Safety early warning device based on multi-source monitoring and ground flow control method

Abstract

The invention discloses a safety early warning device based on multi-source monitoring and a ground process control method, and the method comprises the steps: 1, connecting the outlet end of a production wing valve of a ground test tree with a plurality of ground test devices, and arranging multi-point monitoring devices at a plurality of monitoring positions of a ground test process, emergency shutoff equipment is arranged between the outlet end of the ground test tree production wing valve and the data center, and various risk early warning thresholds are set in the data center; 2, the fluid drilled and produced from the well enters a ground testing process through the ground testing tree and sequentially passes through a plurality of ground testing devices; the multi-point monitoring equipment transmits monitoring data to the data center in a wireless communication mode; 3, the data center carries out calculation analysis and risk judgment on the received monitoring data; and 4, when any risk is judged to exist, a process control system of the data center is triggered, and the process control system sends an instruction to emergency turn-off equipment to control the ground test process to be turned off quickly.

Description

Technical Field

[0001] The present invention belongs to the technical field of natural gas drilling and production, and in particular relates to a safety early warning device based on multi-source monitoring and a ground process control method. Background Art

[0002] This invention is applied in the oil and gas exploration and testing phase. The complex fluid flowing from the well to the surface may contain a mixture of oil, gas, water, and other particulate impurities. The flow pressure, velocity, and flow rate may fluctuate significantly, which can easily cause process erosion, fatigue fracture, and seal damage, resulting in crude oil leakage, flammable gas leakage, and toxic and hazardous gas leakage, which may cause major safety accidents and cause serious damage to personnel, equipment, and the ecological environment. The risk is particularly high for high-temperature and high-pressure wells and wells containing toxic and poisonous gases.

[0003] In view of the high risk of ground testing, the development of domestic ground testing technology has formed means such as wall thickness monitoring, vibration monitoring, pressure monitoring, sand content monitoring, toxic and harmful gas monitoring, and combustible gas monitoring. Each data is monitored separately in the form of single-point monitoring. However, in reality, there is uncertainty in the location and time of accidents. The above monitoring measures are difficult to achieve full-range or large-scale monitoring, and even if effective monitoring is achieved, it is discovered after the fact. If effective corresponding measures are not taken, the situation can easily escalate and cause unimaginable consequences. Summary of the Invention

[0004] The purpose of the present invention is to provide a safety warning device and a ground process control method based on multi-source monitoring, which can realize multi-point real-time monitoring, risk warning and emergency control of the oil and gas ground testing process through multi-source monitoring and intelligent analysis, thereby ensuring the safety and reliability of the ground testing process.

[0005] The technical solution provided by the present invention is:

[0006] A safety early warning device based on multi-source monitoring and a ground process control method, comprising:

[0007] Step 1: Connect the outlet of the production wing valve of the ground test tree to multiple ground test equipment, set up multi-point monitoring equipment at multiple monitoring locations in the ground test process, install emergency shutdown equipment between the outlet of the production wing valve of the ground test tree and the data center, and set various risk warning thresholds at the data center; the multi-point monitoring equipment includes: pressure sensors and temperature sensors;

[0008] Step 2: The fluid drilled from the well enters the surface testing process through the surface testing tree and passes through the multiple surface testing equipment in sequence; the multi-point monitoring equipment uses wireless communication to transmit the monitoring data of each monitoring position to the data center;

[0009] Step 3: The data center calculates the mixed flow velocity of the fluid in the test pipeline based on the received monitoring data, and compares the mixed flow velocity of the fluid with the maximum oil and gas transmission velocity to determine whether there is an erosion risk; at the same time, the received monitoring data is compared with the various risk warning thresholds to determine whether there is a pressure risk, temperature risk, or leakage risk;

[0010] The calculation formula for the mixed flow rate of the fluid is:

[0011]

[0012] Where V m is the mixing flow rate; Q m is the mixed volume flow rate; A is the cross-sectional area of ​​the test pipeline;

[0013] The calculation formula for the maximum oil and gas transmission speed is:

[0014]

[0015] Where V max is the maximum oil and gas transmission velocity allowed in the test pipeline; ρ m is the density of mixed oil and gas; C is the empirical coefficient, which is 100 for continuous flow without sand and 125 for intermittent flow. When sand is transported in the pipeline, the value in the API specification is used;

[0016] Step 4: When it is determined that any risk exists, the process control system of the data center is triggered, and the process control system sends an instruction to the ground test process emergency shutdown system in the emergency shutdown equipment to control the rapid shutdown of the ground test process.

