrometers are used to measure the types and amounts of elements and transmit the data to a controller.

[0030] Furthermore, an alarm is triggered when the atomic absorption spectrometer uploads data showing that the content of a single metallic element is greater than 10 ppm.

[0031] An alarm is triggered when the data uploaded by the infrared spectrometer shows a 20% change in the intensity of the absorption peak of a specific functional group in the drilling fluid.

[0032] An alarm is triggered when the data uploaded by the X-ray fluorescence spectrometer shows a change in the elemental content of the drilling fluid exceeding 10%.

[0033] The beneficial effects of this invention are reflected in the following aspects:

[0034] 1. Possesses high-precision allocation capability

[0035] To cope with complex geological conditions and demanding drilling operations, new intelligent mixing devices are needed to achieve high-precision measurement and control of various drilling fluid parameters, ensuring that the drilling fluid performance is always at its optimal level. For example, it should be able to precisely control the amount of treatment agent added within a very small error range to meet the stringent requirements of special drilling processes on drilling fluid performance.

[0036] 2. It has a rapid response mechanism.

[0037] The new mixing method should be able to quickly sense changes in drilling conditions and make accurate mixing decisions and execute operations in a very short time to ensure the safety and efficiency of drilling operations. When encountering emergencies such as sudden changes in formation pressure or wellbore instability, the mixing device should be able to adjust the properties of the drilling fluid within seconds to avoid accidents.

[0038] 3. Possesses strong adaptive capabilities

[0039] It can analyze various data in real time during the drilling process, including geological parameters, drilling parameters, and drilling fluid performance parameters, and automatically adjust the blending strategy based on this data to ensure that the drilling fluid is always adapted to different drilling conditions; for example, it can automatically adjust the lubrication performance and rock-carrying capacity of the drilling fluid based on the changes in the hardness of the formation rock during drilling.

[0040] 4. Possesses effective data analysis and utilization capabilities.

[0041] The new intelligent allocation system should have powerful data acquisition, storage, analysis and mining capabilities, be able to extract valuable information from massive amounts of historical and real-time data, and provide a scientific basis for optimizing allocation strategies; by establishing data models, it can predict the changing trends of drilling fluid performance, carry out preventive allocation in advance, improve drilling efficiency and reduce costs.

[0042] 5. Low maintenance costs and high reliability

[0043] The intelligent dispatching device features a simple design, reasonable structure, and easy maintenance, reducing vulnerable parts, improving equipment stability and reliability, and lowering operating and maintenance costs. It also employs advanced fault diagnosis and early warning technologies to detect potential problems in advance, reducing losses and impacts caused by equipment failures. Detailed Implementation

[0044] The present invention will be further described below with reference to specific embodiments:

[0045] Example:

[0046] This embodiment provides an adaptive drilling fluid intelligent mixing device; it includes the original drilling fluid circulation system; it also includes a sensor group, a controller, a mixing execution group, and the drilling fluid circulation system;

[0047] The sensor group includes a density sensor, a viscosity sensor, a pH sensor, and a temperature sensor;

[0048] In this embodiment, the density sensor uses the pressure difference measurement principle to monitor the density changes of the drilling fluid in real time. Its function is to provide accurate density data so as to promptly detect situations where the density deviates from the set range.

[0049] The viscosity sensor, based on a rotational measurement method, is capable of accurately measuring the viscosity of drilling fluid. Its primary function is to sense changes in viscosity, providing crucial viscosity information to the controller.

[0050] pH sensors utilize electrochemical principles to accurately detect the acidity or alkalinity of drilling fluids. Their function is to maintain the acid-base balance of the drilling fluid, ensuring its stable performance.

[0051] The temperature sensor uses thermocouple or thermistor technology to monitor the temperature of the drilling fluid in real time. Its function is to prevent excessively high or low temperatures from affecting the performance of the drilling fluid and ensuring drilling operation safety.

[0052] The controller includes a digital-to-analog (DAC) / analog-to-digital (ADC) conversion module, an algorithm module, and a communication module. The DAC module receives real-time data from various sensors and performs rapid filtering, amplification, and digitization to remove noise and interference and extract usable information. The algorithm module incorporates advanced algorithms and models to compare and analyze the processed data against preset drilling fluid performance standards. Based on the analysis results, it formulates corresponding allocation strategies. The communication module generates precise control commands based on the algorithm's decision-making results and sends these commands to various devices in the allocation execution group via a specific communication protocol.

