A tripping automatic grouting system and continuous monitoring and intelligent control method

Abstract

The present application belongs to the technical field of oil and gas drilling engineering, and specifically relates to a tripping automatic grouting system and a continuous monitoring and intelligent control method, which comprises an anti-overflow pipe, a continuous overflow pipeline, an outlet flow accurate measurement unit, a liquid level sensor, a circulating tank, a driller display control unit, a tripping well depth tracking system, a grouting circulation control device and an electric control box. The electric control box is integrated with an intelligent measurement and control unit. The outlet flow accurate measurement unit is arranged on the anti-overflow pipe and connected with the circulating tank through the continuous overflow pipeline. The outlet flow accurate measurement unit is provided with a radar liquid level meter, a radar wave flow speed sensor and an industrial camera. The split structure is combined and installed to accurately measure the return and outlet flow, so that the real-time monitoring is significantly improved, the continuous monitoring is fundamentally improved, the monitoring accuracy is greatly improved, the adaptability to complex working conditions is high, the degree of intelligence is high, the manual intervention is less, and the well control safety is significantly improved.

Description

Technical Field

[0001] This invention relates to the field of oil and gas drilling engineering technology, specifically to an automatic grouting system for tripping in and out of the well and a method for continuous monitoring and intelligent control. Background Technology

[0002] In oil drilling operations, the tripping and running-out process is a high-risk phase for well control accidents. When the drill string is pulled out, the fluid column pressure in the well decreases. If drilling fluid is not replenished in time, formation fluid may enter the wellbore (overflow), which can escalate into a blowout in severe cases. Conversely, when the drill string is lowered into the well, the fluid column pressure increases. If this pressure exceeds the formation fracturing pressure, it can lead to drilling fluid loss (lost circulation). Therefore, automatic grouting and real-time monitoring during the tripping and running-out process are crucial technical aspects for ensuring well control safety.

[0003] Traditional drilling and grouting operations mainly rely on manual labor, which suffers from high labor intensity, numerous human factors, and lagging monitoring. With the development of automation technology, automatic grouting systems have been gradually promoted and applied, but existing technologies still have significant shortcomings.

[0004] Currently, the automatic grouting system for tripping and running out of drilling mainly adopts the following technical solutions: (1) Automatic grouting system based on drilling fluid pool level monitoring This type of system determines changes in the amount of drilling fluid in the wellbore by monitoring changes in the fluid level in the circulation tank (drilling fluid pool). When a drop in fluid level is detected, a grouting pump is activated to replenish drilling fluid into the well.

[0005] (2) Automatic grouting system based on flow metering This type of system installs flow meters on the grouting pipeline and the return pipeline, and determines overflow or leakage by comparing the difference between the inlet and outlet flow rates. When the inlet flow rate is greater than the outlet flow rate, it is considered leakage; otherwise, it is considered overflow. Representative technologies include electromagnetic flow meters and ultrasonic flow meters.

[0006] (3) Automatic grouting system based on pressure monitoring This type of system monitors changes in parameters such as riser pressure and casing pressure, and calculates the displacement of drilling tools to determine the wellbore pressure status and control the grouting process.

[0007] The aforementioned existing technical solutions have the following main technical defects: (1) Monitoring lag problem Existing systems generally use circulating tank level monitoring. The path of drilling fluid from the wellhead through the overflow pipe, vibrating screen, and drilling fluid tank back to the circulating tank is long (usually exceeding 50 meters), resulting in a long monitoring response time (3-5 minutes). The circulating tank has a large internal cross-sectional area (up to 80m²), so small changes in drilling fluid can cause minimal level changes, leading to large monitoring errors (above ±0.5m³). This makes it impossible to detect overflows and leaks early, and can easily cause the optimal time for well shut-in to be missed.

[0008] (2) Problem of intermittent monitoring being unable to quantify Existing systems generally employ an intermittent grouting strategy, which involves a large-scale grouting operation after every 1-3 drill pipes are retrieved. This discrete monitoring method has significant blind spots: if slow overflows or leaks occur during the time interval between two grouting operations, the system cannot detect them in time; furthermore, it cannot quantitatively describe the extent of the overflow or leak, making it difficult to accurately assess well control risks.

