Electric direct drive blowout preventer control method and system for oil and gas drilling

Abstract

The invention discloses an electric direct drive blowout preventer control method and system for oil and gas drilling. The method comprises the steps that the system state is monitored; wherein the system state at least comprises wellhead data, image data and equipment data; adjusting control parameters in real time based on the wellhead data; and generating visualization information based on the system state. Therefore, the electric direct-driven blowout preventer assembled with the explosion-proof servo motor based on the high-precision sensor can ensure quick response under various complex working conditions, realize high-precision control in the electric direct-driven blowout preventer and avoid blowout accidents. Besides, the real-time monitoring data of the wellhead and the equipment are visually presented and are also used for predicting equipment faults, so that the fault burst frequency and the maintenance cost are effectively reduced, the overall maintainability and safety of the system are improved, and the efficiency of drilling operation is greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of oil and gas drilling and safety monitoring, and particularly to an electric direct drive blowout preventer control method and system for oil and gas drilling. Background Art

[0002] The operating environment of oil and gas drilling is complex and the tolerance for accidents is low. The blowout preventer is used here to seal the wellhead and prevent blowout accidents at the wellhead. It is the core equipment to ensure wellhead safety. It can be imagined that the response speed of the blowout preventer is directly related to the safety and efficiency of drilling operations.

[0003] Traditional blowout preventer systems are mostly controlled by hydraulic or pneumatic means, which have problems such as slow response, low control accuracy, hydraulic oil leakage, and high maintenance costs. Although existing electric direct drive blowout preventers have gradually replaced traditional blowout preventers, it is still difficult to achieve high-precision control in aspects such as controlling the movement of the ram. If there is a small positioning deviation between the rams, it may cause seal failure under extreme conditions such as high pressure and high temperature, and then trigger a blowout. In addition, the existing monitoring systems for oil and gas wells and equipment are not perfect, it is difficult to perceive the situation in a timely manner, and often only become aware after an accident or failure occurs, which seriously affects the efficiency of drilling operations and causes huge economic losses. Summary of the Invention

[0004] The first aspect of the present invention discloses an electric direct drive blowout preventer control method for oil and gas drilling, which specifically includes the following content.

[0005] Monitor the system status;

[0006] Wherein, the system status at least includes wellhead data, image data, and equipment data;

[0007] Based on the wellhead data, adjust the control parameters in real time;

[0008] And generate visualization information based on the system status.

[0009] As an optional implementation manner, when a closing instruction is received, the control parameters are used to control the electric direct drive blowout preventer to close the wellhead.

[0010] As an optional implementation manner, the wellhead data at least includes wellhead pressure, wellhead temperature, and mud parameters.

[0011] As an optional implementation manner, when the system status indicates equipment abnormality or wellhead abnormality, an alarm message including abnormal positioning data is output.

[0012] As an optional implementation manner, the visualization information is transmitted to the host computer in real time;

[0013] Moreover, the host computer outputs remote control instructions to remotely control the electric direct-drive blowout preventer.

[0014] As an alternative implementation, test cases are set up to test control accuracy, response time, fault prediction, power supply stability and redundancy, and test results are generated.

[0015] Among them, the redundancy at least includes power redundancy, control redundancy and communication redundancy.

[0016] The second aspect of the present invention discloses a system, which is characterized by including:

[0017] An electric execution module for feeding back the device data of the electric direct-drive blowout preventer;

[0018] A sensor module for real-time acquisition of wellhead data and image data;

[0019] A redundancy control module for controlling the operation of the electric direct-drive blowout preventer;

[0020] A dual-channel communication module for real-time transmission of the device data, the wellhead data and the image data;

[0021] A dual-channel power supply module for performing mains power supply and power-off protection.

[0022] As an alternative implementation, the electric execution module is equipped with an explosion-proof servo motor, an absolute encoder, an incremental encoder and a Hall sensor, which are used to convert the rotational motion of the electric direct-drive blowout preventer into linear displacement, achieve precise control of the wellhead opening degree, and real-time monitor the wellhead position based on multi-sensor fusion technology.

[0023] As an alternative implementation, the sensor module at least includes an electronic pressure sensor for measuring the wellhead pressure, a temperature sensor for measuring the wellhead temperature, a mud composition sensor for measuring mud parameters, and a monitoring device for recording the wellhead image.

