Offshore drilling well control automatic simulation system and operation debugging method thereof

Abstract

The invention relates to the field of offshore oilfield development, and discloses an offshore drilling well control automation simulation system and an operation debugging method thereof.The offshore drilling well control automation simulation system is characterized in that an upper computer is connected with a PLC control box through an optical fiber, and a controller transmits a control signal to the PLC control box through the optical fiber; the PLC control box transmits information of the sensors arranged at the key connection points to the controller through optical fibers; the throttle manifold and control device is connected with the PLC control box through an optical fiber to simulate fluid flowing out of the annulus to generate a throttling effect; the blowout preventer group and the control device are connected with the PLC control box through a cable; the liquid circulation simulation device is connected with the PLC control box through a cable and simulates liquid circulation during well drilling. The gas invasion annulus simulation device is connected with the PLC control box through a cable and simulates gas invasion annulus during well drilling; the simulation top drive and the simulation winch are connected with the PLC control box through cables until the simulation drill column is located at a preset position. According to the invention, manual misoperation probability and manual operation time can be reduced, and offshore drilling well control efficiency can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of offshore oil field development, and in particular to an offshore drilling well control automation simulation system and an operation and debugging method thereof. Background Art

[0002] With the increasing demand for crude oil and the steady production of developed oil fields on land, the safe and efficient development of offshore oil fields has become an important issue in the field of oil and gas drilling and production. Offshore oil fields, especially deepwater blocks, have the characteristics of ultra-high temperature and high pressure, complex wellbore structure and narrow pressure window, which can easily induce complex downhole accidents such as overflow during drilling. The treatment of overflow depends on well control shut-in and well control pressure. At present, conventional well control construction relies on the cooperation of multiple engineers and heavily relies on the experience of engineers. In addition, the operation of engineers during the construction process will cause large fluctuations in downhole pressure, which can easily break through the narrow pressure window and cause more serious downhole accidents.

[0003] In order to improve the efficiency of well control shut-in and well control pressure, manual shut-in and pressure are transformed into automated shut-in and pressure, and fast and efficient well control is achieved without the influence of engineer experience and misoperation, so as to curb the development of complex underground conditions. In recent years, many institutions and scholars at home and abroad have begun to study the field of well control automation and put forward relevant results. For well control automation shut-in, the foreign SafeInflux company determines whether an overflow condition occurs by monitoring the changes in mud in the active pool. If an overflow is detected, the top drive, mud pump, winch, throttle valve and blowout preventer group are automatically controlled through PLC control, realizing automated shut-in during drilling. Sichuan Qing Drilling in China realizes automatic control of five nodes, namely, turntable, mud pump, winch, blowout preventer and flat valve, by controlling the shut-in equipment in series under normal drilling. It can stop the turntable, pump, lift the drilling tool to the specified height, close the blowout preventer and open the flat valve within one minute. For well control automated well pressure reduction, the existing technology applies the dynamic well control method of controlled pressure drilling to deepwater block drilling, and proposes ideas for realizing automated well control in deepwater blocks; in view of the defects of low degree of automation of throttle valves in deepwater well control well pressure reduction, a throttle valve automatic control system was established based on the transfer function of the throttle valve automatic control system, and the system was simulated and analyzed for stability.

[0004] Through the above-mentioned research on the existing technologies, it can be found that the current automation and intelligence of well control shut-in and well control killing equipment are not high. The current well control shut-in automation system realizes the automatic control of shut-in equipment such as blowout preventers and hydraulic throttle valves, but the overall intelligent linkage still has room for improvement, especially for the automated shut-in of other working conditions such as drilling tools and empty wells. As for well control killing automation, only the implementation ideas and simulation models have been developed, and no corresponding equipment or system has been implemented and applied in deepwater drilling and production. Summary of the invention

[0005] In view of the above problems, the purpose of the present invention is to provide an offshore drilling well control automation simulation system and its operation and debugging method. By using well shut-in, well killing equipment and corresponding control devices, an offshore drilling well control automation simulation system is constructed, which can complete well control shut-in automation under multiple working conditions, and at the same time, can perform fine control on the throttle valve to complete the well control and well killing automation under overflow conditions, thereby ensuring the rapid and efficient implementation of offshore well control operations.