[0009] (3) Monitoring accuracy and reliability issues Existing sensor technologies have significant limitations: electromagnetic flowmeters and ultrasonic Doppler flowmeters are limited by their measurement principles, requiring full pipes before and after them, and the placement of elbows, valves, etc. on site affects installation and use; the lining of electromagnetic flowmeters is easily eroded and worn by drilling fluid, resulting in a significant decrease in accuracy; liquid level sensors operate in harsh environments containing sand, gas, and vibration for extended periods, making them susceptible to interference and false alarms.

[0010] (4) Poor adaptability to complex working conditions When the formation fluid is gas, condensate, or a high gas-oil ratio fluid, the gas phase in the drilling fluid exhibits a high-pressure dissolution effect due to the well depth and fluid column pressure, making it difficult to detect overflows early. In horizontal wells with extended reach, overflow material may move forward and conceal itself along the high edge of the horizontal section during pump shutdown, but it will move rapidly upward once it enters the inclined or vertical section, posing a risk to timely well shut-in. In formations with narrow safety density windows, complex situations such as leakage at the top and leakage at the bottom or vice versa may occur, which existing systems cannot accurately determine.

[0011] (5) Insufficient level of intelligence The existing system still requires on-site personnel to make judgments based on return flow, pump suction volume, and theoretical consumption, which is highly dependent on human factors; it lacks adaptive capabilities and cannot dynamically adjust monitoring parameters and alarm thresholds according to working conditions such as formation characteristics, drill string assembly, and tripping speed; and there is a lack of unified standard interfaces between equipment from different manufacturers, making it difficult for the systems to coordinate effectively.

[0012] In summary, existing automatic grouting technology for tripping in and out of the well has significant shortcomings in terms of real-time performance, continuity, accuracy, reliability, and intelligence. There is an urgent need for an automatic grouting system that can achieve real-time continuous monitoring at the wellhead, intelligent identification of multiple parameters, and continuous and precise control of flow rate. Summary of the Invention

[0013] The purpose of this invention is to provide an automatic grouting system for tripping in and out of the drilling site, as well as a continuous monitoring and intelligent control method, to solve the problems mentioned in the background art.

[0014] To achieve the above objectives, the present invention provides the following technical solution: an automatic grouting system for tripping in and out of drilling, comprising: an overflow prevention pipe, a continuous overflow pipeline, an outlet flow rate precision measurement unit, a liquid level sensor, a circulation tank, a driller display and control unit, a tripping in and out drilling depth tracking system, a grouting circulation control device, and an electrical control box, wherein the electrical control box integrates an intelligent measurement and control unit; The precise outlet flow measurement unit is installed on the overflow prevention pipe and connected to the circulation tank through a continuous overflow pipeline. The precise outlet flow measurement unit is equipped with a radar level gauge, a radar wave velocity sensor and an industrial camera, and is assembled in a split structure to accurately return the flow. The liquid level sensor is installed inside the circulation tank, which is connected to the grouting circulation control device. The intelligent measurement and control unit is electrically connected to the tripping depth tracking system, the outlet flow precision measurement unit, the liquid level sensor, the grouting circulation control device, and the driller's display and control unit.

[0015] Preferably, the grouting circulation control device includes an injection slurry pump, a flow regulating valve, an air chamber, a pressure sensor, a flow sensor, a wellhead valve assembly, and a cleaning pipeline; The injection slurry pump inlet is connected to the circulation tank, the injection slurry pump outlet is connected to the first interface of the flow regulating valve, and a pressure sensor is connected to the first interface. The flow regulating valve's second interface is connected to a flow sensor, which is connected to the wellhead valve group. The flow regulating valve's third interface is connected to the circulation tank through a return pipe, and an air manifold is also connected to the flow regulating valve.

[0016] Preferably, the wellhead valve assembly includes a wellhead grouting and cleaning control valve, the first interface of the wellhead valve assembly is connected to a flow sensor, the second interface of the wellhead valve assembly is connected to a wellhead grouting pipeline, and the third interface of the wellhead valve assembly is connected to an external cleaning pipeline.