[0053] The mixing and execution unit includes a metering pump, a mixing device, a feeding pipeline, and valves; the metering pump is used to quantitatively add the specified raw materials to the mixing device; the mixing device is used to fully mix the drilling fluid; the feeding pipeline is responsible for accurately delivering the processing agent output from the metering pump to the drilling fluid circulation system; the valves are located on the feeding pipeline, and the valves' actions are controlled by a controller, which can control the flow rate and opening / closing of the feeding pipeline;

[0054] The density sensor is installed on the main pipeline of the drilling fluid circulation system near the drilling fluid outlet, and it is connected to the controller via a wire.

[0055] The viscosity sensor is installed inside the drilling fluid mixing tank near the mixing blades and is connected to the controller via a wired connection.

[0056] The pH sensor is installed in the drilling fluid storage tank and interacts with the controller wirelessly.

[0057] There are no fewer than three temperature sensors, and these temperature sensors are respectively installed at the wellhead, the drilling fluid outlet, and the drilling fluid mixing tank of the drilling fluid circulation system;

[0058] The method of using this intelligent drilling fluid mixing device includes the following steps:

[0059] S1. The controller collects signals from the density sensor, viscosity sensor, pH sensor, and temperature sensor at a certain frequency; processes the signals through the digital-to-analog / analog-to-digital converter module; and inputs the processed signals into the algorithm module.

[0060] S2. The algorithm module outputs different control commands to the dispatch execution group through the communication module based on the following different conditions:

[0061] When the density sensor transmits a signal indicating that the density of the drilling fluid supplied to the drilling fluid circulation system is outside the range of 1.0~2.5 g / cm³, the corresponding control output will be activated to increase the amount of material or diluent used.

[0062] When the viscosity sensor transmits a signal indicating that the current drilling fluid viscosity is outside the range of 5 to 100 mPa·s, the corresponding control output will be executed to add or reduce the treatment agent.

[0063] When the pH sensor transmits a signal indicating that the pH value of the drilling fluid stored in the drilling fluid storage tank is outside the range of 6.5 to 9.0, the corresponding control output will be executed to add or reduce the acid-base regulator.

[0064] When any temperature sensor uploads a signal indicating that the current drilling fluid temperature is outside the range of 5~80℃, the corresponding control output is dispatched to start the cooling or heating device.

[0065] The density sensor, viscosity sensor, pH sensor, and temperature sensor each output signals to the controller once per minute.

[0066] The sensor group also includes a gas chromatograph and a liquid chromatograph; the gas chromatograph and the liquid chromatograph are also connected to the controller via data cables;

[0067] The sampling points of both the gas chromatograph and the liquid chromatograph are installed near the drilling fluid sample collection port, and both are connected to the controller via a data cable.

[0068] Gas chromatography (GC) is used to vaporize and separate sampled materials using a chromatographic column, detecting the composition and content of organic compounds and transmitting the data to a controller. In a gas chromatograph (GC), after the sample is vaporized, it enters the chromatographic column. Different organic compounds interact differently with the stationary and mobile phases within the column, resulting in varying retention times. A carrier gas carries the separated compounds sequentially out of the column to detectors such as flame ionization detectors (FID) or thermal conductivity detectors (TCD), generating electrical signals that enable qualitative and quantitative analysis of the compounds. Its function is to accurately detect the composition and content of organic compounds in drilling fluids and promptly identify changes in compound composition.

[0069] High-performance liquid chromatography (HPLC): The sample solution is delivered to the chromatographic column by a high-pressure pump, and the column is packed with a stationary phase. Different components are separated due to differences in their partition coefficients between the stationary and mobile phases. The separated components then pass sequentially through detectors such as UV-Vis detectors and fluorescence detectors, generating corresponding signals for detection and analysis. Its function is to accurately analyze the composition of water-soluble components in drilling fluids and promptly detect abnormalities.

[0070] Liquid chromatographs are used to sample, separate, and detect water-soluble components, and transmit the results to the controller.