[0017] Preferably, the plurality of ground test equipment includes:

[0018] A ground safety valve, which is arranged at the outlet end of the production wing valve of the ground test tree and is connected to the emergency shutdown device;

[0019] An oil nozzle manifold assembly, one end of which is connected to the ground safety valve; the oil nozzle manifold assembly includes a multi-stage oil nozzle manifold;

[0020] a heater, one end of which is connected to the other end of the oil nozzle manifold assembly;

[0021] a separator disposed at the other end of the heater;

[0022] The test line has a hollow structure inside and is used to circulate the fluid drilled from the well;

[0023] The test pipeline is used to connect the ground safety valve to the outlet end of the production wing valve of the ground test tree and to connect the ground test equipment.

[0024] Preferably, the pressure sensor is arranged at the outlet end of the production wing valve of the ground test tree, upstream of the first-stage oil nozzle manifold, downstream of the first-stage oil nozzle manifold and on the separator; the temperature sensor is arranged at the outlet end of the production wing valve of the ground test tree, downstream of the last-stage oil nozzle manifold and at the outlet end of the heater.

[0025] Preferably, the data transmission between the multi-point monitoring equipment and the data center adopts a dual-frequency dual-mode wireless communication method with ZigBee as the main method and Lora as the auxiliary method; the data collection frequency is greater than 2 per minute.

[0026] Preferably, the calculation formula of the mixed volume flow rate is:

[0027]

[0028] Among them, Q osc To test the oil quantity; Q wsc To test water volume; Q g is the gas phase volume flow rate; B o is the crude oil volume coefficient; R p is the production gas-oil ratio; R s is the dissolved gas-oil ratio.

[0029] Preferably, various risk warning thresholds set in the data center include: a pressure risk warning value, which is 0.8 times the operating pressure of the equipment; and a temperature risk warning value, which is 0.8 times the maximum temperature that the equipment can withstand.

[0030] Preferably, the leakage risk is judged by pressure changes at various monitoring locations during the ground test process.

[0031] Preferably, the shutdown time of the emergency shutdown system in the ground test process is less than or equal to 2.5 seconds.

[0032] The beneficial effects of the present invention are:

[0033] The safety warning device and ground process control method based on multi-source monitoring provided by the present invention realize large-scale multi-point monitoring of the ground test process, wireless data transmission, risk identification and warning, and process control. Combined with oil and gas erosion calculation theory, process leakage identification method and ESD system, a complete safety warning and control method is established, which shortens the emergency well shutdown time to less than or equal to 2.5 seconds, reduces the risk of ground testing process in high-temperature, high-pressure and high-risk wells, ensures the safety of equipment and personnel, and adopts a dual-frequency dual-mode wireless transmission method to ensure data transmission performance and simplify the data acquisition process. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1This is a flow chart of the safety warning device based on multi-source monitoring and the ground process control method described in the present invention.

[0035] Figure 2 This is a flow chart for calculating the mixed flow rate according to the present invention. DETAILED DESCRIPTION

[0036] The present invention will be described in further detail below in conjunction with the accompanying drawings so that those skilled in the art can implement the invention with reference to the description.

[0037] like Figure 1-2 As shown, the present invention provides a safety warning device and a ground process control method based on multi-source monitoring, and the specific implementation process is as follows.