[0006] To achieve the above-mentioned purpose, in the first aspect, the technical solution adopted by the present invention is: an offshore drilling well control automation simulation system, which includes: a host computer, a PLC control box, a throttling manifold and a control device, a blowout preventer group and a control device, a liquid circulation simulation device, a gas intrusion annulus simulation device, and a simulated top drive and a simulated winch; the host computer has a controller including a data acquisition and monitoring module, a well control equipment identification module, a well control shut-in automation control module and a well control well pressure automation control module, and the host computer is connected to the PLC control box through an optical fiber, and the controller transmits the control signal to the PLC control box via the optical fiber; the PLC control box transmits the information of each sensor set at the key connection point to the controller via the optical fiber, and the data acquisition and monitoring module visualizes the corresponding data on the display interface; wherein, the key connection point is included in the model The inlet and outlet of the simulated annulus pipeline, and the connection between each device and the pipeline; the sensors include pressure sensors, flow sensors and optical sensors; the throttling manifold and the control device are connected to the PLC control box through optical fibers to produce a throttling effect on the fluid flowing out of the simulated annulus; the blowout preventer group and the control device are connected to the PLC control box through cables to control the switch of the blowout preventer; the liquid circulation simulation device is connected to the PLC control box through cables to pump liquid into the simulated annulus according to the set displacement to simulate the liquid circulation during drilling; the gas intrusion annulus simulation device is connected to the PLC control box through cables to simulate the overflow situation occurring during the drilling process to simulate the gas intrusion into the annulus during drilling; the simulated top drive and the simulated winch are connected to the PLC control box through cables to simulate the winch to lift or lower the simulated drill string.

[0007] Furthermore, the data acquisition and monitoring module is used to collect the operating data and images of each device during the system control process and visualize the collected data on the display interface;

[0008] The well control equipment identification module is used to process the collected operation data and images, and determine the operating status of each well control equipment according to the preset numerical conditions and machine vision model;

[0009] The well control and shut-in automation control module controls each well control device in sequence according to the preset equipment control sequence based on the data and identification results of the data acquisition and monitoring module and the well control equipment identification module, thus realizing the well control and shut-in automation;

[0010] The well control and well killing automation control module continuously controls the throttle valve opening according to the preset pressure curve based on the pressure and throttle valve opening data fed back by the data acquisition and monitoring module, thereby changing the pressure distribution in the simulated annulus and realizing well control and well killing automation.

[0011] Further, in the well control equipment identification module, the operation status of each well control equipment includes the identification of the operation status of the blowout preventer and the drill pipe position;

[0012] The machine vision model is a machine vision model trained based on the yolov8 vision model, which can judge the switch status of each blowout preventer and whether the drill pipe joint is in the blowout preventer in real time.

[0013] Furthermore, the method for identifying the operating status of the blowout preventer and the drill pipe position includes:

[0014] During well control shut-in and well control pressure, the data acquisition and monitoring module obtains real-time images of the activities of different BOP operating rods and drilling tools in the BOP group by installing optical sensors near the on-site BOP remote control console and on the fixed point frame above the annular BOP group;

[0015] The well control equipment recognition module extracts frames from the acquired real-time images and converts the video data into image data;

[0016] Through the machine vision model, the switch status of the annular blowout preventer, full-gate blowout preventer, and semi-gate blowout preventer, as well as whether the drill pipe joint is inside the blowout preventer can be identified in real time.

[0017] Further, the throttle manifold and control device include: a hydraulic control box, a throttle valve, a hydraulic pipeline and a throttle manifold;

[0018] The hydraulic control box is connected to the PLC control box through optical fiber, and a set volume of hydraulic oil is pumped out by receiving control signals;

[0019] The throttle valve is connected to the hydraulic control box through a hydraulic pipeline. The hydraulic oil pumped out controls the opening of the throttle valve through the hydraulic pipeline, generating a throttling pressure drop to the throttle manifold to produce a throttling effect on the fluid flowing out of the simulated annulus.

[0020] Further, the blowout preventer group and control device include: a blowout preventer control box, a blowout preventer remote control console, an annular blowout preventer and a double gate blowout preventer;

[0021] The BOP control box is connected to the PLC control box via a cable. By receiving the control signal, the solenoid valve inside the BOP control box will connect different gas paths, and then the air will enter the connected gas paths.

[0022] The remote control console of the blowout preventer is connected to the control box of the blowout preventer through a twenty-core gas circuit. The gas circuit connected to the solenoid valve inside the control box of the blowout preventer is one of the twenty-core gas circuits. The air enters the air reversing valve of the remote control console of the blowout preventer through the twenty-core gas circuit, and the corresponding hydraulic pipeline is connected by pushing the valve to reverse.

[0023] The annular blowout preventer, double-gate blowout preventer and blowout preventer remote control console are connected through multiple hydraulic pipelines. After the blowout preventer remote control console is connected to the corresponding hydraulic pipeline, the pressurized hydraulic oil enters the cavity of the corresponding blowout preventer and pushes it to move, thereby controlling the switch of the blowout preventer.