[0024] As an alternative implementation, the redundancy control module uses a programmable controller or an embedded controller to perform closed-loop / open-loop control on the electric direct-drive blowout preventer and feedback operation parameters for fault prediction;

[0025] The dual-channel communication module supports at least Modbus TCP, Prrofinet, CAN bus, EtherCAT and 5G communication protocols to achieve data connection for the electric execution module, the sensor module and the redundancy control module;

[0026] The dual-channel power supply module has mains power supply, generator power supply and UPS power supply functions at the same time to achieve uninterrupted power supply.

[0027] The third aspect of the present invention discloses a system, which is characterized by comprising:

[0028] A memory storing executable program code;

[0029] A processor coupled to the memory;

[0030] The processor calls the executable program code stored in the memory.

[0031] Compared with the prior art, the embodiments of the present invention have the following beneficial effects:

[0032] Based on a high-precision sensor and an electric direct-drive blowout preventer equipped with an explosion-proof servo motor, it can ensure quick response under various complex working conditions, achieve high-precision control of the electric direct-drive blowout preventer, and avoid blowout accidents. In addition, the real-time monitoring data of the wellhead and equipment is visually presented, which is also used for equipment fault prediction, effectively reducing the frequency of sudden failures and maintenance costs, improving the overall maintainability and safety of the system, and thus greatly improving the efficiency of drilling operations. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the following will briefly introduce the drawings required for the embodiments. Obviously, the drawings in the following description are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0034] Figure 1 It is a schematic working flow diagram of an electric direct-drive blowout preventer control method for oil and gas drilling disclosed in the embodiments of the present invention;

[0035] Figure 2 It is a schematic structural diagram of a system disclosed in the embodiments of the present invention;

[0036] Figure 3 It is a schematic structural diagram of a redundant control module in a system disclosed in the embodiments of the present invention;

[0037] Figure 4 It is a schematic structural diagram of a dual-power supply module in a system disclosed in the embodiments of the present invention;

[0038] Figure 5 It is a schematic structural diagram of another system disclosed in the embodiments of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0039] Next, in combination with the accompanying drawings in the embodiments of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts belong to the scope of protection of the present invention.

[0040] Embodiment 1

[0041] Please refer to Figure 1 , the electric direct-drive blowout preventer control method and system for oil and gas drilling may include the following content.

[0042] 101. Monitor the system status.

[0043] In this embodiment, the system status at least includes wellhead data, image data, and equipment data.

[0044] As an alternative implementation, the wellhead data at least includes wellhead pressure, wellhead temperature, and mud parameters.

[0045] Specifically, an electronic pressure sensor is used to measure the wellhead pressure, a temperature sensor is used to measure the wellhead temperature, a mud composition sensor is used to measure the mud parameters, and a monitoring device is used to record the wellhead image.

[0046] In addition, the explosion-proof servo motor, absolute encoder, incremental encoder, Hall sensor, etc. in the electric direct-drive blowout preventer are used to measure the equipment data. By converting the rotational movement process of the wellhead opening in the electric direct-drive blowout preventer into a linear displacement process, the real-time position and torque of the wellhead and other equipment data are measured.

[0047] Thus, the wellhead status and the equipment operation status are presented in real-time visualization. Staff do not need to know only after wellhead anomalies or equipment failures, and accordingly, accident prevention and equipment maintenance can be carried out.

[0048] As an alternative implementation, when the system status indicates equipment anomalies or wellhead anomalies, an alarm message containing anomaly location data is output.

[0049] Specifically, in the case of data visualization, when there are equipment anomalies, the staff can immediately know, and according to the anomaly location data in the alarm message, replace or maintain the abnormal equipment in time to ensure that the overall system will not stop due to sudden failures.

[0050] Similarly, in the case of data visualization, when there are wellhead anomalies, the staff can act quickly based on this, execute safety measures, and avoid sudden blowout accidents.

[0051] In addition, sealing the wellhead in advance before a blowout occurs is much less difficult than sealing a wellhead during a blowout, and the safety factor is also higher. Therefore, the possibility of triggering a serious accident can be significantly reduced, and the continuity and stability of the drilling operation are effectively guaranteed.

[0052] 102. Adjust the control parameters in real time based on the wellhead data.

[0053] In this embodiment, when a sealing instruction is received, the control parameters are used to control the electric direct-drive blowout preventer to seal the wellhead.

[0054] Specifically, in response to the wellhead data indicating an abnormal wellhead, the control parameters are adjusted according to the current real-time wellhead data to ensure that in extreme cases, the wellhead of the electric direct-drive blowout preventer can be accurately closed without gaps, and the blowout can be suppressed in a timely and reliable manner.

[0055] 103. Generate visual information based on the system status.

[0056] In this embodiment, the visual information is transmitted to the host computer in real time;

[0057] The host computer outputs a remote control instruction to remotely control the electric direct-drive blowout preventer.

