Remote control system and method for under-pressure operation lifting and lowering pipe

Abstract

The invention belongs to the technical field of petroleum automation under-pressure well repair oil pipe lifting and lowering devices, and discloses an under-pressure operation pipe lifting and lowering remote control system and method.The system is composed of an industrial personal computer CPU, a distributed PLC, an I / O module and a CAN bus communication mode, and the industrial personal computer CPU serves as a main station; the distributed PLC serves as a slave station and is responsible for data acquisition of the functional units, meanwhile, data returned by the master station is used for sending a control instruction to an execution mechanism of the corresponding functional unit, corresponding actions are completed, the control system is a PLC program control system, and the PLC program control system is connected with the master station. A proportional hydraulic valve group is controlled through a sensor, a program language and CAN bus communication, movement of a terminal element is achieved, an operator is transferred from a wellhead platform to a ground control room, the working environment of the operator is improved, and life safety is guaranteed; the labor intensity of operators is greatly reduced, and the operation safety is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of oil automation pressure - maintained well workover tubing running and pulling device, and is a remote control system and method for tubing running and pulling during pressure - maintained operation. Background Art

[0002] Currently in the oil well workover industry in China, according to whether the construction process is pressure - maintained, it can be divided into pressure - maintained well workover (i.e., non - kill well) and non - pressure - maintained well workover. Currently, 80% of the work in pressure - maintained well workover operations is tubing running and pulling operations. In the existing traditional pressure - maintained operation tubing running and pulling operation console, it is set on the wellhead platform, and the operator needs to manually operate above the wellhead platform. During the entire tubing running and pulling operation, the operator needs to operate 8 - 12 valve groups with different functions in a certain logical order. Once there is a problem in any step, it will cause a safety accident. The height of the wellhead platform from the ground ranges from 8 meters to 12 meters. When the operator operates on the platform, in case of an accident, it is very difficult to quickly and safely evacuate from the platform. Currently, some manufacturers have moved the operation console down to the ground and remotely control it through an operation handle. Although it solves the safety problem of people, because it is far from the wellhead, the operator cannot timely and accurately judge the running state of the tubing string, does not know the position of the tubing collar, and is very likely to mis - clamp the tubing collar. Moreover, when the operator operates repetitive actions for a long time, it is very easy to get fatigued, resulting in construction accidents.

[0003] Domestic CN202221291069 discloses a non - kill well data acquisition system. This system only collects equipment information and fails to apply the data to the actual construction of pressure - maintained operations. Summary of the Invention

[0004] In order to solve the above problems, the present invention provides a remote control method for tubing running and pulling during pressure - maintained operation, which is a control method for tubing running and pulling operations using an automated operation method for the first time in the industry. This system is applied to an automated pressure - maintained operation device. Compared with the traditional operation method, the use of this method can transfer the operator from the wellhead platform to the ground control room, improve the operator's working environment, and ensure life safety; at the same time, through the remote control module, it is convenient to remotely and automatically control each actuator valve group, thereby realizing automatic tubing running and pulling operations, greatly reducing the labor intensity of the operator, and improving the safety of the operation.

[0005] The above object of the present invention is achieved by the following technical solutions:

[0006] This system is applied to the automated workover rig under pressure, which is divided into an automated control method for pipe lifting and an automated control method for pipe lowering. The two control methods are integrated into a set of software and hardware systems, and a remote control method for the automated workover rig under pressure is composed of an industrial computer CPU, a distributed PLC controller, I / O modules (DI / AI), and a CAN bus communication method. This method separately collects and centrally controls the data of each functional unit. When programming, the program variable structures of each functional unit do not affect each other, and when the number of input and output ports of each functional unit changes, it does not affect the overall I / O allocation of the industrial computer CPU master station.

[0007] The industrial computer CPU mentioned above serves as the master station, centrally processes all the collected data, and returns the processed data to each functional unit.

