A wireless overflow real-time monitoring alarm system

Abstract

The present application relates to the technical field of oil drilling, and particularly relates to a wireless overflow and leakage real-time monitoring and alarming system, which comprises: a flow monitoring unit installed in a hard pipe line between a well head and a vibrating screen of a target well, the flow monitoring unit being used for detecting real-time return discharge capacity of the well head drilling fluid; a pump stroke monitoring unit installed in a mud pump group of the target well, the pump stroke monitoring unit being used for detecting real-time pump stroke of a mud pump in the mud pump group, and determining real-time injection discharge capacity of the mud pump group to the target well according to the pump stroke; the flow monitoring unit and the pump stroke monitoring unit being connected with a master control unit through a wireless transmission module, and the master control unit judging when a difference between the real-time injection discharge capacity and the real-time return discharge capacity exceeds a predetermined value, and then controlling an alarm unit to start overflow and leakage early warning. The present application can realize real-time injection and return discharge capacity, and can accurately and timely find the downhole overflow and leakage, so as to carry out corresponding treatment, reduce cost loss, and improve production efficiency.

Description

Technical Field

[0001] This invention relates to the field of oil drilling technology, and in particular to a wireless real-time monitoring and alarm system for leaks. Background Technology

[0002] Shale oil formations are characterized by well-developed fractures and good connectivity, abundant associated gas, and high formation pressure. Drilling and completion processes face numerous technical challenges, including a high risk of lost circulation and slow turnaround times, hindering the acceleration, efficiency, and quality improvement of shale oil drilling under complex geological conditions. Currently, leakage is mainly monitored by adjusting the mud tank level or manually measuring the drilling fluid density. However, these methods are inaccurate, and by the time technicians detect abnormal changes in level and density, leakage has often already occurred. Summary of the Invention

[0003] This invention proposes a wireless real-time monitoring and alarm system for leaks, which solves the problems of low accuracy and long delays in the previous method of leak monitoring by measuring drilling fluid level and density, which could not detect leaks in time and reduced production efficiency.

[0004] According to one aspect of the present invention, a wireless real-time monitoring and alarm system for overflow is provided, comprising: a flow monitoring unit, a pump flushing monitoring unit, and a main control unit; A flow monitoring unit is installed in the rigid pipeline between the wellhead of the target well and the vibrating screen. The flow monitoring unit is used to detect the real-time return flow rate of the drilling fluid at the wellhead. A pump flushing monitoring unit is installed inside the mud pump group of the target well. The pump flushing monitoring unit is used to detect the real-time pump flushing of the mud pump in the mud pump group and determine the real-time injection rate of drilling fluid injected into the target well by the mud pump group based on the pump flushing. The flow monitoring unit and the pump flushing monitoring unit are connected to the main control unit via a wireless transmission module. The main control unit determines, based on the received real-time injection volume and real-time return volume, that when the difference between the real-time injection volume and the real-time return volume exceeds a predetermined value, it controls the alarm unit connected to it to start an overflow warning.

[0005] Preferably, the overflow warning includes: overflow warning and leakage warning; The main control unit determines whether the real-time injection volume is greater than the real-time return volume when the difference between the real-time injection volume and the real-time return volume exceeds a predetermined value. If yes, it controls the leakage warning to be issued; if no, it controls the overflow warning to be issued.

[0006] Preferably, it also includes: a pump pressure detection unit, a density detection unit, a temperature detection unit, and a mud tank level detection unit; The pump pressure detection unit is installed in the mud pump group and is used to detect the real-time pump pressure of the mud pump. The density detection unit, temperature detection unit, and mud tank level detection unit are installed inside the mud tank of the target well. The density detection unit is used to detect the real-time drilling fluid density inside the mud tank, the temperature detection unit is used to detect the real-time drilling fluid temperature inside the mud tank, and the mud tank level detection unit is used to detect the real-time drilling fluid level inside the mud tank. The pump pressure detection unit, density detection unit, temperature detection unit, and mud tank level detection unit are each connected to the main control unit via a wireless transmission module.

[0007] Preferably, the pump pressure detection unit includes a pump pressure sensor, the density detection unit includes a density sensor, the temperature detection unit includes a temperature sensor, and the mud tank level detection unit includes a first level sensor.

[0008] Preferably, the flow monitoring unit is also used to detect the real-time return fluid level and real-time return fluid flow rate in the hard pipeline; When the main control unit controls the alarm unit to activate the early warning prompt, the main control unit determines whether one or any of the values ​​of the target well mud pump pressure, drilling fluid density in the mud tank, drilling fluid temperature, drilling fluid level, drilling fluid return fluid level in the hard pipeline, and drilling fluid return flow rate exceeds or falls below their corresponding predetermined range. If so, the main control unit controls the alarm unit connected to it to activate the overflow and leakage alarm prompt.