[0024] Further, the liquid circulation simulation device includes: a frequency converter, a plunger pump and a simulated annulus;

[0025] The inverter is connected to the PLC control box through a cable, and the inverter parameters are changed by receiving control signals;

[0026] The plunger pump is connected to the frequency converter via a cable. When the frequency converter parameters are changed, the displacement of the plunger pump changes.

[0027] The simulated annulus is connected to the plunger pump through a fixed hose. The plunger pump pumps liquid into the simulated annulus according to the set displacement to simulate the liquid circulation during drilling.

[0028] Further, the gas intrusion annulus simulation device includes: a gas valve, an air compressor and a gas storage tank;

[0029] The gas valve is connected to the PLC control box through a cable, connected to the air compressor and the gas storage tank through a gas pipeline, and connected to the simulated annulus in the liquid circulation simulation device through a fixed hose;

[0030] By receiving the control signal, the gas valve injects the pressurized air in the gas tank into the simulated annulus at a set flow rate. The injected air and the liquid injected by the plunger pump form a gas-liquid two-phase flow, thereby simulating the overflow situation that occurs during the drilling process.

[0031] Furthermore, the simulated top drive and the simulated winch are connected to the PLC control box through cables, and are used for the simulated winch to lift or lower the simulated drill string, including:

[0032] The simulated top drive and the simulated drawworks receive control signals, and the simulated top drive rotates the clamped simulated drill string to simulate the top drive work during drilling;

[0033] The simulated drawworks determines whether the drill bit joint is inside the blowout preventer through the well control equipment identification module in the controller, and generates a control signal to control the simulated drawworks to lift or lower the simulated drill string until the simulated drill string is in a preset position.

[0034] In the second aspect, the technical solution adopted by the present invention is: an operation and debugging method of an offshore drilling well control automation simulation system, which is implemented based on the above-mentioned offshore drilling well control automation simulation system, and comprises:

[0035] Build a simulation system, configure three-phase power supply, and install the host computer equipped with the controller, PLC control box, simulated annulus, throttle manifold and control device, blowout preventer group and control device, plunger pump and control device, air compressor and air storage tank, simulated top drive and simulated winch in sequence;

[0036] Pressure sensors and flow sensors are installed at the inlet and outlet of the pipeline simulating the annulus and at the key connection points between each device and the pipeline; industrial cameras are installed above the BOP remote control console and the annular BOP group as optical information sensors;

[0037] Use the controller to set the liquid flow and gas flow of the plunger pump, air compressor and air storage tank pumped into the simulated annulus to simulate overflow during drilling;

[0038] When overflow is observed through sensors or visually, the controller issues a one-button well shut-in command; the PLC control box sends stop operation signals to the simulated top drive and plunger pump in turn; after sending the stop operation signal of a device, each sensor will collect the operating status parameters of the relevant equipment. After collecting the data, the well control equipment identification module determines the operating and operation status of the simulated top drive and plunger pump according to the preset conditions;

[0039] When the simulated top drive and plunger pump completely stop running, the optical sensor in the data acquisition and monitoring module collects the image of the drill tool above the blowout preventer group, and the well control equipment recognition module determines whether the drill tool joint is inside the blowout preventer based on the machine vision model; according to the recognition result, the PLC control box sends a control signal to the simulated winch to lift and lower the drill tool until the recognition result shows that the drill tool joint is not inside the blowout preventer, and then executes the next step;

[0040] When the simulated top drive, plunger pump and simulated winch control are completed, the PLC control box controls the throttle valve in the throttle manifold and the annular blowout preventer and double gate blowout preventer in the blowout preventer group in sequence according to the well shut-in procedure;

[0041] After completing the well control shut-in automation process, the PLC control box first closes the gas valve in front of the air compressor to simulate overflow stop; according to the set well control well pressure curve, the throttle valve opening is continuously controlled by controlling the hydraulic control box. The change of the throttle valve opening will affect the pressure distribution in the simulated annulus, thereby completing the well control well pressure automation process.

[0042] The present invention adopts the above technical solution, which has the following advantages:

[0043] The simulation system of the present invention can simulate the occurrence of overflow, and can obtain the operating status of certain key well control equipment without the need for cooperation between engineers during the well control process. At the same time, the system will automatically control the switch status of the simulated top drive and plunger pump according to the identified status, and reasonably lift and lower the drilling tools, and finally control the switch status of the throttle valve of the throttle manifold and the annular blowout preventer and gate blowout preventer of the blowout preventer group; after completing the well control shut-in process, the throttle valve opening is continuously controlled according to the well control curve designed by the engineer to complete the well control well control automation process. The present invention can complete the well control equipment status identification, well control shut-in and well control well control automation control without the need for engineer coordination and control, can minimize the probability of manual misoperation and manual operation time, improve the efficiency of offshore drilling well control, and has a very broad prospect. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, they should not be understood as limitations of the present invention. They can obtain other drawings based on these drawings without paying any creative work.