[0017] Preferably, the intelligent measurement and control unit is configured to: collect data from the outlet flow precision measurement unit; collect data from the liquid level sensor; receive control commands from the driller's display and control unit; and, based on the above data and control commands, use a multi-parameter fusion algorithm to identify overflow or leakage events. Based on the identification results and the drill string displacement prediction model, the grouting circulation control device is controlled to perform micro-continuous grouting or to issue an alarm signal. The multi-parameter fusion algorithm includes: acquiring monitoring data of the grouting circulation control device with a sampling period of 0.5-2 seconds, and performing filtering, noise reduction, and outlier removal; calculating the liquid level change rate, inlet / outlet flow difference, pressure fluctuation characteristic value, and cumulative volume difference; dynamically calculating the overflow / leakage judgment threshold based on the current drilling speed, drill string assembly parameters, and formation characteristics; and determining an overflow or leakage event when at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue to exceed a preset time window. The dynamic threshold is calculated using an adaptive algorithm, which is adjusted in real time based on historical monitoring data from the previous N tripping in and out of the drilling cycle, where N is an integer from 3 to 10.

[0018] Preferably, the intelligent monitoring and control unit is also configured to: calculate the instantaneous leakage amount and the cumulative leakage amount; and assess the severity level of the leakage based on the cumulative leakage amount and the formation pressure coefficient. Preferably, the drill string displacement prediction model calculates the theoretical displacement flow rate based on the tripping speed and drill string structural parameters, and introduces a correction coefficient to consider drilling fluid compressibility, temperature effects, and wellbore filtration loss factors.

[0019] Preferably, the grouting circulation control device continuously injects drilling fluid into the wellbore at a flow rate of 10-200 L / min, and the flow rate is dynamically adjusted according to the theoretical displacement flow rate.

[0020] Preferably, the intelligent measurement and control unit uses a PID control algorithm, a fuzzy PID control algorithm, or an adaptive PID control algorithm to adjust the grouting circulation control device based on the flow rate measured by the outlet flow rate precision measurement unit and the real-time feedback from the liquid level sensor, so that the actual liquid level is maintained within the range of ±5cm of the target liquid level. The intelligent measurement and control unit is also configured to: record monitoring data, identification results and control commands throughout the entire drilling process, and generate a digital construction report; optimize the correction coefficient of the drill string displacement prediction model, the calculation parameters of the dynamic threshold and the PID control parameters based on historical monitoring data.

[0021] A continuous monitoring and intelligent control method, employing an automatic grouting system for tripping in and out of the drilling rig, includes the following steps: S1: Real-time monitoring step, acquiring monitoring data with a sampling period of 0.5-2 seconds; S2: Data preprocessing step, which involves filtering and denoising the monitoring data and removing outliers; S3: Overflow and leakage identification step, which uses a multi-parameter fusion algorithm to determine whether an overflow or leakage has occurred, and the degree of overflow or leakage; Calculate the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation characteristic value; dynamically calculate the overflow judgment threshold based on the current tripping speed, drill string assembly parameters, and formation characteristics; when at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue for more than a preset time window, it is determined as an overflow or leakage event; calculate the instantaneous overflow and cumulative overflow, and assess the severity level of the overflow. S4: Decision control steps, based on the identification results: if normal, perform continuous micro-grouting; if overflow, issue a level one alarm and stop grouting, prepare to shut down the well; if leakage, issue a level two alarm and increase the grouting volume to maintain the liquid level; Micro-volume continuous grouting includes: establishing a drilling fluid displacement prediction model, calculating the theoretical displacement flow rate based on tripping speed and drilling tool structural parameters; introducing correction coefficients to consider drilling fluid compressibility, temperature effects, and wellbore filtration loss factors, and calculating the actual target grouting flow rate; controlling grouting to continuously inject within a flow rate range of 10-200 L / min, and using a PID control algorithm to adjust the flow rate based on the outlet flow rate measurement unit and real-time liquid level feedback, so that the actual liquid level is maintained within ±5 cm of the target liquid level; S5: Feedback adjustment step, adjusts grouting parameters according to real-time liquid level feedback to form closed-loop control; S6: Data recording steps, recording monitoring data, identification results and control instructions throughout the entire drilling process, and generating a digital construction report; S7: Self-learning optimization step, optimizing the correction coefficient of the drill string displacement prediction model, the calculation parameters of the dynamic threshold, and the PID control parameters based on historical data.