[0009] Preferably, the predetermined range is the range of numerical changes in real-time pump pressure, real-time drilling fluid density, real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate under the condition that no leakage occurs.

[0010] Preferably, the overflow alarm includes: overflow alarm and leakage alarm; The main control unit determines whether the real-time drilling fluid density is lower than its corresponding predetermined range, and / or whether the value of one or more of the real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate exceeds its corresponding predetermined range. If so, the overflow alarm is triggered. The main control unit determines whether the real-time pump pressure is lower than its corresponding predetermined range, and / or whether the value of one or more of the real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate is lower than its corresponding predetermined range. If so, it controls the leakage alarm to be triggered.

[0011] Preferably, when the main control unit controls the overflow alarm, the main control unit determines the rated time injection volume and rated time return volume based on the real-time injection volume and real-time return volume, and determines the downhole fracture width based on the rated time injection volume and rated time return volume.

[0012] Preferably, the flow monitoring unit includes: a second liquid level sensor, a flow sensor, and a first microcontroller; The second liquid level sensor and the flow sensor are connected to the first microcontroller, and the first microcontroller is connected to the main control unit through the wireless transmission module; The first microcontroller is used to determine the real-time cross-sectional area of ​​the drilling fluid in the hard pipeline based on the real-time return fluid level of the drilling fluid in the hard pipeline detected by the second level sensor and the internal diameter of the hard pipeline, and to determine the real-time return discharge rate based on the real-time cross-sectional area and the real-time return drilling fluid flow rate of the drilling fluid in the hard pipeline detected by the flow sensor.

[0013] Preferably, the pump surge monitoring unit includes: a pump surge sensor and a second microcontroller; The second microcontroller is connected to the main control unit via the wireless transmission module; The second microcontroller is used to determine the real-time injection discharge rate based on the number of pump strokes per minute of each mud pump in the mud pump group detected by the pump stroke sensor and the discharge rate corresponding to one pump stroke.

[0014] Preferably, the main control unit determines the total injection volume, total return volume, and total pump stroke based on the real-time injection volume, real-time return volume, and real-time pump stroke.

[0015] Preferably, the main control unit plots curves showing the changes in return displacement and injection displacement based on the real-time return displacement and the real-time injection displacement, and displays them on the display screen.

[0016] This invention proposes a wireless real-time leakage monitoring and alarm system. By setting up a pump flushing monitoring unit in the mud pump group and a flow monitoring unit in the hard pipeline at the wellhead outlet, the real-time injection and return flow rates of drilling fluid can be obtained. Based on the real-time injection and return flow rates, downhole leakage can be accurately and timely detected, allowing for appropriate handling, reducing cost losses, and improving production efficiency. Attached Figure Description

[0017] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the present invention and, together with the specification, serve to explain the technical solutions of the present invention.

[0018] Figure 1A schematic diagram of the structure of a wireless real-time monitoring and alarm system for leakage according to an embodiment of the present invention is shown; Figure 2 An overflow monitoring curve is shown according to an embodiment of the present invention.

[0019] In the diagram, 1-Pump flushing monitoring unit, 2-Wireless transmitter, 3-Flow monitoring unit, 4-Wireless receiver, 5-Main control unit, 6-Alarm unit. Detailed Implementation

[0020] Various exemplary embodiments, features, and aspects of the present invention will now be described in detail with reference to the accompanying drawings. The same reference numerals in the drawings denote elements that have the same or similar functions. Although various aspects of the embodiments are shown in the drawings, they are not necessarily drawn to scale unless specifically indicated otherwise.

[0021] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0022] In this document, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent three cases: A alone, A and B simultaneously, and B alone. Furthermore, the term "at least one" in this document means any combination of at least two of any one or more elements. For example, including at least one of A, B, and C can mean including any one or more elements selected from the set consisting of A, B, and C.

[0023] Furthermore, to better illustrate the present invention, numerous specific details are set forth in the following detailed embodiments. Those skilled in the art will understand that the present invention can be practiced without certain specific details. In some instances, methods, means, elements, and circuits well known to those skilled in the art have not been described in detail in order to highlight the spirit of the invention.