[0045] Figure 1 It is a logic diagram of the modules of the offshore drilling well control automation simulation system in the embodiment of the present invention;

[0046] Figure 2 This is a hardware connection diagram of the offshore drilling well control automation simulation system in an embodiment of the present invention;

[0047] Figure 3 Schematic diagram of an offshore drilling well control automation simulation system in an embodiment of the present invention;

[0048] Figure 4 This is a flow chart for identifying the operating status of the blowout preventer and drill pipe positions in the well control equipment identification module of the offshore drilling well control automation simulation system in an embodiment of the present invention. DETAILED DESCRIPTION

[0049] As major oil fields increase their efforts to develop deep-water offshore oil fields and demand for automation and intelligent transformation of well control equipment, and in view of the current reality that well control is extremely dependent on engineer experience and multi-person collaborative operation when overflow occurs in deep-water offshore blocks, the present invention proposes an offshore drilling well control automation simulation system and its operation and debugging method, including: firstly, a host computer equipped with a controller, a PLC control box, a simulated annulus, a throttling manifold and a control device, a blowout preventer group and a control device, a plunger pump and a control device, an air compressor and an air storage tank, a simulated top drive and a simulated winch are set up indoors in sequence, and then an industrial camera is set up above the blowout preventer remote control console and the blowout preventer group as an optical information sensor, and a pressure and flow sensor is set in the connected fluid pipeline. Based on the above equipment, firstly, the controller controls the plunger pump and the air compressor to pump liquid and gas into the simulated annulus to simulate overflow during drilling, and then the well control shut-in automation and well control well killing automation processes are completed through the interaction of various pressure, flow, optical sensors and equipment information.

[0050] The present invention can automatically monitor the operating status of each well-shut-in device when overflow occurs in offshore drilling, and automatically control the well-shut-in device according to the built-in well-shut-in steps to complete the well-control well-shut-in steps. After the well is shut in, the system automatically controls the throttle valve according to the well-shut-in pressure curve set by the driller to complete the well-control well-shut-in steps. The present invention refers to automatic control theory, data mining and computer vision theory, and has a reliable principle and rapid control response. As the basis for promoting offshore drilling well control automation, it can provide certain guiding significance for well control automation and has broad application prospects.

[0051] In order to make the purpose, technical solution and advantages of the embodiment of the present invention clearer, the technical solution of the embodiment of the present invention will be clearly and completely described below in conjunction with the drawings of the embodiment of the present invention. Obviously, the described embodiment is a part of the embodiment of the present invention, not all of the embodiments. Based on the described embodiment of the present invention, all other embodiments obtained by ordinary technicians in this field belong to the scope of protection of the present invention.

[0052] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit exemplary embodiments according to the present invention. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprising" and / or "including" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0053] In one embodiment of the present invention, an offshore drilling well control automation simulation system is provided. Based on PLC control and automatic control theory, the offshore drilling well control automation simulation system is constructed using the well control equipment after automation transformation. The system can monitor and automatically control the top drive, drawworks, mud pump, blowout preventer and throttle valve during offshore drilling well control, and complete well control shut-in and well control pressure on behalf of field engineers, thereby preventing manual misoperation during the well control process and improving the efficiency of well control.

[0054] Specifically, in this embodiment, Figures 1 to 3 As shown, the offshore drilling well control automation simulation system includes a host computer, a PLC control box, a throttling manifold and a control device, a blowout preventer group and a control device, a liquid circulation simulation device, a gas intrusion annulus simulation device, and a simulated top drive and a simulated winch; all the equipment and connecting cables constitute the offshore drilling well control automation simulation system of the present invention.

[0055] The host computer has a controller including a data acquisition and monitoring module, a well control equipment identification module, a well control shut-in automation control module and a well control pressure automation control module, and the host computer is connected to the PLC control box through optical fiber. The controller transmits the control signal to the PLC control box through optical fiber; the PLC control box transmits the information of each sensor set at the key connection point to the controller through optical fiber, and the data acquisition and monitoring module visualizes the corresponding data on the display interface. Among them, the key connection points include the pipeline inlet and outlet of the simulated annulus, and the connection between each device and the pipeline; each sensor includes a pressure sensor, a flow sensor, and an optical sensor, such as Figure 3 shown.

[0056] The throttling manifold and the control device are connected to the PLC control box through optical fiber, and are used to produce a throttling effect on the fluid flowing out of the simulated annulus.

[0057] The blowout preventer group and control device are connected to the PLC control box through cables to control the switch of the blowout preventer.