[0038] Step 1: Complete the connection between the surface test tree 111 and multiple surface test equipment; wherein the surface test tree 111 is a wellhead equipment and is the starting link of the surface test process. The oil and gas medium enters the surface test process through the surface test tree 111; the multiple surface test equipment include: a surface safety valve 112, which is arranged at the outlet end of the production wing valve of the surface test tree 111 and is connected to the emergency shutdown device 140 via a wire 150; an oil nozzle manifold group 113, one end of which is connected to the surface safety valve 112; the oil nozzle manifold group 113 includes a multi-stage oil nozzle manifold; a heater 114, one end of which is connected to the other end of the oil nozzle manifold group 113; a separator 115, which is arranged at the other end of the heater 114; a test pipeline 116, which has a hollow structure inside and is used to circulate fluid drilled from the well; wherein the test pipeline 116 is used to connect the surface safety valve 112 and the outlet end of the production wing valve of the surface test tree 111, and the surface test equipment.

[0039] Multi-point monitoring equipment is set up at multiple monitoring locations in the ground test process, wherein the multi-point monitoring equipment includes: multiple pressure sensors, which are respectively set at the outlet of the production wing valve of the ground test tree 111, upstream of the first-stage oil nozzle manifold, downstream of the first-stage oil nozzle manifold, and on the separator 115, and pressure monitoring is performed by the pressure sensors; multiple temperature sensors, which are respectively set at the outlet of the production wing valve of the ground test tree 111, downstream of the last-stage oil nozzle manifold, and at the outlet of the heater 114, and temperature monitoring is performed by the temperature sensors.

[0040] The emergency shutdown device 140 with a ground test process emergency shutdown system is provided between the ground safety valve 112 and the data center 120. The emergency shutdown device 140 and the data center 120 are connected by a wire 150. Various risk warning thresholds are set in the data center 120. In this embodiment, the data center 120 is a central control computer. The data center 120 can also be other equipment with data analysis, risk judgment and process control functions. The risk warning value of the pressure risk is 0.8 times the equipment operating pressure, the risk warning value of the temperature risk is 0.8 times the maximum temperature that the equipment can withstand, and the risk warning value of the erosion risk is the maximum oil and gas transportation speed V specified in the API specification. max .

[0041] In 1981, the API specification mentioned the destructive effects of oil and gas on pipelines and limited the maximum oil and gas transmission rate allowed in the production process. The calculation formula for the maximum oil and gas transmission rate of the fluid in the test pipeline 116 is:

[0042]

[0043] Among them, V max is the maximum oil and gas transmission velocity allowed in the test pipeline; ρ m is the density of mixed oil and gas; C is the empirical coefficient, which is 100 for continuous flow without sand and 125 for intermittent flow. When sand is transported in the pipeline, the value in the API specification is used.

[0044] Step 2: The fluid drilled from the well is an oil and gas medium. The oil and gas medium enters the ground testing process through the ground test tree 111, and passes through the ground safety valve 112, the oil nozzle manifold group 113, the heater 114 and the separator 115 in sequence; the multi-point monitoring equipment uses wireless communication to continuously transmit the monitoring data of each monitoring position to the data center 120; wherein, the data transmission between the multi-point monitoring equipment and the data center 120 is based on industrial Internet of Things technology, using a dual-frequency dual-mode wireless communication method with ZigBee as the main method and Lora as the auxiliary method; the data acquisition frequency is greater than 2 / minute.

[0045] Step three: The data center 120 performs calculations, analysis, and risk assessment on the received monitoring data. The data center 120 calculates the mixed flow rate of the fluid in the test pipeline based on the received monitoring data, and compares the mixed flow rate of the fluid with the maximum oil and gas transmission rate to determine whether there is an erosion risk. At the same time, the received monitoring data is compared with the various risk warning thresholds to determine whether there is a pressure risk, temperature risk, or leakage risk.

[0046] The mixed flow rate of the fluid in the test line 116 is calculated as follows:

[0047] The starting pressure of the test line 116 is obtained by the pressure sensor, and the starting temperature of the test line 116 is obtained by the temperature sensor.

[0048] The gas and the oil-water mixed liquid are separated by the separator 115, and a flow meter is set at the output end of the separator 115 to obtain the separated gas production and the production of the oil-water mixed liquid, and then the surface oil production and water production are obtained by proportional calculation. The gas production, surface oil production and water production are the surface test production, which are recorded as test gas production, test oil production and test water production. The production of the separated oil-water mixed liquid can also be obtained by other testing methods. For example, a measuring tank is connected to the output end of the separator 115, and the production of the oil-water mixed liquid is obtained by measuring the oil-water mixed liquid in the measuring tank. Other fluid physical parameters can also be obtained by looking up the table or calculating by on-site measurement.