[0024] Figure 1 A schematic diagram of the structure of a wireless real-time monitoring and alarm system for leakage according to an embodiment of the present invention is shown; Figure 2 An overflow monitoring curve is shown according to an embodiment of the present invention. Figure 1 and 2As shown, a wireless real-time overflow monitoring and alarm system includes: a flow monitoring unit 3, a pump flush monitoring unit 1, and a main control unit 5. The flow monitoring unit 3 is installed in the rigid pipeline between the wellhead of the target well and the vibrating screen. The flow monitoring unit 3 is used to detect the real-time return flow rate of the drilling fluid at the wellhead. The pump flush monitoring unit 1 is installed inside the mud pump group of the target well. The pump flush monitoring unit 1 is used to detect the real-time pump flush of the mud pump in the mud pump group and determine the real-time injection flow rate of the drilling fluid injected into the target well by the mud pump group based on the pump flush. The flow monitoring unit 3 and the pump flush monitoring unit 1 are connected to the main control unit 5 via a wireless transmission module. The main control unit 5 determines, based on the received real-time injection flow rate and the real-time return flow rate, that when the difference between the real-time injection flow rate and the real-time return flow rate exceeds a predetermined value, it controls the alarm unit 6 connected to it to activate and provide an overflow warning.

[0025] In embodiments of the present invention, such as Figure 1 As shown, the mud pump unit is connected to the wellhead and mud tank via mud pipelines. The wellhead is connected to the vibrating screen via a rigid pipeline. During drilling, the mud pump unit is started to pump the drilling fluid (mud) from the mud tank and transport it downhole through the mud pipelines.

[0026] During monitoring, the main control unit 5 controls the flow monitoring unit 3 and the pump flush monitoring unit 1 to start via a wireless transmission module. After starting, the pump flush monitoring unit 1 detects the real-time pump flush count of the mud pumps in the mud pump group and determines the real-time flow rate of the drilling fluid injected into the wellhead, i.e., the real-time injection displacement, based on this real-time pump flush count. This real-time injection displacement is then transmitted to the main control unit 5 via the wireless transmission module. Similarly, after starting, the flow monitoring unit 3 detects the real-time flow rate of the drilling fluid (return fluid) returning from the wellhead to the hard pipeline, i.e., the real-time return displacement, and transmits this real-time return displacement to the main control unit 5 via the wireless transmission module.

[0027] After receiving the real-time injection volume and the real-time output volume, the main control unit 5 compares the two and determines the difference. When the difference between the two exceeds the first predetermined value, the main control unit 5 controls the alarm unit 6 to issue an alarm prompt.

[0028] In the absence of leakage, the real-time injection and return flow rates will not differ significantly. When leakage occurs, the returned drilling fluid volume will exceed or fall below a predetermined value compared to the injected volume. By monitoring the injection and return drilling fluid flow rates, leakage can be detected immediately, ensuring both operational efficiency and safety.

[0029] In this invention, the overflow warning includes an overflow warning and a leakage warning; the main control unit 5 determines whether the real-time injection volume is greater than the real-time return volume when the difference between the real-time injection volume and the real-time return volume exceeds a predetermined value. If yes, the leakage warning is triggered; if no, the overflow warning is triggered.

[0030] In this embodiment of the invention, leakage includes both overflow and loss. When overflow occurs, downhole fluid returns to the wellhead along with drilling fluid through the tubing and enters the hard pipeline, thereby increasing the real-time return flow rate. When loss occurs, drilling fluid injected downhole enters the downhole fractures, thereby reducing the amount of drilling fluid returning to the wellhead, i.e., reducing the real-time return flow rate within the hard pipeline. Therefore, when the difference between the real-time return flow rate and the real-time injection flow rate is too large, and when the real-time return flow rate exceeds the real-time injection flow rate, it indicates that an overflow may occur; when the real-time return flow rate is lower than the real-time injection flow rate, it indicates that a loss may occur.

[0031] This invention further includes: a pump pressure detection unit, a density detection unit, a temperature detection unit, and a mud tank level detection unit; the pump pressure detection unit is installed inside the mud pump group and is used to detect the real-time pump pressure of the mud pump; the density detection unit, temperature detection unit, and mud tank level detection unit are installed inside the mud tank of the target well, the density detection unit is used to detect the real-time drilling fluid density inside the mud tank, the temperature detection unit is used to detect the real-time drilling fluid temperature inside the mud tank, and the mud tank level detection unit is used to detect the real-time drilling fluid level inside the mud tank; the pump pressure detection unit, density detection unit, temperature detection unit, and mud tank level detection unit are each connected to the main control unit 5 via a wireless transmission module.

[0032] In this invention, the pump pressure detection unit includes a pump pressure sensor, the density detection unit includes a density sensor, the temperature detection unit includes a temperature sensor, and the mud tank level detection unit includes a first level sensor.

[0033] In this embodiment of the invention, during monitoring, the main control unit 5 controls the pump pressure sensor of the pump pressure detection unit, the density sensor of the density detection unit, the temperature sensor of the temperature detection unit, and the first liquid level sensor of the mud tank liquid level detection unit to start through the wireless transmission module.