[0071] An alarm is issued when the signal uploaded by the liquid chromatograph shows that the deviation of the water-soluble component content in the current drilling fluid is greater than 5%.

[0072] It also includes an analytical testing laboratory; the analytical testing laboratory is equipped with an atomic absorption spectrometer, an infrared spectrometer, and a X-ray fluorescence spectrometer; all three are connected to the controller via data cables;

[0073] Atomic absorption spectrometers are used to determine the content of metallic elements and transmit the data to a controller.

[0074] Infrared spectrometers are used to determine molecular structure and chemical composition and transmit this information to the controller.

[0075] X-ray fluorescence spectrometers are used to measure the types and amounts of elements and transmit the data to a controller.

[0076] Atomic absorption spectrometry (AAS) involves atomizing a sample to form atomic vapor. When characteristic spectral lines emitted by a light source (usually a hollow cathode lamp) pass through the atomic vapor, some of the light is absorbed. According to the Lambert-Beer law, the concentration of the analyte in the sample is determined by measuring the absorbance. Its function is to accurately determine the content of metal elements in drilling fluids and to promptly monitor changes in element concentration.

[0077] Infrared spectroscopy (IR) involves the absorption of specific wavelengths of infrared light by molecules when a sample is exposed to infrared light, triggering transitions in molecular vibrational and rotational energy levels. Different functional groups and chemical bonds produce absorption peaks at specific infrared wavelengths. By analyzing the position, intensity, and shape of these absorption peaks, the molecular structure and chemical composition of the sample can be determined. Its function is to effectively identify the molecular structures of organic and inorganic substances in drilling fluids and to promptly detect structural changes.

[0078] X-ray fluorescence spectrometry (XRF): When a sample is excited by X-rays, it emits characteristic X-ray fluorescence. By measuring the energy and intensity of this fluorescence, the types and contents of elements in the sample can be determined. Its function is to accurately detect the types and contents of elements in drilling fluids and to promptly detect changes in elemental composition.

[0079] An alarm is triggered when the atomic absorption spectrometer uploads data showing that the content of a single metallic element is greater than 10 ppm.

[0080] An alarm is triggered when the data uploaded by the infrared spectrometer shows a 20% change in the intensity of the absorption peak of a specific functional group in the drilling fluid.

[0081] An alarm is triggered when the data uploaded by the X-ray fluorescence spectrometer shows a change in the elemental content of the drilling fluid exceeding 10%.

[0082] The working principle of the inventive device in this embodiment is as follows:

[0083] In this embodiment, various sensors are distributed at key locations in the drilling fluid circulation system, continuously monitoring parameters such as the density, composition, viscosity, pH value, and temperature of the drilling fluid. For example, the density sensor measures the pressure difference of the drilling fluid multiple times per second and converts it into a density value; the rotating part of the viscosity sensor rotates continuously in the drilling fluid, determining the viscosity by measuring the rotational resistance. These sensors rapidly transmit the measured real-time data to the controller in the form of electrical signals.

[0084] After receiving a large amount of data from the sensors, the controller first preprocesses the data to remove outliers and noise. Then, it uses a built-in complex algorithm and pre-set drilling fluid performance standards to perform in-depth analysis of the data. For example, if the current density measurement value is lower than the set lower limit, the controller calculates the amount of weighting material that needs to be added; for pH deviations, the controller determines the type and quantity of acid-base adjusters that need to be added. Based on these analysis results, the controller makes a decision and generates corresponding mixing instructions.

[0085] After receiving instructions from the controller, the mixing unit precisely extracts the required amount of treatment agent from the metering pump and injects it into the drilling fluid through the feeding pipe and valves. Simultaneously, the agitator starts, stirring the drilling fluid at high speed to ensure rapid and uniform distribution of the newly added treatment agent. During the addition process, sensors continuously monitor the process, forming a feedback mechanism. If the parameters after the first addition do not reach the ideal range, the controller will issue adjustment instructions again until all parameters of the drilling fluid meet the set requirements. For example, after adding weighting material, the density sensor will provide real-time feedback of the new density value, and the controller will decide whether further addition is needed or to stop adding based on the feedback.