[0058] Here, the visual information is uploaded to nodes such as the cloud server and remote monitoring equipment in real time. Based on the communication connection and account authentication login, the staff can realize remote monitoring and execute remote control at nodes such as the explosion-proof HMI touch screen, handheld tablet, button driller's console, and cloud server.

[0059] For the above-mentioned various types of remote node devices, multi-device collaborative control can also be realized according to the account permission relationship.

[0060] For example, a high-privilege account logged in to the cloud server can obtain the system status monitoring permission and remote control permission, while a low-privilege account logged in to the handheld tablet only has the system status monitoring permission and does not have the remote control permission.

[0061] Accordingly, the overall system will operate under the joint monitoring of different personnel, and in case of an abnormality, the relevant on-site and remote staff can cooperate to eliminate the abnormal situation.

[0062] It should be understood that during drilling operations, the conditions of different strata vary greatly, and the possibility of unexpected situations occurring at the front end of the drill pipe cannot be eliminated. In addition, extreme disaster situations also need to be considered for system control, communication connection, and power supply.

[0063] As an optional implementation method, test cases are set to test the control accuracy, response time, fault prediction, power supply stability, and redundancy, and test results are generated;

[0064] Among them, the redundancy includes at least power redundancy, control redundancy, and communication redundancy.

[0065] Specifically, equipment such as a laser interferometer can be used to test the positioning accuracy of the wellhead of the electric direct-drive blowout preventer at different positions to verify whether there is a deviation between the set position and the actual position.

[0066] A timing device can be used to test the response time of the electric direct-drive blowout preventer to open / close to verify whether it can ensure timely suppression of blowouts under different working conditions.

[0067] Faults can be artificially set for different devices, and faulty devices can be artificially assembled to verify whether the sensor can timely and accurately feedback equipment abnormalities. The accuracy rate of the fault prediction process and the early warning time can be detailedly recorded, and the monitoring mechanism can be optimized accordingly to check for omissions and deficiencies.

[0068] The UPS can be enabled, and the electric direct-drive blowout preventer can be triggered to run simultaneously / one by one. Record the output voltage, current, running stability, and continuous power supply duration of the UPS during this process; the UPS can be discharged and then connected to the mains power supply, and record its charging parameters, temperature change, and charging duration, and accordingly evaluate its charging efficiency and battery performance; the mains power supply and the UPS power supply can also be switched back and forth to evaluate the power supply stability of the system under various working conditions.

[0069] In addition, when the system is running normally, the main power supply can be cut off to simulate a main power supply failure, and accordingly, a power redundancy test can be carried out to observe the running state of the system when switching to the generator or the UPS.

[0070] The main controller failure can also be simulated by disconnecting the main controller communication connection, artificially creating program errors, etc., and observing the system control parameters and the operation of the actuator during this process to evaluate the continuity and accuracy of the control system.

[0071] The stability of communication can also be verified by cutting off the wired network, interfering with the wireless signal, etc.

[0072] In summary, based on the electric direct-drive blowout preventer equipped with an explosion-proof servo motor and high-precision sensors, it can ensure a quick response under various complex working conditions, achieve high-precision control of the electric direct-drive blowout preventer, and avoid blowout accidents. In addition, the real-time monitoring data visualization of the wellhead and equipment is also used for equipment fault prediction, effectively reducing the frequency of sudden faults and maintenance costs, improving the overall maintainability and safety of the system, and thus greatly improving the efficiency of drilling operations.

[0073] Embodiment 2

[0074] Please refer to Figures 2 - 4 , the system may include the following.

[0075] An electric actuator module for feeding back the device data of an electric direct-drive blowout preventer;

[0076] A sensor module for obtaining wellhead data and image data in real time;

[0077] A redundant control module for controlling the operation of an electric direct-drive blowout preventer;

[0078] A dual-channel communication module for transmitting device data, wellhead data, and image data in real time;

[0079] A dual-channel power supply module for performing mains power supply and power-off protection.

[0080] As an optional implementation, the electric actuator module is equipped with an explosion-proof servo motor, an absolute encoder, an incremental encoder, and Hall sensors to convert the rotational motion of the electric direct-drive blowout preventer into linear displacement, achieve precise control of the wellhead opening, and monitor the wellhead position in real time based on multi-sensor fusion technology.

[0081] As an optional implementation, the sensor module at least includes an electronic pressure sensor for measuring wellhead pressure, a temperature sensor for measuring wellhead temperature, a mud composition sensor for measuring mud parameters, and a monitoring device for recording wellhead images.