[0058] The liquid circulation simulation device is connected to the PLC control box through a cable and is used to pump liquid into the simulated annulus according to the set displacement to simulate the liquid circulation during drilling.

[0059] The gas intrusion annulus simulation device is connected to the PLC control box through a cable and is used to simulate the overflow situation occurring during the drilling process to simulate the gas intrusion into the annulus during drilling.

[0060] The simulated top drive and simulated drawworks are connected to the PLC control box through cables. By receiving the control signal, the simulated top drive rotates the clamped simulated drill string to simulate the top drive work during drilling; the simulated drawworks determines whether the drill tool joint is inside the blowout preventer through the well control equipment identification module in the controller, and generates a control signal to control the simulated drawworks to lift or lower the simulated drill string until the simulated drill string is in the preset position.

[0061] In the above embodiment, the data acquisition and monitoring module, the well control equipment identification module, the well control shut-in automation control module and the well control killing automation control module in the controller are specifically:

[0062] The data acquisition and monitoring module is used to collect the operating data and images of each device during the system control process, and visualize the collected data on the display interface.

[0063] The well control equipment identification module is used to process the collected operation data and images, and determine the operating status of each well control equipment based on preset numerical conditions and machine vision models.

[0064] The well control and shut-in automation control module controls each well control equipment in sequence according to the preset equipment control sequence based on the data and identification results of the data acquisition and monitoring module and the well control equipment identification module to realize the well control and shut-in automation.

[0065] The well control and well killing automation control module continuously controls the throttle valve opening according to the preset pressure curve based on the pressure, throttle valve opening and other data fed back by the data acquisition and monitoring module, so as to change the pressure distribution in the simulated annulus and realize the well control and well killing automation.

[0066] In this embodiment, in the well control equipment identification module, the operating status of each well control equipment includes the identification of the blowout preventer and the drill pipe position. The machine vision model is a machine vision model trained based on the yolov8 vision model that can judge the switch status of each blowout preventer and whether the drill pipe joint is in the blowout preventer in real time.

[0067] like Figure 4 As shown, the method for identifying the operating status of the blowout preventer and the drill pipe position includes the following steps:

[0068] (1) During well control shut-in and well control pressure, the data acquisition and monitoring module sets up optical sensors on a fixed point frame near the on-site BOP remote control console and above the annular BOP group, and uses the optical sensors to obtain real-time images of the activities of different BOP operating rods and drilling tools in the BOP group.

[0069] (2) The well control equipment recognition module extracts frames from the acquired real-time images and converts the video data into image data.

[0070] (3) Through the machine vision model, the switch status of the annular blowout preventer, the full-gate blowout preventer, and the semi-gate blowout preventer, as well as whether the drill pipe joint is inside the blowout preventer can be identified in real time without the need for manual observation.

[0071] In the above embodiment, if Figure 2 As shown, the throttle manifold and control device include: a hydraulic control box, a throttle valve, a hydraulic pipeline and a throttle manifold, etc.

[0072] The hydraulic control box is connected to the PLC control box through optical fiber, and a set volume of hydraulic oil is pumped out by receiving control signals. The throttle valve is connected to the hydraulic control box through a hydraulic pipeline, and the pumped hydraulic oil controls the opening of the throttle valve through the hydraulic pipeline, generating a throttling pressure drop to the throttling manifold, thereby generating a throttling effect on the fluid flowing out of the simulated annulus.

[0073] In the above embodiments, the BOP group and the control device include: a BOP control box, a BOP remote control console, an annular BOP and a double-gate BOP.

[0074] The BOP control box is connected to the PLC control box through a cable. By receiving the control signal, the solenoid valve inside the BOP control box will connect different air circuits, and then the air will enter the connected air circuit. The remote control console of the BOP is connected to the BOP control box through a twenty-core air circuit. The air circuit connected by the solenoid valve inside the BOP control box is one of the twenty-core air circuits. The air enters the air reversing valve of the remote control console of the BOP through the twenty-core air circuit, and the corresponding hydraulic pipeline is connected by pushing the valve to switch. The annular BOP, double-gate BOP and remote control console of the BOP are connected through multiple hydraulic pipelines. After the remote control console of the BOP is connected to the corresponding hydraulic pipeline, the pressurized hydraulic oil will enter the cavity of the corresponding BOP and push the movement to control the switch of the BOP.

[0075] In the above embodiments, the liquid circulation simulation device includes: a frequency converter, a plunger pump, a simulated annulus, etc.

[0076] The inverter is connected to the PLC control box through a cable, and the inverter parameters are changed by receiving control signals. The plunger pump is connected to the inverter through a cable, and when the inverter parameters are changed, the displacement of the plunger pump will change. The simulated annulus is connected to the plunger pump through a fixed hose, and the plunger pump pumps liquid into the simulated annulus according to the set displacement to simulate the liquid circulation during drilling.