[0034] After the pump pressure sensor is activated, it detects the real-time pump pressure of each mud pump in the mud pump group and sends it to the main control unit 5 via a wireless transmission module; after the density sensor is activated, it detects the real-time density of the drilling fluid in the mud tank, i.e., the real-time drilling fluid density, and sends it to the main control unit 5; after the temperature sensor is activated, it detects the real-time temperature of the drilling fluid in the mud tank, i.e., the real-time drilling fluid temperature, and sends it to the main control unit 5; after the first level sensor is activated, it detects the real-time level of the drilling fluid in the mud tank, i.e., the real-time drilling fluid level, and sends it to the main control unit 5. The first level sensor for drilling fluid is an ultrasonic first level sensor.

[0035] After receiving the real-time pump pressure, real-time drilling fluid density, real-time drilling fluid temperature, and real-time drilling fluid level, the main control unit 5 plots them as curves showing the changes in real-time pump pressure, real-time drilling fluid density, real-time drilling fluid temperature, and real-time drilling fluid level over time, and displays them on the screen for easy monitoring by operators.

[0036] In this invention, the flow monitoring unit 3 is also used to detect the real-time return fluid level and real-time return fluid flow rate of the drilling fluid in the hard pipeline; when the main control unit 5 controls the alarm unit 6 to start the early warning prompt, the main control unit 5 determines whether the value of one or any number of items exceeds or falls below its corresponding predetermined range based on the received real-time pump pressure of the target well mud pump, the real-time drilling fluid density, the real-time drilling fluid temperature, the real-time drilling fluid level, the real-time return fluid level of the drilling fluid in the hard pipeline, and the real-time return fluid flow rate. If so, the main control unit 5 controls the alarm unit 6 connected to it to start the overflow and leakage alarm prompt.

[0037] In this embodiment of the invention, in order to prevent false alarms caused by errors in the real-time injection and output discharge values ​​detected by the flow monitoring unit 3 and the pump flushing monitoring unit 1, it is necessary to comprehensively judge the leakage situation by using other parameters related to leakage, so as to reduce the false alarm rate.

[0038] When the main control unit 5 determines that an overflow or leakage has occurred based on the real-time injection and return discharge rates, the control alarm unit 6 will activate to issue a warning. The control unit will then determine whether the real-time pump pressure detected by the pump pressure detection unit in the mud pump group, the real-time drilling fluid density detected by the density detection unit in the mud tank, the real-time drilling fluid temperature detected by the temperature detection unit, the real-time drilling fluid level detected by the level detection unit, the real-time return fluid level in the hard pipeline detected by the flow monitoring unit 3, and the real-time return fluid flow rate exceed their respective predetermined ranges. If one or more of these exceed their respective predetermined ranges, an overflow can be determined, and the main control unit 5 will control the alarm unit 6 to issue an overflow alarm.

[0039] When construction workers receive a leak warning, they can first observe or inspect without taking any action. When a leak alarm is triggered, they need to deal with it immediately to prevent greater losses.

[0040] In this invention, the predetermined range refers to the range of numerical variations of real-time pump pressure, real-time drilling fluid density, real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate under the condition that no leakage occurs.

[0041] In this embodiment of the invention, during construction, without leakage, the changes in real-time pump pressure, real-time drilling fluid density, real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate will remain stable within a certain range and will not suddenly change significantly. Therefore, the range of changes in each parameter during normal construction of the target well is used as this predetermined range to achieve accurate monitoring of leakage.

[0042] In this invention, the overflow alarm includes an overflow alarm and a leakage alarm; the main control unit 5 determines whether the real-time drilling fluid density is lower than its corresponding predetermined range, and / or whether the value of one or more of the real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate exceeds its corresponding predetermined range. If yes, the overflow alarm is triggered; the main control unit 5 determines whether the real-time pump pressure is lower than its corresponding predetermined range, and / or whether the value of one or more of the real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate is lower than its corresponding predetermined range. If yes, the leakage alarm is triggered.

[0043] In this embodiment of the invention, if an overflow occurs, the downhole fluid will rise back to the wellhead and enter the mud tank through the hard pipeline and vibrating screen, causing a decrease in the real-time drilling fluid density in the mud tank. After the downhole fluid enters the mud tank, the fluid level inside the mud tank will rise. Because the downhole fluid has a high temperature, the real-time drilling fluid temperature in the mud tank will also rise. Simultaneously, after the downhole fluid enters the hard pipeline, the real-time return fluid level and real-time return fluid flow rate detected by the flow monitoring unit 3 will increase. Therefore, when it is determined that the real-time drilling fluid density is below its corresponding predetermined range, and / or the real-time drilling fluid temperature exceeds its corresponding predetermined range, and / or the real-time drilling fluid level exceeds its corresponding predetermined range, and / or the real-time return fluid level exceeds its corresponding predetermined range, and / or the real-time return fluid flow rate exceeds its corresponding predetermined range, the main control unit 5 will trigger an overflow alarm.