[0049] The starting pressure, the starting temperature, the test gas volume, the test oil volume, the test water volume, and the fluid physical properties are used as known quantities to calculate the mixed flow rate of the fluid in the test pipeline 116:

[0050] The formula for calculating the mixed volume flow rate is:

[0051]

[0052] Where Q m is the mixed volume flow rate, m 3 / day;Q osc is the test oil volume, m 3 / day;Q wsc The test water volume, m 3 / day;Q g is the gas phase volume flow rate; B o is the crude oil volume coefficient; R p is the production gas-oil ratio, m 3 / m 3 ; R s is the dissolved gas-oil ratio, m 3 / m 3 ;

[0053] The calculation formula for the gas phase volume flow rate is:

[0054]

[0055] The calculation formula for production gas-oil ratio is:

[0056]

[0057] The calculation formula of solution gas-oil ratio is:

[0058] R s =R sb (R s / R sb )

[0059]

[0060] The calculation formula of crude oil volume coefficient is:

[0061]

[0062] The volume coefficient of natural gas is calculated as follows:

[0063]

[0064] Where Q gsc is the test gas volume, m 3 / day; B g is the natural gas volume coefficient; R sb is the dissolved gas-oil ratio of crude oil at the bubble point pressure; P is the pressure of the fluid in the test pipeline, MPa; P b is the bubble point pressure; γ g is the relative density of natural gas; γ o is the relative density of crude oil; T is the temperature of the fluid in the test pipeline, ℃; Z g is the natural gas compression factor, which can be obtained by looking up the table.

[0065] like Figure 2 The figure shows a mixed flow rate calculation flow chart. When the surface oil production is zero, that is, the test flow is zero, it indicates that the fluid is pure gas phase, and only the gas phase volume flow rate needs to be calculated. The mixed volume flow rate is equal to the sum of the gas phase volume and the water volume flow rate. When the surface oil production is greater than zero, that is, the test flow rate is greater than zero, it indicates that the fluid is liquid phase and may dissolve some gas. If the production oil ratio is less than the crude oil solubility ratio, it indicates that the fluid is pure liquid and there is no need to calculate the gas phase volume flow rate, that is, the gas phase volume flow rate is zero, and only the liquid phase volume flow rate needs to be calculated. If the production oil ratio is greater than or equal to the crude oil solubility ratio, it indicates that the fluid contains gas and the gas phase volume flow rate needs to be calculated. The mixed volume flow rate is equal to the sum of the liquid phase volume flow rate and the gas phase volume flow rate, where the liquid phase volume flow rate includes the water volume flow rate and the oil volume flow rate.

[0066] The formula for calculating the mixing flow rate is:

[0067]

[0068] Where V m is the mixing flow rate, m / day; Q m is the mixed volume flow rate; A is the cross-sectional area of ​​the test pipeline;

[0069] in,

[0070]

[0071] Where q m is the mixed volume flow rate, m 3 / s; π is the pi ratio; d is the diameter of the test pipeline;

[0072] The final calculation formula for the mixed flow rate is:

[0073]

[0074] Where, v m is the mixing flow velocity, m / s.

[0075] The risk assessment performed by the data center 120 on the received monitoring data includes:

[0076] Pressure risk judgment is mainly based on the designed pressure resistance of pipelines and equipment at various locations in the ground test process, and the pressure risk warning pressure threshold is set accordingly, which is usually not greater than 0.8 times the equipment operating pressure; if the pressure risk warning value is exceeded, it is judged that there is a pressure risk; temperature risk judgment is mainly based on the designed high temperature resistance of pipelines and equipment at various locations in the ground test process, and the temperature risk warning temperature threshold is set accordingly, which is usually not greater than 0.8 times the maximum temperature that the equipment can withstand; if the temperature risk warning value is exceeded, it is judged that there is a temperature risk; leakage risk judgment is based on the pressure changes at various monitoring locations in the ground test process to judge whether there is a leak, and thus make a leakage risk judgment. For example, if the pressure downstream of the first-level nozzle manifold suddenly drops and the pressure upstream of the first-level nozzle manifold does not change, there may be a fluid leakage risk downstream of the first-level nozzle manifold; erosion risk judgment is based on the mixed flow velocity V m Is it greater than the maximum oil and gas delivery velocity V specified in the API specification? max , so as to determine whether there is an erosion risk at each position in the ground test process; if the mixed flow rate of the fluid is greater than the maximum oil and gas transmission rate, it is determined that there is an erosion risk.