[0008] The distributed PLC controller mentioned above serves as a slave station, is responsible for collecting the data of each functional unit, and at the same time sends control instructions to the actuators of this functional unit for the data returned by the master station to complete corresponding actions.

[0009] The functional units mentioned above include an automatic operation functional unit, a remote control functional unit, a power system functional unit, a pipe string lifting and lowering functional unit, a make-up and break-out functional unit, a pipe string transfer functional unit, etc.

[0010] The automatic operation functional unit is set on the console in the remote control room. Various function switches and display screens are set on the console surface. The switches are connected to the slave station through I / O modules, and the display screens are connected to the slave station through Ethernet. The master station is integrated in the console and communicates with each slave station through the CAN bus.

[0011] The remote control functional unit is composed of a receiving unit and a transmitting unit. The receiving unit is fixed at an appropriate position of the equipment to facilitate receiving signals; the transmitting unit is an independent and movable control unit, which transmits wirelessly with the receiving unit, and the receiving unit is connected to the master station through the CAN bus.

[0012] The power system functional unit is set in the power house. Its main functions are to remotely control the speed regulation and start / stop of the engine. At the same time, by collecting the oil temperature and liquid level of the hydraulic oil tank, the system is protected safely. The entire functional unit is connected to the master station through the CAN bus.

[0013] The pipe string tripping function unit is installed on the derrick and consists of a wellhead pressure detection device, a pipe string coupling detection device, a working state detection device for the slip blowout preventer, a lifting cylinder displacement detection device, etc. By detecting the wellhead pressure in real time, it automatically calculates the required lifting and lowering amplitude. Through the pipe string coupling detection device, it can accurately capture the real-time data of the pipe string coupling and automatically calculate the number of trips according to the lifting and lowering amplitude. The working state detection device of the slip blowout preventer can reflect the current working state of the slip blowout preventer in real time, and through program automatic logic switching, it cooperates with the lifting cylinder to complete the pipe string lifting or lowering operation. The lifting cylinder position detection device can reflect the current height information of the lifting cylinder in real time. Through the automatic operation of the program, the remote automatic tripping of the pipe string is realized. When manually performing the remote tripping of the pipe string, a running instruction is sent through the remote control, and the operator manually switches each action through the remote data display to realize the manual remote tripping of the pipe string.

[0014] The make-up and break-out function unit is installed on the hydraulic tongs. Through the revolution counting device and torque measuring device of the hydraulic tongs, it can accurately complete the automatic make-up and break-out operations of the pipe string.

[0015] The pipe string transfer function unit is installed on the pipe transporter. Through functional sensors such as the manipulator lifting position sensor, manipulator clamping sensor, and inclination sensor installed on the pipe transporter, the data is transmitted to the slave station, and the transfer of the pipe string is automatically completed according to the functions of the slave station.

[0016] The control system is a PLC program control system. Through sensors, programming languages, and CAN bus communication, it controls the proportional hydraulic valve group to realize the movement of the terminal components, thereby realizing the remote control of the pipe string tripping during the workover operation.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0018] The use of this method can transfer the operator from the wellhead platform to the ground control room, improve the operator's working environment, and ensure life safety. At the same time, through the remote control module, it is convenient to realize the remote automatic control of each actuator group, thereby realizing the automatic tripping of the pipe string, greatly reducing the labor intensity of the operator, and improving the safety of the operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The above is only an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention, the following further detailed description of the present invention is provided in conjunction with the drawings and specific embodiments.