[0022] Compared with the prior art, the beneficial effects of the present invention are: (1) The real-time performance of monitoring has been significantly improved. By setting up a precise outlet flow measurement unit at the wellhead, the monitoring point is moved forward to the wellhead. The returned drilling fluid can be monitored in real time without having to travel a long distance. The monitoring response time is shortened from the traditional 3-5 minutes to less than 30 seconds (a reduction of more than 80%), enabling early detection of overflow and leakage.

[0023] (2) Fundamental improvement in monitoring continuity The micro-volume continuous grouting strategy (flow rate 10-200L / min continuously adjustable) replaces the traditional intermittent large-volume grouting (grouting once every 1-3 columns), eliminating monitoring blind spots and realizing continuous monitoring throughout the entire tripping process, which can capture hidden working conditions such as slow overflow and micro-leakage.

[0024] (3) Monitoring accuracy has been greatly improved By optimizing the flow field stability through the precise measurement unit of the outlet flow rate and combining it with a multi-parameter fusion algorithm (fusion of multi-source data of liquid level, flow rate and pressure), the overflow identification accuracy has been improved from ±0.5m³ to ±0.05m³ (a 10-fold improvement), and the false alarm rate has been reduced by more than 80%.

[0025] (4) Strong adaptability to complex working conditions The dynamic threshold adaptive algorithm can adjust the monitoring parameters in real time according to the tripping speed, drill string combination, and formation characteristics, adapting to different working conditions such as conventional wells, horizontal wells, deep wells, and narrow density window wells; the multi-parameter fusion judgment mechanism can effectively identify complex situations such as gas phase fluids and cuttings interference.

[0026] (5) High degree of intelligence and little human intervention The drill string displacement prediction model and closed-loop feedback control strategy realize the automation and intelligent control of the grouting process. On-site personnel only need to monitor the system's operating status and do not need to operate it manually frequently. The self-learning optimization function enables the system performance to continuously improve with the number of uses.

[0027] (6) Well control safety has been significantly improved In summary, the present invention reduces the overflow detection time from minutes to seconds, improves the quantitative accuracy of leakage by 10 times, significantly reduces the risk of well control accidents such as blowouts and lost circulation, and improves the safety and economy of drilling operations. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the connection path of the present invention; Figure 2 This is a schematic diagram of the grouting circulation control device of the present invention.

[0029] In the diagram: 1. Injection slurry pump; 2. Flow control valve; 3. Air chamber; 4. Pressure sensor; 5. Electrical control box; 6. Flow sensor; 7. Wellhead valve assembly. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0032] Example 1: Please see Figure 1-2 The present invention provides a technical solution: an automatic grouting system for tripping in and out of the well, comprising: an overflow prevention pipe, a continuous overflow pipeline, an outlet flow rate precision measurement unit, a liquid level sensor, a circulation tank, a driller display and control unit, a tripping in and out well depth tracking system, a grouting circulation control device, and an electrical control box 5, wherein the electrical control box 5 integrates an intelligent measurement and control unit; The outlet flow rate precision measurement unit is installed on the overflow prevention pipe and connected to the circulation tank through a continuous overflow pipeline. The outlet flow rate precision measurement unit is equipped with a radar level gauge, a radar wave velocity sensor and an industrial camera. The split structure is combined and installed to accurately return the flow rate, and adopts the patented algorithm CN202510607843. The liquid level sensor is installed in the circulation tank, which is connected to the grouting circulation control device. The intelligent measurement and control unit is electrically connected to the tripping and running-out drilling depth tracking system, the outlet flow precise measurement unit, the liquid level sensor, the grouting circulation control device, and the driller's display and control unit. The grouting circulation control device includes an injection slurry pump 1, a flow regulating valve 2, a pressure sensor 4, an air chamber 3, a wellhead valve group 7, a flow sensor 6, and a cleaning pipeline; The inlet of the injection slurry pump 1 is connected to the circulation tank, the outlet of the injection slurry pump 1 is connected to the first interface of the flow regulating valve 2, and the first interface is connected to the pressure sensor 4. The second interface of the flow regulating valve 2 is connected to the flow sensor 6, the flow sensor 6 is connected to the wellhead valve group 7, the third interface of the flow regulating valve 2 is connected to the circulation tank through the return pipe, and the flow regulating valve 2 is also connected to the air chamber 3.