[0082] As an optional implementation, the redundant control module uses a programmable controller or an embedded controller to perform closed-loop / open-loop control on the electric direct-drive blowout preventer and feed back operation parameters for fault prediction;

[0083] The dual-channel communication module supports at least Modbus TCP, Prrofinet, CAN bus, EtherCAT, and 5G communication protocols to achieve data connection for the electric actuator module, sensor module, and redundant control module;

[0084] The dual-channel power supply module has mains power supply, generator power supply, and UPS power supply functions at the same time to achieve uninterrupted power supply.

[0085] Here, based on high-precision sensors and an electric direct-drive blowout preventer equipped with an explosion-proof servo motor, it can ensure fast response under various complex working conditions, achieve high-precision control of the electric direct-drive blowout preventer, and the energy consumption of the above devices is lower than that of hydraulic devices, with fewer mechanical components, convenient maintenance, and at the same time, it completely solves the problem of hydraulic oil leakage, significantly improves the device performance, and eliminates environmental protection hazards.

[0086] In addition, the visual presentation of real-time monitoring data of the wellhead and the device is also used for device fault prediction, effectively reducing the frequency of sudden failures and maintenance costs, improving the overall maintainability and safety of the system, and thus greatly improving the efficiency of drilling operations.

[0087] Example 3

[0088] Please refer to Figure 5 , the system may include the following

[0089] A memory storing executable program code;

[0090] A processor coupled to the memory;

[0091] The processor invokes the executable program code stored in the memory.

Claims

1. An electric direct drive blowout preventer control method for oil and gas drilling, characterized in that, The method includes: Monitoring the system status; wherein, the system status at least includes wellhead data, image data and equipment data; Based on the wellhead data, adjusting the control parameters in real time; and generating visualization information based on the system status.

2. The electric direct drive blowout preventer control method for oil and gas drilling according to claim 1, characterized in that, The method further includes: When a closing instruction is received, the control parameters are used to control the electric direct-drive blowout preventer to close the wellhead.

3. A direct electric drive blowout preventer control method for oil and gas drilling according to claim 1, characterized in that, The method further includes: The wellhead data at least includes wellhead pressure, wellhead temperature and mud parameters.

4. The electro - direct - drive blowout preventer control method for oil and gas drilling according to claim 1, characterized in that, The method further includes: When the system status indicates equipment abnormality or wellhead abnormality, an alarm message including abnormality location data is output.

5. The electro-direct drive blowout preventer control method for oil and gas drilling according to claim 1, characterized in that, The method further includes: The visualization information is transmitted to the host computer in real time; and the host computer outputs a remote control instruction to perform remote control on the electric direct-drive blowout preventer.

6. The electric direct drive blowout preventer control method for oil and gas drilling according to claim 1, characterized in that, The method further includes: Setting test cases to test control accuracy, response time, fault prediction, power supply stability and redundancy, and generating test results; wherein, the redundancy at least includes power redundancy, control redundancy and communication redundancy.

7. A system, characterized in that, It includes: An electric execution module for feeding back the equipment data of the electric direct-drive blowout preventer; A sensor module for acquiring wellhead data and image data in real time; A redundant control module for controlling the operation of the electric direct-drive blowout preventer; A dual-channel communication module for transmitting the equipment data, the wellhead data and the image data in real time; A dual-channel power supply module for performing mains power supply and power-off protection.

8. A system according to claim 7, wherein It includes: The electric execution module is equipped with an explosion-proof servo motor, an absolute encoder, an incremental encoder and a Hall sensor, which are used to convert the rotational motion of the electric direct-drive blowout preventer into linear displacement, realize precise regulation of the wellhead opening degree, and monitor the wellhead position in real time based on multi-sensor fusion technology.

9. A system according to claim 7, wherein It includes: The sensor module at least includes an electronic pressure sensor for measuring wellhead pressure, a temperature sensor for measuring wellhead temperature, a mud composition sensor for measuring mud parameters, and a monitoring device for recording wellhead images.

10. A system according to claim 7, characterized in that, It includes: The redundant control module uses a programmable controller or an embedded controller to perform closed-loop / open-loop control on the electric direct-drive blowout preventer and feedback operation parameters for fault prediction; The dual-channel communication module at least supports Modbus TCP, Prrofinet, CAN bus, EtherCAT and 5G communication protocols to realize data connection for the electric execution module, the sensor module and the redundant control module; The dual-channel power supply module simultaneously has the functions of mains power supply, generator power supply and UPS power supply to realize uninterrupted power supply.

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