[0020] Appendix Figure 1 is a schematic composition diagram of a remote control method for tripping pipes during workover operations with pressure;

[0021] Appendix Figure 2It is a schematic diagram of the circuit structure of the automatic operation unit;

[0022] Appendix Figure 3 It is a schematic diagram of the circuit structure of the power system unit;

[0023] Appendix Figure 4 It is a schematic diagram of the circuit structure of the pipe string tripping unit;

[0024] Appendix Figure 5 It is a schematic diagram of the circuit structure of the make-up and break-out unit;

[0025] Appendix Figure 6 It is a schematic diagram of the circuit structure of the pipe string transfer unit;

[0026] Appendix Figure 7 It is a schematic diagram of the circuit structure of the remote control unit. Detailed implementation manner

[0027] As shown in the accompanying drawings, the present invention provides a remote control system and method for tripping pipes under pressure, and the system is based on an automated under-pressure operation device. The remote control method for tripping pipes under pressure includes an industrial control computer master station and multiple slave stations (6 are used in this case), and the connection is achieved through a CAN bus (in this case, a master-slave connection method is adopted, and a ring connection method can also be adopted, both of which are within the protection scope of the present invention). Each slave station is installed near the actuator as close as possible and corresponds to different functional units. In this case, 6 slave stations are used, namely slave station 01, slave station 02, slave station 03, slave station 04, slave station 05, and slave station 06, and the corresponding functional units are: automatic operation unit, power system unit, pipe string tripping unit, make-up and break-out unit, pipe string transfer unit, and remote control unit.

[0028] The specific method is as follows: The console in the control room is used as the industrial control computer master station, and a slave station 01 that separately processes various switch knobs on the console is set. The slave station is composed of a digital input module, an analog input module, a PLC controller, and a communication interface. Various function switches and knobs on the console are connected to the PLC controller through the digital input module and the analog input module. One or more display screens are set on the console for displaying the operation page, and are connected to the PLC controller of the slave station 01 through an Ethernet communication interface. The slave station 01 is connected to the industrial control computer master station through a CAN communication interface.

[0029] The I / O slave station 02 of the power system unit connects the engine start switch of the power system to the PLC controller of the slave station 02 through the digital input module interface, forming a dual-control switch with the engine start / stop switch in the slave station 01 to achieve proximal and remote start / stop of the engine. At the same time, the engine speed control knob is also connected to the PLC controller of the slave station 02 through the analog module interface, working with the engine speed control knob of the slave station 01 to achieve the remote speed control function of the engine. At the same time, to ensure the safe operation of the power system, switch quantity signals such as the hydraulic oil temperature and hydraulic oil level in the hydraulic oil tank are connected to the PLC controller of the slave station 02 through the digital input module, controlling the power system to issue an alarm when the oil temperature is too high or the liquid level is too low, and cutting off the power output when necessary to ensure the safe operation of the equipment. At the same time, the accumulator pressure sensor set in the power system is connected to the PLC through the analog input module, and the stamping function can be automatically started when the accumulator pressure is lower than the set value. All data is connected to the industrial control computer master station through the CAN communication interface to achieve remote control.

[0030] The I / O slave station 03 of the pipe string tripping unit connects the data of the wellhead pressure sensor to the PLC controller of the slave station 03 through the analog input module, and determines the tripping amplitude of the pipe string according to the pressure magnitude; connects the data measured by the pipe coupling detection sensor to the PLC controller of the slave station 03 through the analog input module, determines whether the pipe coupling passes the detection position according to the data change, and applies this result to the automatic tripping process of the pipe string; connects the displacement sensor of the lifting system to the PLC controller of the slave station 03 through the analog input module to monitor the position of the traveling beam of the lifting system in real time; connects the slip blowout preventer switch to the PLC controller of the slave station 03 through the digital input module. All data is connected to the industrial control computer master station through the CAN communication interface, and according to the position states of each slip and blowout preventer, combined with the data of other controllers transmitted from the master station, controls each slip and blowout preventer to execute according to the set actions, and cooperates with the lifting system to achieve the automatic tripping operation of the pipe string.