[0033] The wellhead valve group 7 includes a wellhead grouting and cleaning control valve. The first interface of the wellhead valve group is connected to a flow sensor, the second interface of the wellhead valve group is connected to a wellhead grouting pipeline, and the third interface of the wellhead valve group is connected to an external cleaning pipeline.

[0034] The intelligent measurement and control unit is configured to: collect data from the outlet flow precision measurement unit; collect data from the liquid level sensor; receive control commands from the driller's display and control unit; and, based on the above data and control commands, use a multi-parameter fusion algorithm to identify overflow or leakage events. Based on the identification results and the drill string displacement prediction model, the grouting circulation control device is controlled to perform micro-continuous grouting or to issue an alarm signal. The multi-parameter fusion algorithm includes: acquiring monitoring data of the grouting circulation control device with a sampling period of 0.5-2 seconds, and performing filtering, noise reduction, and outlier removal; calculating the liquid level change rate, inlet / outlet flow difference, pressure fluctuation characteristic value, and cumulative volume difference; dynamically calculating the overflow / leakage judgment threshold based on the current drilling speed, drill string assembly parameters, and formation characteristics; and determining an overflow or leakage event when at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue to exceed a preset time window. The dynamic threshold is calculated using an adaptive algorithm, which is adjusted in real time based on historical monitoring data from the previous N tripping in and out of the drilling cycle, where N is an integer from 3 to 10; The intelligent monitoring and control unit is also configured to: calculate the instantaneous leakage and cumulative leakage; and assess the severity level of leakage based on the cumulative leakage and the formation pressure coefficient.

[0035] The drill string displacement prediction model calculates the theoretical displacement flow rate based on the tripping speed and drill string structural parameters, and introduces a correction coefficient to consider drilling fluid compressibility, temperature effects, and wellbore filtration loss factors.

[0036] The grouting circulation control device continuously injects drilling fluid into the wellbore at a flow rate of 10-200 L / min, and the flow rate is dynamically adjusted according to the theoretical displacement flow rate.

[0037] The intelligent measurement and control unit uses PID control algorithm, fuzzy PID control algorithm or adaptive PID control algorithm to adjust the grouting circulation control device based on the real-time feedback of the flow rate measured by the outlet flow rate precision measurement unit and the liquid level sensor, so that the actual liquid level is maintained within the range of ±5cm of the target liquid level. The intelligent measurement and control unit is also configured to: record monitoring data, identification results and control commands throughout the entire drilling process, and generate a digital construction report; optimize the correction coefficient of the drill string displacement prediction model, the calculation parameters of the dynamic threshold and the PID control parameters based on historical monitoring data.

[0038] Analysis of the above content: The multi-parameter fusion algorithm used by the intelligent control unit includes the following steps: Data Acquisition and Preprocessing The monitoring data of the liquid level sensor, inlet flow sensor, outlet flow sensor, and pressure sensor are acquired with a sampling period of 0.5-2 seconds. The monitoring data is filtered and denoised (using Kalman filtering or wavelet denoising algorithm) and outlier removal is performed (using 3σ criterion or Grubbs criterion).

[0039] Feature parameter calculation Calculate the rate of change of liquid level (dh / dt); Calculate the difference between inlet and outlet flow rates (ΔQ = Q_in - Q_out); Calculate pressure fluctuation characteristic values ​​(pressure change rate, pressure variance, etc.); Calculate the cumulative volume difference (integrate the flow rate difference over time).

[0040] Dynamic threshold calculation Based on the current tripping speed (v), drill string assembly parameters (outer diameter D_o, inner diameter Di_i, displacement per unit length V_d), and formation characteristic coefficient (k), the leakage judgment threshold is dynamically calculated: Threshold calculation formula: Liquid level change rate threshold: Th_h=f(v,V_d,k) Flow difference threshold: Th_Q=g(v,V_d,ε) (ε is the measurement error compensation coefficient) Pressure fluctuation threshold: Th_p=h(v,ρ,g) (ρ is the drilling fluid density, g is the gravitational acceleration) The dynamic threshold adopts an adaptive algorithm, which is adjusted in real time based on historical monitoring data from the previous N tripping in and out of the drilling cycle (N=3-10). The calculation formula is as follows: Th_new=α·Th_old+(1-α)·Th_calculated Where α is the smoothing coefficient (0.5-0.9), and Th_calculated is the theoretical threshold calculated based on the current operating conditions.