[0044] If leakage occurs, the drilling fluid injected downhole will enter the formation fractures, causing a drop in the real-time pump pressure during mud pump injection; the drilling fluid cannot completely return to the mud tank through the hard pipeline and vibrating screen, causing a drop in the real-time drilling fluid level in the mud tank; simultaneously, the reduction in the returned drilling fluid will lead to a decrease in the real-time return fluid level and real-time return fluid flow rate in the hard pipeline. Therefore, when it is determined that the real-time pump pressure exceeds its corresponding predetermined range, and / or the real-time drilling fluid level is below its corresponding predetermined range, and / or the real-time return fluid level is below its corresponding predetermined range, and / or the real-time return fluid flow rate is below its corresponding predetermined range, the main control unit 5 will trigger a leakage alarm.

[0045] In this invention, when the main control unit 5 controls the overflow alarm, the main control unit 5 determines the rated time injection volume and rated time return volume based on the real-time injection volume and real-time return volume, and determines the downhole fracture width based on the rated time injection volume and rated time return volume.

[0046] In this embodiment of the invention, by using the real-time injection and return volumes detected by the flow monitoring unit 3 and the pump flushing monitoring unit 1, the main control unit 5 can calculate the total injection and return volumes within a certain time period, i.e., within the rated time, thereby estimating the width of the downhole fracture. Based on the width of the downhole fracture, the operator can select the appropriate plugging tool and method for corresponding construction.

[0047] In this invention, the flow monitoring unit 3 includes: a second liquid level sensor, a flow sensor, and a first microcontroller; the second liquid level sensor and the flow sensor are connected to the first microcontroller, and the first microcontroller is connected to the main control unit 5 through the wireless transmission module; the first microcontroller is used to determine the real-time cross-sectional area of ​​the drilling fluid in the hard pipeline based on the real-time return fluid level of the drilling fluid in the hard pipeline detected by the second liquid level sensor and the internal diameter of the hard pipeline, and to determine the real-time return discharge rate based on the real-time cross-sectional area and the real-time return drilling fluid flow rate of the drilling fluid in the hard pipeline detected by the flow sensor.

[0048] In this embodiment of the invention, a flow sensor is installed at the bottom of the rigid pipeline between the wellhead and the vibrating screen to detect the flow rate of drilling fluid passing through the rigid pipeline, i.e., the real-time return discharge rate. A second level sensor is installed at the top of the rigid pipeline to detect the level of the drilling fluid within the pipeline. While the flow sensor alone can detect the drilling fluid flow rate within the rigid pipeline, this flow rate is generally obtained when the pipeline is full. If the pipeline is not full, the measurement will have some error. Therefore, by using a second level sensor to detect the real-time return fluid level, the detection results of the flow sensor can be corrected.

[0049] After receiving the real-time return fluid level detected by the second level sensor, the first microcontroller can calculate the current cross-sectional area of ​​the fluid inside the rigid pipe based on the pre-stored internal diameter of the rigid pipe. The flow sensor can detect the real-time flow velocity of the fluid (drilling fluid) inside the rigid pipe. The first microcontroller can determine the current accurate fluid flow rate by multiplying the cross-sectional area by the real-time flow velocity, and compare it with the real-time flow rate detected by the flow sensor. If they are different, the real-time flow rate detected by the flow sensor is corrected, and the corrected real-time flow rate, i.e., the real-time return fluid discharge rate, is sent to the main control unit 5 via the wireless transmission module.

[0050] The flow sensor is an ultrasonic flow meter. The flow meter uses a 4-20mA standard signal.

[0051] In this invention, the pump flushing monitoring unit 1 includes: a pump flushing sensor and a second microcontroller; the second microcontroller is connected to the main control unit 5 through the wireless transmission module; the second microcontroller is used to determine the real-time injection discharge rate based on the number of pump flushes per minute of each mud pump in the mud pump group detected by the pump flushing sensor and the discharge rate corresponding to a pump flush.

[0052] In this embodiment of the invention, a mud pump group includes three mud pumps, and a pump flushing sensor is installed between the pump pressure gauge and the mud pumps. The pump flushing sensor detects the pump flushing of the three mud pumps and transmits the data to a second microcontroller. The second microcontroller counts the total number of pump flushing times per minute (real-time pump flushing) and multiplies it by the pre-stored displacement corresponding to each pump flushing time of each mud pump, thereby determining the total displacement of all mud pumps within one minute, i.e., the real-time injection displacement. Simultaneously, the second microcontroller sends the real-time pump flushing data detected by the pump flushing sensor to the main control unit 5.