Claims

1. An adaptive drilling fluid intelligent mixing device, characterized in that: It includes a sensor array, controller, dispensing and execution array, and drilling fluid circulation system; The sensor group includes a density sensor, a viscosity sensor, a pH sensor, and a temperature sensor; The controller includes a digital-to-analog / analog-to-digital conversion module; an algorithm module; and a communication module. The mixing and execution unit includes a metering pump, a mixing device, a feeding pipeline, and valves; the metering pump is used to quantitatively add the specified raw materials to the mixing device; the mixing device is used to fully mix the drilling fluid; the feeding pipeline is used to provide different raw materials; the valves are installed on the feeding pipeline, and the valves' actions are controlled by a controller, which can control the opening and closing of the feeding pipeline; The density sensor is installed on the main pipeline of the drilling fluid circulation system near the drilling fluid outlet, and it is connected to the controller via a wire. The viscosity sensor is installed inside the drilling fluid mixing tank near the mixing blades and is connected to the controller via a wired connection. The pH sensor is installed in the drilling fluid storage tank and interacts with the controller wirelessly. There are no fewer than three temperature sensors, and these temperature sensors are respectively installed at the wellhead, the drilling fluid outlet, and the drilling fluid mixing tank of the drilling fluid circulation system; It also includes an analytical testing laboratory; the analytical testing laboratory is equipped with an atomic absorption spectrometer, an infrared spectrometer, and a X-ray fluorescence spectrometer; all three are connected to the controller via data cables; Atomic absorption spectrometers are used to determine the content of metallic elements and transmit the data to a controller. Infrared spectrometers are used to determine molecular structure and chemical composition and transmit this information to the controller. X-ray fluorescence spectrometer is used to measure the type and content of elements and transmit the data to the controller; An alarm is triggered when the atomic absorption spectrometer uploads data showing that the content of a single metallic element is greater than 10 ppm. An alarm is triggered when the data uploaded by the infrared spectrometer shows a 20% change in the intensity of the absorption peak of a specific functional group in the drilling fluid. An alarm is triggered when the data uploaded by the X-ray fluorescence spectrometer shows that the change in elemental content in the drilling fluid exceeds 10%. The method of using this intelligent drilling fluid mixing device includes the following steps: S1. The controller collects signals from the density sensor, viscosity sensor, pH sensor, and temperature sensor at a certain frequency; processes the signals through the digital-to-analog / analog-to-digital converter module; and inputs the processed signals into the algorithm module. S2. The algorithm module outputs different control commands to the dispatch execution group through the communication module based on the following different conditions: When the density sensor transmits a signal indicating that the density of the drilling fluid supplied to the drilling fluid circulation system is outside the range of 1.0 ~ 2.5 g / cm³, the corresponding control output will be activated to increase the amount of material or diluent used. When the viscosity sensor transmits a signal indicating that the current drilling fluid viscosity is outside the range of 5 to 100 mPa·s, the corresponding control output will be executed to add or reduce the treatment agent. When the pH sensor transmits a signal indicating that the pH value of the drilling fluid stored in the drilling fluid storage tank is outside the range of 6.5 to 9.0, the corresponding control output will be executed to add or reduce the acid-base regulator. When any temperature sensor uploads a signal indicating that the temperature of the drilling fluid at the corresponding location is outside the range of 5~80℃, the corresponding control output is dispatched to start the cooling or heating device.

2. The adaptive drilling fluid intelligent mixing device according to claim 1, characterized in that: The density sensor, viscosity sensor, pH sensor, and temperature sensor each output signals to the controller once per minute.

3. The adaptive drilling fluid intelligent mixing device according to claim 1, characterized in that: The sensor array also includes a gas chromatograph and a liquid chromatograph; the gas chromatograph and the liquid chromatograph are also connected to the controller via data cables; The sampling points of both the gas chromatograph and the liquid chromatograph are installed near the drilling fluid sample collection port, and both are connected to the controller via a data cable. Gas chromatographs are used to vaporize and separate samples using chromatographic columns, and to detect the composition and content of organic compounds, transmitting the data to the controller. Liquid chromatographs are used to sample, separate, and detect water-soluble components, and transmit the results to the controller.

4. The adaptive drilling fluid intelligent mixing device according to claim 3, characterized in that: An alarm is issued when the signal uploaded by the liquid chromatograph shows that the deviation of the water-soluble component content in the current drilling fluid is greater than 5%.