[0041] Multi-parameter fusion judgment When at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue for more than a preset time window (T=5-30 seconds), it is determined to be an overflow or leakage event. Based on the trend of the cumulative volume difference, overflow (the cumulative difference is positive and increasing) or leakage (the cumulative difference is negative and the absolute value increases) can be distinguished.

[0042] Quantitative assessment of leakage level Calculate the instantaneous leakage rate (Q_leak=|ΔQ-ΔQ_theory|); Integrate the instantaneous leakage over time to obtain the cumulative leakage (V_leak=∫Q_leakdt). Based on the cumulative leakage volume and formation pressure coefficient, assess the severity level of the leakage (minor, moderate, severe).

[0043] The micro-continuous grouting control method executed by the intelligent control unit includes: (1) Establishment of a model for predicting the displacement of drilling tools Based on the tripping speed (v) and drill string structural parameters, a theoretical displacement volume calculation model is established: Theoretical replacement flow: Q_theory = v·A_effective Where: A_effective = π / 4·(D_hole² - D_o²) (drilling start, annular volume change) Alternatively: A_effective = π / 4·D_i² (drilling down, change in drill string volume) Considering factors such as drilling fluid compressibility, temperature effects, and wellbore filtration loss, a correction factor β (0.85-1.15) is introduced: Actual target grouting flow rate: Q_target = β·Q_theory (2) Micro-continuous grouting implementation The grouting pump is controlled to inject grout continuously at a flow rate matching the theoretical displacement volume, rather than the traditional intermittent large-volume injection. The flow rate of the micro-volume continuous grouting is in the range of 10-200 L / min, and is dynamically adjusted according to the wellbore volume and tripping speed. A variable frequency drive device is used to adjust the opening angle of the grouting pump valve, thereby achieving stepless flow regulation. (3) Closed-loop feedback control The changes in wellbore liquid level are monitored in real time by the outlet flow rate precision measurement unit and the liquid level sensor. The actual liquid level is compared with the target liquid level to obtain the liquid level deviation (e=h_target-h_actual). The flow regulation amount is calculated using a PID control algorithm (or fuzzy PID, adaptive PID): ΔQ=Kp·e+Ki·∫e·dt+Kd·de / dt Where Kp, Ki, and Kd are PID parameters that are adaptively adjusted according to the operating conditions; Adjust the grouting pump speed and / or the valve opening according to the flow rate adjustment amount to maintain the actual liquid level within ±5cm of the target liquid level.

[0044] (4) Abnormal operating condition handling strategy Overflow determination: Immediately stop grouting, issue a Level 1 alarm (audible and visual alarm + remote notification), and prompt preparation to shut down the well; Leakage detection: Increase the grouting volume (increase the target liquid level maintenance value), issue a level 2 alarm, record the leakage amount, and prompt preparation for leak plugging; Sensor failure: Automatically switch to a backup sensor or use model-based predictive control to ensure continuous system operation.

[0045] Data recording function: Record monitoring data (liquid level, flow rate, pressure, temperature, etc., sampling frequency 1-10Hz) throughout the entire drilling process. Record the identification results (normal / overflow / leakage, severity, time of occurrence); Record control commands (grouting flow rate, pump speed, valve opening, etc.); Generates digital construction reports, supporting historical data query, trend analysis, and report export. Self-learning optimization function: Based on historical data, the correction coefficient β in the drill string displacement prediction model is optimized. Optimize the calculation parameters of the dynamic threshold based on historical false alarms / missed alarms; Based on the control effect, optimize the PID control parameters.