[0053] Because the pressure in the mud pipeline connecting the wellhead and the mud pump unit is high, ordinary flow meters cannot withstand the high pressure, which may damage the sensor components. Therefore, it is impossible to install a traditional flow meter for input flow (displacement) detection. Furthermore, installing a flow meter at the inlet is cumbersome and affected by water supply efficiency; even if it could be installed, the measured data would be inaccurate. This invention uses a pump flushing sensor to detect the number of pump flushes and then calculates the injection displacement, thereby extending its service life and improving measurement accuracy.

[0054] In this invention, the main control unit 5 determines the total injection volume, total return volume, and total pump stroke based on the real-time injection volume, real-time return volume, and real-time pump stroke.

[0055] In this embodiment of the invention, after receiving the real-time injection volume from the first microcontroller of the flow monitoring unit 3, the real-time return volume from the second microcontroller of the pump flush monitoring unit 1, and the real-time pump flush from the second microcontroller of the pump flush monitoring unit 1 via the wireless transmission module, the main control unit 5 determines the total injection volume within a predetermined time based on the real-time injection volume, the total return volume within a predetermined time based on the real-time return volume, and the total pump flush within a predetermined time based on the real-time pump flush, and then displays the results on the display screen for easy observation and statistics by the operator.

[0056] In this invention, the main control unit 5 plots curves showing the changes in return displacement and injection displacement based on the real-time return displacement and the real-time injection displacement, and displays them on the display screen.

[0057] In this embodiment of the invention, the wireless transmission module includes a wireless transmitter 2 and a wireless receiver 4. The wireless transmitter 2 is installed at the mud pump set, the mud tank, and the rigid pipeline, respectively. The wireless transmitter 2 at the mud pump set is connected to a second microcontroller, a pump flush sensor, and a pump pressure sensor, respectively. The wireless transmitter 2 at the mud tank is connected to a temperature sensor, a density sensor, and a first liquid level sensor, respectively. The wireless transmitter 2 at the rigid pipeline is connected to a first microcontroller, a second liquid level sensor, and a flow sensor, respectively. The wireless receiver 4 is located in the driller's cabin and is connected to the main control unit 5 in the driller's cabin.

[0058] During monitoring, the second microcontroller transmits the determined real-time injection displacement and real-time pump flush, the real-time pump pressure detected by the pump pressure sensor, the real-time drilling fluid temperature detected by the temperature sensor, the real-time drilling fluid density detected by the density sensor, the real-time drilling fluid level detected by the first level sensor, the real-time return displacement determined by the first microcontroller, and the real-time return fluid level detected by the second level sensor to the wireless receiver 4 via the wireless transmitter 2 connected to it. The wireless receiver 4 transmits the received data to the main control unit 5. The main control unit 5 then performs statistical analysis on the received parameter data and plots the corresponding curves for display on the screen for easy viewing.

[0059] The wireless transmission module uses the Model Bus signal format to achieve stable data transmission at the well site.

[0060] The alarm unit 6 includes the main control unit 5, which displays the alarm on the host screen and is connected to an explosion-proof alarm.

[0061] The main control unit 5 system has functions such as displaying curves, printing, playback, and supporting data export from USB flash drives.

[0062] In this embodiment of the invention, the wireless leak real-time monitoring and alarm system needs to be installed before the drilling team starts drilling. The flow monitoring unit 3 is installed at the end of the rigid pipeline between the wellhead and the vibrating screen. The explosion-proof alarm is installed in the mud operator's duty room on the mud tank.

[0063] All field sensors transmit data via a full-site wireless network. The architecture employs a wireless main controller (wireless receiver 4) + wireless sub-controllers (wireless transmitter 2). Each sensor not only collects field data but also has an integrated independent processing chip to process the collected data locally and directly calculate the required parameter values, similar to a DCS structure. The sub-wireless sub-controllers output processed digital signals, ensuring reliable data transmission while reducing the computational load on the main station (main control unit 5). Each wireless sub-controller operates independently and does not interfere with the others.

[0064] The main control unit 5 is the "brain" of the entire system, responsible for signal processing, correction, and final user display of all data. It also manages the operation of all terminals of the drilling instrument system, and all mathematical models run within the main control unit 5. It also provides external data and operation interfaces.

[0065] Through the flow monitoring unit 3 and the pump surge monitoring unit 1, the changes in inlet and outlet flow rates can be accurately measured. Combined with parameters such as pump pressure, drilling fluid density, and drilling fluid level, the frequency of false alarms caused by on-site working conditions and other reasons can be effectively reduced, thereby enabling accurate early detection of well leakage or well kick risks.