[0077] In the above-mentioned embodiment, the gas intrusion annulus simulation device includes: a gas valve, an air compressor and a gas storage tank, etc.

[0078] The gas valve is connected to the PLC control box through a cable, connected to the air compressor and gas tank through a gas pipeline, and connected to the simulated annulus in the liquid circulation simulation device through a fixed hose. By receiving the control signal, the gas valve injects the pressurized air in the gas tank into the simulated annulus at a set flow rate, and the injected air and the liquid injected by the plunger pump form a gas-liquid two-phase flow, thereby simulating the overflow situation that occurs during the drilling process, and realizing the simulation of gas intrusion into the annulus during drilling.

[0079] In one embodiment of the present invention, a method for running and debugging an offshore drilling well control automation simulation system is provided. The method is implemented based on the offshore drilling well control automation simulation system in the above embodiments. Figure 3 As shown, it clearly shows Figure 2 The relative positions of the devices and the connecting cables and the setting positions of the sensors between the devices. In this embodiment, the operation debugging method includes the following steps:

[0080] Step 1) Configure 380V three-phase power supply in the laboratory, and install the host computer equipped with the controller, PLC control box, simulated annulus, throttling manifold and control device, blowout preventer group and control device, plunger pump and control device, air compressor and air storage tank, simulated top drive 1 and simulated winch 2 in sequence.

[0081] Step 2) Pressure sensors 3 and flow sensors 4 are set at the inlet and outlet of the pipeline simulating the annulus and the key connection points between each device and the pipeline; industrial cameras are set above the BOP remote control console and the annular BOP group 5 as optical information sensors.

[0082] Step 3) After the system is built, run and debug the system functions: Use the controller to set the plunger pump, air compressor and air tank to pump liquid and gas flow into the simulated annulus to simulate overflow during drilling.

[0083] Step 4) When overflow is observed through sensors or visual observation, the controller issues a one-button well shut-in command; the PLC control box sends a stop signal to the simulated top drive 1 and the plunger pump in turn. After sending a stop signal for a device, the sensors in the system's data acquisition and monitoring module will collect the operating status parameters of the relevant equipment. For example, the simulated top drive 1 will collect the speed and torque of the motor, and the plunger pump will collect the pump pressure and displacement. After collecting the above data, the well control equipment identification module determines the operation and operating status of the simulated top drive 1 and the plunger pump according to the preset conditions.

[0084] Step 5), when the simulated top drive 1 and the plunger pump completely stop running, the optical sensor in the data acquisition and monitoring module will collect the drilling tool image above the blowout preventer group 5, and the well control equipment recognition module will determine whether the drilling tool joint is inside the blowout preventer based on the machine vision model. According to the recognition result, the PLC control box sends a control signal to the simulated winch 2 to lift and lower the drilling tool until the recognition result is that the drilling tool joint is not inside the blowout preventer, so that the simulated drill string 10 is in the preset position and the next control step is executed.

[0085] Step 6), when the control of the simulated top drive 1, the plunger pump and the simulated winch 2 is completed, the PLC control box will control the throttle valve 6 in the throttle manifold 9 and the annular blowout preventer 7 and the double gate blowout preventer 8 in the blowout preventer group 5 in sequence according to the well shut-in steps.

[0086] When controlling the throttle valve 6, the opening of the throttle valve 6 is collected through the hydraulic control box until the throttle valve 6 is controlled in place, and then the blowout preventer is controlled.

[0087] When controlling the blowout preventer, the optical sensor in the data acquisition and monitoring module will collect the image of the operating handle of the remote control console of the blowout preventer. The well control equipment identification module determines the switch status of each blowout preventer based on the machine vision model. The system will close the annular blowout preventer 7 and the double-gate blowout preventer 8 in turn according to the identification results, and then open the annular blowout preventer 7 to complete the well control shut-in automation process.

[0088] Step 7), after the well control shut-in automation process is completed, the PLC control box first closes the gas valve in front of the air compressor to simulate the overflow stop. According to the set well control well killing pressure curve, the throttle valve 6 opening is continuously controlled by controlling the hydraulic control box. The change of the throttle valve 6 opening will affect the pressure distribution in the simulated annulus, thereby completing the well control well killing automation process.