[0046] Example 2: Please see Figure 1-2 This invention provides a technical solution: a continuous monitoring and intelligent control method, employing an automatic grouting system for tripping in and out of the drilling rig, comprising the following steps: S1: Real-time monitoring step, acquiring monitoring data with a sampling period of 0.5-2 seconds; S2: Data preprocessing step, which involves filtering and denoising the monitoring data and removing outliers; S3: Overflow and leakage identification step, which uses a multi-parameter fusion algorithm to determine whether an overflow or leakage has occurred, and the degree of overflow or leakage; Calculate the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation characteristic value; dynamically calculate the overflow judgment threshold based on the current tripping speed, drill string assembly parameters, and formation characteristics; when at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue for more than a preset time window, it is determined as an overflow or leakage event; calculate the instantaneous overflow and cumulative overflow, and assess the severity level of the overflow. S4: Decision control steps, based on the identification results: if normal, perform continuous micro-grouting; if overflow, issue a level one alarm and stop grouting, prepare to shut down the well; if leakage, issue a level two alarm and increase the grouting volume to maintain the liquid level; Micro-volume continuous grouting includes: establishing a drilling fluid displacement prediction model, calculating the theoretical displacement flow rate based on tripping speed and drilling tool structural parameters; introducing correction coefficients to consider drilling fluid compressibility, temperature effects, and wellbore filtration loss factors, and calculating the actual target grouting flow rate; controlling grouting to continuously inject within a flow rate range of 10-200 L / min, and using a PID control algorithm to adjust the flow rate based on the outlet flow rate measurement unit and real-time liquid level feedback, so that the actual liquid level is maintained within ±5 cm of the target liquid level; S5: Feedback adjustment step, adjusts grouting parameters according to real-time liquid level feedback to form closed-loop control; S6: Data recording steps, recording monitoring data, identification results and control instructions throughout the entire drilling process, and generating a digital construction report; S7: Self-learning optimization step, optimizing the correction coefficient of the drill string displacement prediction model, the calculation parameters of the dynamic threshold, and the PID control parameters based on historical data.

[0047] The precise outlet flow measurement unit is equipped with a radar level gauge, a radar wave velocity sensor, and an industrial camera, and adopts the patented algorithm CN202510607843 with an innovative structural design.

[0048] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0049] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An automatic grouting system for tripping in and out of drilling, characterized in that, include: Overflow prevention pipe, continuous overflow pipeline, outlet flow precision measurement unit, liquid level sensor, circulation tank, driller display and control unit, tripping and drilling depth tracking system, grouting circulation control device and electrical control box (5), wherein the electrical control box (5) integrates an intelligent measurement and control unit; The outlet flow rate precision measurement unit is installed on the overflow prevention pipe and connected to the circulation tank through a continuous overflow pipeline. The outlet flow rate precision measurement unit is equipped with a radar level gauge, a radar wave velocity sensor and an industrial camera. The separate structure is combined and installed to accurately measure the return flow rate. The liquid level sensor is installed inside the circulation tank, which is connected to the grouting circulation control device. The intelligent measurement and control unit is electrically connected to the tripping depth tracking system, the outlet flow precision measurement unit, the liquid level sensor, the grouting circulation control device, and the driller's display and control unit.

2. The automatic grouting system for tripping in and out of the drilling rig according to claim 1, characterized in that: The grouting circulation control device includes an injection slurry pump (1), a flow regulating valve (2), a pressure sensor (4), an air bag (3), a wellhead valve group (7), a flow sensor (6), and a cleaning pipeline; The inlet of the injection slurry pump (1) is connected to the circulation tank, the outlet of the injection slurry pump (1) is connected to the first interface of the flow regulating valve (2), and a pressure sensor (4) is connected to the first interface. The second interface of the flow regulating valve (2) is connected to the flow sensor (6), the flow sensor (6) is connected to the wellhead valve group (7), the third interface of the flow regulating valve (2) is connected to the circulation tank through the return pipe, and an air bag (3) is also connected to the flow regulating valve (2).

3. The automatic grouting system for tripping in and out of the drilling rig according to claim 2, characterized in that: The wellhead valve assembly (7) includes a wellhead grouting and cleaning control valve. The first interface of the wellhead valve assembly (7) is connected to the flow sensor (6), the second interface of the wellhead valve assembly (7) is connected to the wellhead grouting pipeline, and the third interface of the wellhead valve assembly (7) is connected to the external cleaning pipeline.

4. The automatic grouting system for tripping in and out of the drilling rig according to claim 1, characterized in that: The intelligent measurement and control unit is configured to: collect data from the outlet flow precision measurement unit; collect data from the liquid level sensor; receive control commands from the driller's display and control unit; and, based on the above data and control commands, use a multi-parameter fusion algorithm to identify overflow or leakage events. Based on the identification results and the drill string displacement prediction model, the grouting circulation control device is controlled to perform micro-continuous grouting or to issue an alarm signal. The multi-parameter fusion algorithm includes: acquiring monitoring data of the grouting circulation control device with a sampling period of 0.5-2 seconds, and performing filtering, noise reduction, and outlier removal; calculating the liquid level change rate, inlet / outlet flow difference, pressure fluctuation characteristic value, and cumulative volume difference; dynamically calculating the overflow / leakage judgment threshold based on the current drilling speed, drill string assembly parameters, and formation characteristics; and determining an overflow or leakage event when at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue to exceed a preset time window. The dynamic threshold is calculated using an adaptive algorithm, which is adjusted in real time based on historical monitoring data from the previous N tripping in and out of the drilling cycle, where N is an integer from 3 to 10.