[0066] The monitoring software within the main control unit 5 can monitor 14 parameters in real time, including instantaneous (real-time) injection volume, instantaneous return volume, rated (predetermined) time injection volume, rated time return volume, total injection volume, total return volume, real-time pump pressure, real-time pump flush, total pump flush, real-time drilling fluid density, real-time drilling fluid temperature, real-time drilling fluid level in the mud tank, real-time return fluid flow rate, and real-time return fluid level. All parameters can be displayed in the form of specific data or in an instrument panel mode. The data can be compared and displayed with multiple parameters such as injection volume and return volume, making it more intuitive. When leakage occurs, the left instrument panel will flash a color warning.

[0067] like Figure 2 As shown, when displaying curves, they are shown in pairs of the same type for easy comparison. Four small windows are used to display instantaneous injection and return flow rates, rated time injection and return flow rates, real-time return fluid velocity and level from flow monitoring unit 3, and real-time drilling fluid levels from multiple mud tanks. The left side of the interface also displays the real-time data of the curves in digital format. In the event of an overflow, the system software automatically issues a pop-up alarm.

[0068] The parameter settings page allows for the calibration, setting, and alarm threshold (preset range) of various parameters.

[0069] By installing ultrasonic level sensors in multiple mud tanks involved in the circulation, the mud tank level, total volume, and volume changes within a rated time can be monitored in real time, which can help determine when leakage occurs.

[0070] During field operations, false alarms can frequently occur due to sensor malfunctions and other reasons. This invention reduces the false alarm rate by comprehensively judging data from multiple sensors. When a leak occurs on-site, several parameters in the monitoring software of the main control unit 5 will change. For example, when a leak occurs, the curves in the monitoring software will show that the real-time injection rate and the real-time return rate, which were originally basically in sync, will suddenly slope downwards, and a difference will appear between the two curves, indicating a leak. The drilling team can be notified immediately for an early warning. After a few minutes, because the mud tank level changes relatively slowly, a decrease in the mud tank level and a decrease in pump pressure can be observed, which can finally confirm a leak. A final confirmation is then sent to the drilling team, ultimately reducing false alarms and avoiding unnecessary losses. The screen data displayed in the main control unit 5 in the driller's cabin can be sent to the signal secondary receiving unit through an independent module in the wireless main controller. Then, the wireless data is converted into 485 format and transmitted to the display unit in the engineer's cabin and the display unit in the team leader's office for display.

[0071] It is understood that the various embodiments mentioned above in this invention can be combined with each other to form combined embodiments without violating the principle and logic. Due to space limitations, this invention will not elaborate further.

[0072] This invention solves the problems of previous methods that relied on monitoring the mud tank's fluid level or manually measuring density to predict overflows. These methods often resulted in delayed detection of overflows, poor early warning times, and reliance on human negligence when changes in the fluid level were detected by an ultrasonic detector on the mud tank. By installing a flow monitoring unit 3 and a pump flow monitoring unit 1 at the drilling fluid inlet and outlet, the invention monitors and compares the injection and return flow rates of the drilling fluid in real time during drilling operations. When overflow or leakage occurs, an alarm is triggered promptly. This allows for real-time monitoring of the injection and return flow rates of the drilling fluid, and provides timely warnings and audible / optical / electric alarms in case of overflow or leakage, ensuring construction safety and improving operational efficiency.

[0073] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen to best explain the principles, practical application, or technical improvements to the embodiments in the market, or to enable others skilled in the art to understand the embodiments disclosed herein.

Claims

1. A wireless real-time monitoring and alarm system for leaks, characterized in that, include: Flow monitoring unit (3), pump flushing monitoring unit (1) and main control unit (5); A flow monitoring unit (3) is installed in the rigid pipeline between the wellhead of the target well and the vibrating screen. The flow monitoring unit (3) is used to detect the real-time return flow rate of the drilling fluid at the wellhead. A pump flushing monitoring unit (1) is installed inside the mud pump group of the target well. The pump flushing monitoring unit (1) is used to detect the real-time pump flushing of the mud pump in the mud pump group and determine the real-time injection rate of the drilling fluid injected into the target well by the mud pump group based on the pump flushing. The flow monitoring unit (3) and the pump flushing monitoring unit (1) are connected to the main control unit (5) through a wireless transmission module. The main control unit (5) determines, based on the received real-time injection discharge and real-time return discharge, that when the difference between the real-time injection discharge and the real-time return discharge exceeds a predetermined value, it controls the alarm unit (6) connected to it to start to provide an overflow warning.

2. The wireless leakage real-time monitoring and alarm system according to claim 1, characterized in that: The overflow and leakage warning prompts include: overflow warning and leakage warning; The main control unit (5) determines whether the real-time injection volume is greater than the real-time return volume when the difference between the real-time injection volume and the real-time return volume exceeds a predetermined value. If yes, it controls the leakage warning; if no, it controls the overflow warning.