[0031] The I / O slave station 04 of the make-up / break-out unit connects the data of the revolution counter sensor to the PLC controller of the slave station 04 through the digital input module, and connects the measurement data of the torque measuring device to the PLC controller of the slave station 04 through the analog input module. Through the centralized processing of the two data, it is used to judge whether the make-up quality of the hydraulic tong is up to standard and whether the break-out is complete, so as to achieve the automatic make-up / break-out function. All data is connected to the industrial control computer master station through the CAN communication interface, and the break-out completion information is transmitted to the automatic control program.

[0032] The I / O slave station 05 of the pipe string transfer unit accesses the data of each position sensor of the hoist and the data of the manipulator position sensor into the PLC controller of the slave station 05 through the digital input module, and accesses the data of the inclination sensor and the data of each pressure sensor into the PLC controller of the slave station 05 through the analog input module. The collected data is centrally processed by the PLC, and the pipe string transfer function is automatically realized according to the program. All data is docked with the industrial computer master station through the CAN communication interface, and the motion information of each action of the pipe string transfer is transmitted to the automatic control program to realize the linkage parallel automatic operation.

[0033] The I / O slave station 06 of the remote control unit consists of a transmitter and a receiver. Data is transmitted between the transmitter and the receiver through wireless transmission. The transmitter accesses the input information of the function switch and the function joystick on the remote control through the digital input module and the analog input module. A data processing module is set in the transmitter, and the data is processed and sent to the receiver through wireless transmission. The receiver transmits the data to the industrial computer master station through the CAN bus, and the master station transmits the action instruction information to each slave station for action execution.

[0034] The above are only the preferred embodiments of the present invention, and do not impose any form of limitation on the present invention. Any simple modifications, equivalent changes or decorations made by those skilled in the art using the disclosed technical content above all fall within the protection scope of the present invention.

Claims

1. A remote control system for tripping pipes under pressure, characterized in that, it includes a pipe pulling automation control system and a pipe running automation control system, integrated in a set of software and hardware systems, and consists of an industrial computer CPU, a distributed PLC controller, an I / O module, and a CAN bus communication method. The industrial computer CPU serves as the master station, centrally processes all the collected data and returns the processed data to each functional unit. The distributed PLC controller serves as the slave station, responsible for data collection of each functional unit, and at the same time sends control instructions to the actuators of this functional unit for the data returned by the master station to complete corresponding actions. The functional units are divided into an automatic operation functional unit, a remote control functional unit, a power system functional unit, a pipe string tripping functional unit, a make-up / break-out functional unit, and a pipe string transfer functional unit. The control system is a PLC program control system, which controls the proportional hydraulic valve group through sensors, programming languages, and CAN bus communication to realize the movement of the terminal components, thereby realizing the remote control of tripping pipes under pressure operation.

2. The remote control system for tripping pipes under pressure according to claim 1, characterized in that, the automatic operation functional unit is arranged on the console in the remote control room. Function switches and display screens are arranged on the console surface. The switches are connected to the slave station through the I / O module, and the display screens are connected to the slave station through Ethernet. The master station is integrated in the console and communicates with each slave station through the CAN bus.

3. The remote control system for tripping pipes under pressure according to claim 1, characterized in that, the remote control functional unit consists of a receiving unit and a transmitting unit. The receiving unit is fixed at an appropriate position of the equipment to facilitate signal reception; the transmitting unit is an independent movable control unit, which is wirelessly transmitted with the receiving unit, and the receiving unit is connected to the master station through the CAN bus.

4. The remote control system for tripping pipes under pressure according to claim 1, characterized in that, the power system functional unit is arranged in the power house and is connected to the master station through the CAN bus.

5. The remote control system for tripping pipes under pressure according to claim 1, characterized in that, the pipe string tripping functional unit is arranged on the derrick and includes a wellhead pressure detection device, a pipe string collar detection device, a working state detection device of the slip blowout preventer, and a displacement detection device of the lifting cylinder.