[0089] In summary, the present invention is based on PLC control and automatic control theory, and uses the well control equipment after automation transformation to construct an offshore drilling well control automation simulation system. The status of each well control equipment is collected and monitored by sensors, and the well control shut-in and well control pressure automation processes are completed based on this. In the process, the top drive, winch, mud pump, blowout preventer and throttle valve can be monitored and automatically controlled. Therefore, the present invention can complete the well control equipment status identification, well control shut-in and well control pressure automation control without the need for engineers to coordinate and control, can minimize the probability of manual misoperation and manual operation time, improve the efficiency of offshore drilling well control, and has a very broad prospect.

[0090] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. An offshore drilling well control automation simulation system, characterized in that: include: Host computer, PLC control box, throttle manifold and control device, blowout preventer group and control device, liquid circulation simulation device, gas intrusion annulus simulation device, simulated top drive and simulated winch; The host computer has a controller including a data acquisition and monitoring module, a well control equipment identification module, a well control shut-in automation control module and a well control well killing automation control module, and the host computer is connected to the PLC control box through an optical fiber, and the controller transmits the control signal to the PLC control box through the optical fiber; the PLC control box transmits the information of each sensor set at the key connection point to the controller through the optical fiber, and the data acquisition and monitoring module visualizes the corresponding data on the display interface; wherein, the key connection points include the pipeline inlet and outlet of the simulated annulus, and the connection between each device and the pipeline; each sensor includes a pressure sensor, a flow sensor and an optical sensor; The throttling manifold and control device are connected to the PLC control box through optical fiber to produce a throttling effect on the fluid flowing out of the simulated annulus; The BOP group and control device are connected to the PLC control box through cables to control the switch of the BOP; The liquid circulation simulation device is connected to the PLC control box through a cable and is used to pump liquid into the simulated annulus according to the set displacement to simulate the liquid circulation during drilling; The gas intrusion annulus simulation device is connected to the PLC control box through a cable to simulate the overflow situation that occurs during the drilling process, so as to simulate the gas intrusion into the annulus during drilling; The simulated top drive and the simulated winch are connected to the PLC control box through cables, and the simulated winch is used to lift or lower the simulated drill string.

2. The offshore drilling well control automation simulation system as claimed in claim 1, characterized in that: The data acquisition and monitoring module is used to collect the operating data and images of each device during the system control process, and visualize the collected data on the display interface; The well control equipment identification module is used to process the collected operation data and images, and determine the operating status of each well control equipment according to the preset numerical conditions and machine vision model; The well control and shut-in automation control module controls each well control device in sequence according to the preset equipment control sequence based on the data and identification results of the data acquisition and monitoring module and the well control equipment identification module, thus realizing the well control and shut-in automation; The well control and well killing automation control module continuously controls the throttle valve opening according to the preset pressure curve based on the pressure and throttle valve opening data fed back by the data acquisition and monitoring module, thereby changing the pressure distribution in the simulated annulus and realizing well control and well killing automation.

3. The offshore drilling well control automation simulation system as claimed in claim 2, characterized in that: In the well control equipment identification module, the operating status of each well control equipment includes the identification of the operating status of the blowout preventer and the drill pipe position; The machine vision model is a machine vision model trained based on the yolov8 vision model, which can judge the switch status of each blowout preventer and whether the drill pipe joint is in the blowout preventer in real time.

4. The offshore drilling well control automation simulation system as claimed in claim 3, characterized in that: The method for identifying the operating status of the BOP and drill pipe position includes: During well control shut-in and well control pressure, the data acquisition and monitoring module obtains real-time images of the activities of different BOP operating rods and drilling tools in the BOP group by installing optical sensors near the on-site BOP remote control console and on the fixed point frame above the annular BOP group; The well control equipment recognition module extracts frames from the acquired real-time images and converts the video data into image data; Through the machine vision model, the switch status of the annular blowout preventer, full-gate blowout preventer, and semi-gate blowout preventer, as well as whether the drill pipe joint is inside the blowout preventer can be identified in real time.

5. The offshore drilling well control automation simulation system as claimed in claim 1, characterized in that: The throttle manifold and control device include: a hydraulic control box, a throttle valve, a hydraulic pipeline and a throttle manifold; The hydraulic control box is connected to the PLC control box through optical fiber, and a set volume of hydraulic oil is pumped out by receiving control signals; The throttle valve is connected to the hydraulic control box through a hydraulic pipeline. The hydraulic oil pumped out controls the opening of the throttle valve through the hydraulic pipeline, generating a throttling pressure drop to the throttle manifold to produce a throttling effect on the fluid flowing out of the simulated annulus.