5. The automatic grouting system for tripping in and out of the drilling rig according to claim 4, characterized in that: The intelligent monitoring and control unit is also configured to: calculate the instantaneous leakage and cumulative leakage; and assess the severity level of leakage based on the cumulative leakage and the formation pressure coefficient.

6. The automatic grouting system for tripping in and out of drilling according to claim 4, characterized in that: The drill string displacement prediction model calculates the theoretical displacement flow rate based on the tripping speed and drill string structural parameters, and introduces a correction coefficient to consider drilling fluid compressibility, temperature effects, and wellbore filtration loss factors.

7. The automatic grouting system for tripping in and out of the drilling rig according to claim 4, characterized in that: The grouting circulation control device continuously injects drilling fluid into the wellbore at a flow rate of 10-200 L / min, and the flow rate is dynamically adjusted according to the theoretical displacement flow rate.

8. The automatic grouting system for tripping in and out of the drilling rig according to claim 4, characterized in that: The intelligent measurement and control unit uses PID control algorithm, fuzzy PID control algorithm or adaptive PID control algorithm to adjust the grouting circulation control device based on the real-time feedback of the flow rate measured by the outlet flow rate precision measurement unit and the liquid level sensor, so that the actual wellbore liquid level is maintained within the target liquid level ±5cm range. The intelligent measurement and control unit is also configured to: record monitoring data, identification results and control commands throughout the entire drilling process, and generate a digital construction report; optimize the correction coefficient of the drill string displacement prediction model, the calculation parameters of the dynamic threshold and the PID control parameters based on historical monitoring data.

9. A continuous monitoring and intelligent control method, characterized in that: The automatic grouting system for tripping in and out of the drill string as described in any one of claims 1-8 is characterized by comprising the following steps: S1: Real-time monitoring step, acquiring monitoring data with a sampling period of 0.5-2 seconds; S2: Data preprocessing step, which involves filtering and denoising the monitoring data and removing outliers; S3: Overflow and leakage identification step, which uses a multi-parameter fusion algorithm to determine whether an overflow or leakage has occurred, and the degree of overflow or leakage; Calculate the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation characteristic value; dynamically calculate the overflow judgment threshold based on the current tripping speed, drill string assembly parameters, and formation characteristics; when at least two of the liquid level change rate, inlet / outlet flow difference, and pressure fluctuation simultaneously exceed the dynamic threshold and continue for more than a preset time window, it is determined as an overflow or leakage event; calculate the instantaneous overflow and cumulative overflow, and assess the severity level of the overflow. S4: Decision control steps, based on the identification results: if normal, perform continuous micro-grouting; if overflow, issue a level one alarm and stop grouting, prepare to shut down the well; if leakage, issue a level two alarm and increase the grouting volume to maintain the liquid level; Micro-volume continuous grouting includes: establishing a drilling fluid displacement prediction model, calculating the theoretical displacement flow rate based on tripping speed and drilling fluid structural parameters; introducing a correction coefficient to consider drilling fluid compressibility, temperature effects, and wellbore filtration loss factors, and calculating the actual target grouting flow rate; controlling grouting to continuously inject within a flow rate range of 10-200 L / min, and using a PID control algorithm to adjust the flow rate based on real-time liquid level feedback, so that the actual liquid level is maintained within ±5 cm of the target liquid level; S5: Feedback adjustment step, adjusts grouting parameters according to real-time liquid level feedback to form closed-loop control; S6: Data recording step, recording monitoring data, identification results and control commands throughout the drilling process, and generating a digital construction report; S7: Self-learning optimization step, optimizing the correction coefficient of the drill string displacement prediction model, the calculation parameters of the dynamic threshold and the PID control parameters based on historical data.

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