6. The remote control system for tripping pipes under pressure according to claim 1, characterized in that, the make-up / break-out functional unit is arranged on the hydraulic tong, and through the revolution counting device and torque measuring device of the hydraulic tong, the automatic make-up and break-out operations of the pipe string are completed.

7. The remote control system for tripping pipes under pressure according to claim 1, characterized in that, the pipe string transfer functional unit is arranged on the pipe transporter. Through functional sensors such as a manipulator lifting position sensor, a manipulator clamping sensor, and an inclination sensor arranged on the pipe transporter, the data is transmitted to the slave station, and the transfer of the pipe string is automatically completed according to the functions of the slave station.

8. A remote control method for tripping pipes under pressure, characterized in that, it includes the following steps: Take the console in the control room as the industrial control computer master station, and set up a slave station 01 that separately processes various switch knobs on the console. The slave station consists of a digital input module, an analog input module, a PLC controller, and a communication interface. Various function switches and knobs on the console are connected to the PLC controller through the digital input module and the analog input module. One or more display screens are set on the console for displaying the operation page, and are connected to the PLC controller of the slave station 01 through the Ethernet communication interface. The slave station 01 is connected to the industrial control computer master station through the CAN communication interface. The I / O slave station 02 of the power system unit connects the engine start switch of the power system to the PLC controller of the slave station 02 through the digital input module interface, forming a dual-control switch with the engine start-stop switch in the slave station 01. The engine speed control knob is also connected to the PLC controller of the slave station 02 through the analog module interface, and works with the engine speed control knob of the slave station 01 to achieve the engine remote speed control function. The hydraulic oil temperature and hydraulic oil level switch signal of the hydraulic oil tank are connected to the PLC controller of the slave station 02 through the digital input module, controlling the power system to issue an alarm when the oil temperature is too high or the liquid level is too low, and cutting off the power output when necessary to ensure the safe operation of the equipment. At the same time, the accumulator pressure sensor set in the power system is connected to the PLC through the analog input module, and can automatically start the stamping function when the accumulator pressure is lower than the set value. The I / O slave station 03 of the pipe string tripping unit connects the wellhead pressure sensor data to the PLC controller of the slave station 03 through the analog input module, and determines the amplitude of the pipe string tripping according to the pressure magnitude; The data measured by the pipe coupling detection sensor is connected to the PLC controller of slave station 03 through the analog input module. According to the data change, it is determined whether the pipe coupling passes the detection position, and this result is applied to the automatic tripping process of the pipe string. The displacement sensor of the lifting system is connected to the PLC controller of slave station 03 through the analog input module to monitor the position of the traveling beam of the lifting system in real time. The slip blowout preventer switch is connected to the PLC controller of slave station 03 through the digital input module. The I / O slave station 04 of the make-up and break-out unit connects the data of the revolution counter sensor to the PLC controller of slave station 04 through the digital input module, and connects the measurement data of the torque measuring device to the PLC controller of slave station 04 through the analog input module. Through the centralized processing of the two data, it is used to judge whether the make-up quality of the tongs meets the standard and whether the break-out is complete, so as to realize the automatic make-up and break-out function. The I / O slave station 05 of the pipe string transfer unit connects the data of each position sensor of the hoist and the data of the manipulator position sensor to the PLC controller of slave station 05 through the digital input module, and connects the data of the inclination sensor and the data of each pressure sensor to the PLC controller of slave station 05 through the analog input module. The collected data is centrally processed by the PLC, and the pipe string transfer function is automatically realized according to the program. The I / O slave station 06 of the remote control unit consists of a transmitter and a receiver. Data is transmitted between the transmitter and the receiver through wireless transmission. The transmitter connects the input information of the function switch and the function crank on the remote control to the transmitter through the digital input module and the analog input module. A data processing module is set in the transmitter, and the data is processed and sent to the receiver through wireless transmission. The receiver transmits the data to the industrial control computer master station through the CAN bus, and the master station transmits the action instruction information to each slave station for action execution.

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