6. The offshore drilling well control automation simulation system according to claim 1, characterized in that: The BOP group and control device include: BOP control box, BOP remote control console, annular BOP and double gate BOP; The BOP control box is connected to the PLC control box via a cable. By receiving the control signal, the solenoid valve inside the BOP control box will connect different gas paths, and then the air will enter the connected gas paths. The remote control console of the blowout preventer is connected to the control box of the blowout preventer through a twenty-core gas circuit. The gas circuit connected to the solenoid valve inside the control box of the blowout preventer is one of the twenty-core gas circuits. The air enters the air reversing valve of the remote control console of the blowout preventer through the twenty-core gas circuit, and the corresponding hydraulic pipeline is connected by pushing the valve to reverse. The annular blowout preventer, double-gate blowout preventer and blowout preventer remote control console are connected through multiple hydraulic pipelines. After the blowout preventer remote control console is connected to the corresponding hydraulic pipeline, the pressurized hydraulic oil enters the cavity of the corresponding blowout preventer and pushes it to move, thereby controlling the switch of the blowout preventer.

7. The offshore drilling well control automation simulation system as claimed in claim 1, characterized in that: The liquid circulation simulation device includes: a frequency converter, a plunger pump and a simulated annulus; The inverter is connected to the PLC control box through a cable, and the inverter parameters are changed by receiving control signals; The plunger pump is connected to the frequency converter via a cable. When the frequency converter parameters are changed, the displacement of the plunger pump changes. The simulated annulus is connected to the plunger pump through a fixed hose. The plunger pump pumps liquid into the simulated annulus according to the set displacement to simulate the liquid circulation during drilling.

8. The offshore drilling well control automation simulation system as claimed in claim 1, characterized in that: The gas intrusion annulus simulation device includes: a gas valve, an air compressor and a gas storage tank; The gas valve is connected to the PLC control box through a cable, connected to the air compressor and the gas storage tank through a gas pipeline, and connected to the simulated annulus in the liquid circulation simulation device through a fixed hose; By receiving the control signal, the gas valve injects the pressurized air in the gas tank into the simulated annulus at a set flow rate. The injected air and the liquid injected by the plunger pump form a gas-liquid two-phase flow, thereby simulating the overflow situation that occurs during the drilling process.

9. The offshore drilling well control automation simulation system as claimed in claim 1, characterized in that: The simulated top drive and simulated winch are connected to the PLC control box through cables, and are used to simulate the winch to lift or lower the simulated drill string, including: The simulated top drive and the simulated drawworks receive control signals, and the simulated top drive rotates the clamped simulated drill string to simulate the top drive work during drilling; The simulated drawworks determines whether the drill bit joint is inside the blowout preventer through the well control equipment identification module in the controller, and generates a control signal to control the simulated drawworks to lift or lower the simulated drill string until the simulated drill string is in a preset position.

10. An operation and debugging method of an offshore drilling well control automation simulation system, implemented based on the offshore drilling well control automation simulation system according to any one of claims 1 to 9, characterized in that: include: Build a simulation system, configure three-phase power supply, and install the host computer equipped with the controller, PLC control box, simulated annulus, throttle manifold and control device, blowout preventer group and control device, plunger pump and control device, air compressor and air storage tank, simulated top drive and simulated winch in sequence; Pressure sensors and flow sensors are installed at the inlet and outlet of the pipeline simulating the annulus and at the key connection points between each device and the pipeline; industrial cameras are installed above the BOP remote control console and the annular BOP group as optical information sensors; Use the controller to set the liquid flow and gas flow of the plunger pump, air compressor and air storage tank pumped into the simulated annulus to simulate overflow during drilling; When overflow is observed through sensors or visually, the controller issues a one-button well shut-in command; the PLC control box sends stop operation signals to the simulated top drive and plunger pump in turn; after sending the stop operation signal of a device, each sensor will collect the operating status parameters of the relevant equipment. After collecting the data, the well control equipment identification module determines the operating and operation status of the simulated top drive and plunger pump according to the preset conditions; When the simulated top drive and plunger pump completely stop running, the optical sensor in the data acquisition and monitoring module collects the image of the drill tool above the blowout preventer group, and the well control equipment recognition module determines whether the drill tool joint is inside the blowout preventer based on the machine vision model; according to the recognition result, the PLC control box sends a control signal to the simulated winch to lift and lower the drill tool until the recognition result shows that the drill tool joint is not inside the blowout preventer, and then executes the next step; When the simulated top drive, plunger pump and simulated winch control are completed, the PLC control box controls the throttle valve in the throttle manifold and the annular blowout preventer and double gate blowout preventer in the blowout preventer group in sequence according to the well shut-in procedure; After completing the well control shut-in automation process, the PLC control box first closes the gas valve in front of the air compressor to simulate overflow stop; according to the set well control well pressure curve, the throttle valve opening is continuously controlled by controlling the hydraulic control box. The change of the throttle valve opening will affect the pressure distribution in the simulated annulus, thereby completing the well control well pressure automation process.

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