[0077] Step 4. When it is determined that any of the above risks exists, the process control system of the data center 120 is triggered, and the process control system sends instructions to the ground test process emergency shutdown system in the emergency shutdown equipment 140 to control the ground safety valve 112 to be quickly shut down, thereby realizing rapid ground well shut-in; wherein, the shutdown time of the ground test process emergency shutdown system is ≤2.5 seconds, and the ESD system (ground test process emergency shutdown system) is also provided with multiple ground emergency control buttons, which have two control modes: automatic control and manual control.

[0078] In one embodiment of the present invention, in a well in the South China Sea, the ground test process equipment is connected as follows: Figure 1 The pressure risk warning value at the outlet of the production wing valve of the ground test tree is set to 12000Psi, and the equipment operating pressure is 15000Psi; during the well opening period, the pressure detection value detected by the pressure sensor at the outlet of the production wing valve of the ground test tree suddenly increases to 12232Psi, and the pressure sensor sends the pressure detection data to the data center via wireless transmission; after receiving the pressure detection value, the data center compares it with the set pressure risk warning value for risk judgment. After the risk judgment, the data center determines that it is an overpressure risk, and the system immediately issues an alarm. The process control system automatically sends a well shut-in instruction to the ESD system. The ESD system controls the ground safety valve to close the valve within 2 seconds, realizing the rapid shutdown of the ground test process and avoiding the occurrence of overpressure leakage accidents.

[0079] In another embodiment of the present invention, in a high temperature and high pressure well in the East China Sea, the ground test process equipment is connected as follows Figure 1 The temperature risk warning value at the outlet of the production wing valve of the ground test tree is set to 96°C, and the equipment operating temperature is 120°C; during the well opening period, the temperature detection value detected by the temperature sensor at the outlet of the production wing valve of the ground test tree suddenly increases to 101°C, and the temperature sensor sends the temperature detection data to the data center via wireless transmission; after receiving the temperature detection value, the data center compares it with the set temperature risk warning value to make a risk judgment. After the risk judgment, the data center determines that there is an over-temperature risk, and the system immediately issues an alarm. The process control system automatically sends a well-closing instruction to the ESD system. The ESD system controls the ground safety valve to close the valve within 2 seconds, realizing the rapid shutdown of the ground test process and avoiding the occurrence of safety accidents caused by equipment overheating.

[0080] The safety warning device and ground process control method based on multi-source monitoring provided by the present invention realize large-scale multi-point monitoring of the test ground process, wireless data transmission, risk identification and warning, and process control, and combine the oil and gas erosion calculation theory and process leakage identification method and the ESD system to establish a test ground process safety warning device and a ground process control method, which shortens the emergency well shutdown time to ≤2.5 seconds, can effectively prevent the situation from further developing, reduce the risk of high-temperature, high-pressure, and high-risk well test ground processes, and ensure the health and safety of equipment and personnel; the wireless data transmission method adopted creates conditions for realizing multi-source and multi-point monitoring of the process, and the dual-frequency dual-mode communication method adopted effectively ensures the stability and reliability of data transmission while increasing the data acquisition frequency and simplifying the data acquisition process.

[0081] Although the embodiments of the present invention have been disclosed above, they are not limited to the applications listed in the description and implementation methods. They can be fully applied to various fields suitable for the present invention. For those familiar with the art, additional modifications can be easily implemented. Therefore, without departing from the general concept defined by the claims and the scope of equivalents, the present invention is not limited to the specific details and illustrations shown and described herein.