3. The wireless leakage real-time monitoring and alarm system according to claim 1, characterized in that, Also includes: Pump pressure detection unit, density detection unit, temperature detection unit, and mud tank level detection unit; The pump pressure detection unit is installed in the mud pump group and is used to detect the real-time pump pressure of the mud pump. The density detection unit, temperature detection unit, and mud tank level detection unit are installed inside the mud tank of the target well. The density detection unit is used to detect the real-time drilling fluid density inside the mud tank, the temperature detection unit is used to detect the real-time drilling fluid temperature inside the mud tank, and the mud tank level detection unit is used to detect the real-time drilling fluid level inside the mud tank. The pump pressure detection unit, density detection unit, temperature detection unit, and mud tank level detection unit are respectively connected to the main control unit (5) via a wireless transmission module.

4. The wireless leakage real-time monitoring and alarm system according to claim 3, characterized in that: The pump pressure detection unit includes a pump pressure sensor, the density detection unit includes a density sensor, the temperature detection unit includes a temperature sensor, and the mud tank level detection unit includes a first level sensor.

5. The wireless leakage real-time monitoring and alarm system according to any one of claims 1-4, characterized in that: The flow monitoring unit (3) is also used to detect the real-time return fluid level and real-time return fluid flow rate of the drilling fluid in the hard pipeline. When the main control unit (5) controls the alarm unit (6) to start issuing an early warning, the main control unit (5) determines whether the value of one or any of the following items exceeds or falls below its corresponding predetermined range based on the received real-time pump pressure of the target well mud pump, the real-time drilling fluid density, the real-time drilling fluid temperature, the real-time drilling fluid level, the real-time return fluid level of the drilling fluid in the hard pipeline, and the real-time return fluid flow rate. If so, the main control unit (5) controls the alarm unit (6) connected to it to start an overflow alarm.

6. The wireless leakage real-time monitoring and alarm system according to claim 5, characterized in that, The predetermined range refers to the range of numerical variations of real-time pump pressure, real-time drilling fluid density, real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate under the condition that no leakage occurs.

7. The wireless leakage real-time monitoring and alarm system according to claim 5, characterized in that: The overflow alarm prompts include: overflow alarm and leakage alarm; The main control unit (5) determines whether the real-time drilling fluid density is lower than its corresponding predetermined range, and / or whether the value of one or any of the real-time drilling fluid temperature, real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate exceeds its corresponding predetermined range. If yes, the overflow alarm is triggered. The main control unit (5) determines whether the real-time pump pressure is lower than its corresponding predetermined range, and / or whether the value of one or any of the real-time drilling fluid level, real-time return fluid level, and real-time return fluid flow rate is lower than its corresponding predetermined range. If so, it controls the leakage alarm to be triggered.

8. The wireless leakage real-time monitoring and alarm system according to claim 5, characterized in that: When the main control unit (5) controls the overflow alarm prompt, the main control unit (5) determines the rated time injection volume and rated time return volume based on the real-time injection volume and real-time return volume, and determines the downhole fracture width based on the rated time injection volume and rated time return volume.

9. The wireless leakage real-time monitoring and alarm system according to claim 1, characterized in that, The flow monitoring unit (3) includes: a second liquid level sensor, a flow sensor, and a first microcontroller; The second liquid level sensor and the flow sensor are connected to the first microcontroller, and the first microcontroller is connected to the main control unit (5) through the wireless transmission module. The first microcontroller is used to determine the real-time cross-sectional area of ​​the drilling fluid in the hard pipeline based on the real-time return fluid level of the drilling fluid in the hard pipeline detected by the second level sensor and the internal diameter of the hard pipeline, and to determine the real-time return discharge rate based on the real-time cross-sectional area and the real-time return drilling fluid flow rate of the drilling fluid in the hard pipeline detected by the flow sensor.

10. The wireless leakage real-time monitoring and alarm system according to claim 1, characterized in that, The pump surge monitoring unit (1) includes: a pump surge sensor and a second microcontroller; The second microcontroller is connected to the main control unit (5) through the wireless transmission module; The second microcontroller is used to determine the real-time injection discharge rate based on the number of pump strokes per minute of each mud pump in the mud pump group detected by the pump stroke sensor and the discharge rate corresponding to one pump stroke.

11. The wireless leakage real-time monitoring and alarm system according to claim 1, characterized in that: The main control unit (5) determines the total injection volume, total return volume, and total pump stroke based on the real-time injection volume, real-time return volume, and real-time pump stroke.

12. The wireless leakage real-time monitoring and alarm system according to any one of claims 1-11, characterized in that: The main control unit (5) plots the change curves of return displacement and injection displacement based on the real-time return displacement and the real-time injection displacement, and displays them on the display screen.

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