Claims

1. A safety warning device based on multi-source monitoring and a ground process control method, characterized in that: include: Step 1: Connect the outlet of the production wing valve of the ground test tree to multiple ground test equipment, set up multi-point monitoring equipment at multiple monitoring locations in the ground test process, install emergency shutdown equipment between the outlet of the production wing valve of the ground test tree and the data center, and set various risk warning thresholds in the data center; The multi-point monitoring equipment includes: a pressure sensor and a temperature sensor; Step 2: The fluid drilled from the well enters the surface testing process through the surface testing tree and passes through the multiple surface testing equipment in sequence; the multi-point monitoring equipment uses wireless communication to transmit the monitoring data of each monitoring position to the data center; Step 3: The data center calculates the mixed flow velocity of the fluid in the test pipeline based on the received monitoring data, and compares the mixed flow velocity of the fluid with the maximum oil and gas transmission velocity to determine whether there is an erosion risk; at the same time, the received monitoring data is compared with the various risk warning thresholds to determine whether there is a pressure risk, temperature risk, or leakage risk; The calculation formula for the mixed flow rate of the fluid is: Where V m is the mixing flow rate; Q m is the mixed volume flow rate; A is the cross-sectional area of ​​the test pipeline; The calculation formula for the maximum oil and gas transmission speed is: Where V max is the maximum oil and gas transmission velocity allowed in the test pipeline; ρ m is the density of mixed oil and gas; C is the empirical coefficient, which is 100 for continuous flow without sand and 125 for intermittent flow. When sand is transported in the pipeline, the value in the API specification is used; Step 4: When it is determined that any risk exists, the process control system of the data center is triggered, and the process control system sends an instruction to the ground test process emergency shutdown system in the emergency shutdown equipment to control the rapid shutdown of the ground test process.

2. The safety warning device and ground process control method based on multi-source monitoring according to claim 1 is characterized in that: The plurality of ground test equipment includes: A ground safety valve, which is arranged at the outlet end of the production wing valve of the ground test tree and is connected to the emergency shutdown device; An oil nozzle manifold assembly, one end of which is connected to the ground safety valve; the oil nozzle manifold assembly includes a multi-stage oil nozzle manifold; a heater, one end of which is connected to the other end of the oil nozzle manifold assembly; a separator disposed at the other end of the heater; The test line has a hollow structure inside and is used to circulate the fluid drilled from the well; The test pipeline is used to connect the ground safety valve to the outlet end of the production wing valve of the ground test tree and to connect the ground test equipment.

3. The safety warning device and ground process control method based on multi-source monitoring according to claim 2 is characterized in that: The pressure sensor is arranged on the outlet end of the production wing valve of the ground test tree, upstream of the first-stage oil nozzle manifold, downstream of the first-stage oil nozzle manifold and the separator; the temperature sensor is arranged on the outlet end of the production wing valve of the ground test tree, downstream of the last-stage oil nozzle manifold and the outlet end of the heater.

4. The safety warning device and ground process control method based on multi-source monitoring according to claim 1 is characterized in that: The data transmission between the multi-point monitoring equipment and the data center adopts a dual-frequency dual-mode wireless communication method with ZigBee as the main method and Lora as the auxiliary method; the data collection frequency is greater than 2 per minute.

5. The safety warning device and ground process control method based on multi-source monitoring according to claim 3 is characterized in that: The calculation formula of the mixed volume flow rate is: Among them, Q osc To test the oil quantity; Q wsc To test water volume; Q g is the gas phase volume flow rate; B o is the crude oil volume coefficient; R p is the production gas-oil ratio; R s is the dissolved gas-oil ratio.

6. The safety warning device and ground process control method based on multi-source monitoring according to claim 1 is characterized in that: Various risk warning thresholds are set in the data center, including: a pressure risk warning value, which is 0.8 times the equipment operating pressure; and a temperature risk warning value, which is 0.8 times the maximum temperature that the equipment can withstand.

7. The safety warning device and ground process control method based on multi-source monitoring according to claim 1 is characterized in that: The leakage risk is determined by the pressure changes at each monitoring location during the ground test process.

8. The safety warning device and ground process control method based on multi-source monitoring according to claim 1 is characterized in that: The shutdown time of the emergency shutdown system in the ground test process is less than or equal to 2.5 seconds.

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