An intelligent continuous circulation drilling flow splitter and its use method

Abstract

This invention relates to the field of drilling technology and discloses an intelligent continuous circulation drilling manifold and its usage method. The manifold includes a main passage, a bypass passage, a bypass grouting passage, a main grouting passage, and a pressure relief passage. The main passage includes a main gate valve connected to the top drive drilling device to input drilling fluid into the drill pipe. The bypass passage includes a bypass gate valve connected to the circulation sub to input drilling fluid into the circulation sub. The bypass grouting passage includes a bypass grouting gate valve, a bypass grouting throttle valve, and a bypass grouting check valve connected in sequence. The main grouting passage includes a main grouting gate valve, a main grouting throttle valve, and a main grouting check valve connected in sequence. The pressure relief passage includes a pressure relief gate valve connected to the bypass grouting throttle valve, the main grouting throttle valve, and the mud tank. This invention, by controlling the opening degree of the throttle valves in the main and bypass grouting passages, reduces pressure fluctuations when switching between the main and bypass passages, making operation safer and more reliable.

Description

Technical Field

[0001] This invention relates to the field of drilling technology, and in particular to an intelligent continuous circulation drilling manifold and its usage method. Background Technology

[0002] During drilling operations, pump shutdown is required when connecting new drill pipes or drill strings. However, frequent pump starts and stops can easily lead to downhole malfunctions such as well kicks, lost circulation, stuck pipe, and gas intrusion, severely impacting drilling safety and efficiency. Continuous circulation drilling systems can maintain continuous drilling fluid circulation and a stable equivalent circulation density during drill pipe connection, continuously removing cuttings and effectively avoiding the aforementioned risks. The shunt manifold, as the core component of this system, directly determines the stability and safety of continuous circulation operations.

[0003] The current manifold system still has many problems. Its operation relies on manual labor, the procedures are cumbersome, and it is prone to safety accidents due to human error. When switching, the idle channels lack drilling fluid filling, which can easily lead to short-term interruption of the drilling string circulation and instability of surface and bottom hole pressure. When valves malfunction on site, repeated switching and troubleshooting are required, which is time-consuming and labor-intensive, seriously affecting the construction progress. Moreover, the manifold is often used in different well sites and under different operating conditions, resulting in large differences in valve wear and making it difficult to accurately predict the service life. Using it beyond its service life can easily lead to sudden failures, and blind maintenance increases construction costs. Summary of the Invention

[0004] The technical problem to be solved by this invention is: how to quickly identify fault points and predict valve life, thereby reducing fault identification time and maintenance frequency, and improving the safety and stability of existing manifold systems. In order to solve the above technical problem, this invention provides an intelligent continuous circulation drilling manifold and its usage method, including a top drive drilling device, a circulation sub and a mud tank, including a main passage, a bypass passage, a bypass grouting passage, a main passage grouting passage and a pressure relief passage.

[0005] The main passage includes a main gate valve connected to the top drive drilling unit to supply drilling fluid to the drill pipe; the bypass passage includes a bypass gate valve connected to the circulation sub to supply drilling fluid to the circulation sub; the bypass grouting path includes a bypass grouting gate valve, a bypass grouting throttle valve, and a bypass grouting check valve connected in sequence, the bypass grouting gate valve connecting the main gate valve and the top drive drilling unit, and the bypass grouting check valve connecting the bypass... The gate valve is connected to the circulation sub; the main grouting circuit includes a main grouting gate valve, a main grouting throttle valve, and a main grouting check valve connected in sequence. The main grouting gate valve connects the bypass gate valve to the circulation sub, and the bypass grouting check valve connects the main gate valve to the top drive drilling device; the pressure relief circuit includes a pressure relief gate valve, one end of which connects the bypass grouting throttle valve to the main grouting throttle valve, and the other end of which connects to the mud tank.

[0006] Preferably, the main passage includes a first acoustic sensor for monitoring the status of the main gate valve; the bypass passage includes a second acoustic sensor for monitoring the status of the bypass gate valve; the bypass grouting passage includes a third and a fourth acoustic sensor, the third acoustic sensor for monitoring the status of the bypass grouting gate valve and the fourth acoustic sensor for monitoring the status of the bypass grouting check valve; the main grouting passage includes a fifth and a sixth acoustic sensor, the fifth acoustic sensor for monitoring the status of the main grouting gate valve and the sixth acoustic sensor for monitoring the status of the main grouting check valve; and the pressure relief passage includes a seventh acoustic sensor for monitoring the status of the pressure relief gate valve.

[0007] Preferably, the main passage includes a first pressure sensor, which is disposed between the main gate valve and the drill pipe to monitor the pressure status of the main passage; the bypass passage includes a second pressure sensor, which is disposed between the bypass gate valve and the drill pipe to monitor the pressure status of the bypass passage; the pressure relief passage includes a third pressure sensor, which is connected to the pressure relief gate valve to monitor the pressure status of the pressure relief passage.

[0008] Preferably, it also includes a manifold mud inlet, an electromagnetic flowmeter, and a normally open gate valve connected in sequence, with the other end of the normally open gate valve connected to the main gate valve and the bypass gate valve respectively; The normally open gate valve is connected to an eighth acoustic sensor and a fourth pressure sensor. The eighth acoustic sensor is used to monitor the status of the normally open gate valve, and the fourth pressure sensor is used to monitor the mud input pressure.

[0009] The present invention also provides a method for using an intelligent continuous circulation drilling manifold, for use in the intelligent continuous circulation drilling manifold described above, comprising the following steps: The control system controls the diversion manifold to sequentially execute the interlock mechanism judgment process and the fault diagnosis and life prediction process to determine whether the safety operation logic is met and whether each gate valve is normal. If the safety operation logic or the gate valve is abnormal, the operation is refused and an alarm is triggered. If the safe operation logic is met and all gate valves are functioning normally, open the bypass grouting gate valve, and dynamically grout the bypass path until it is balanced with the main path. Then, open the bypass gate valve to form a dual-path circulation. Finally, close the main gate valve and release the residual pressure in both the main and bypass grouting paths to complete the switching process. Continuously cycle the connection to the column; or... Open the main grouting gate valve and dynamically grout the main passage until the main passage and the bypass passage are balanced. Then open the main gate valve again to form a dual-passage circulation. Then close the bypass gate valve and release the residual pressure in the bypass passage and the main grouting passage to complete the switching and continue drilling.

[0010] Preferably, the fault diagnosis and life prediction process includes the following steps: The control system issues valve opening and closing commands and records the opening degree and output torque timing of each valve in real time. Determine whether there is a sudden spike in torque that deviates from the historical normal threshold. If the torque suddenly spikes without deviating from the historical normal threshold, the valve opening and closing will be completed normally. If the torque suddenly spikes and changes dramatically, deviating from the historical normal threshold, a mechanical jamming fault is identified, and an alarm is issued.

[0011] Preferably, the fault diagnosis and life prediction process includes the following steps: After all gate valves are closed and the pipeline is depressurized, the monitoring data of the first pressure sensor, the second pressure sensor, the third pressure sensor, and the acoustic sensor corresponding to each gate valve are retrieved. Determine if the pressure of each pressure sensor is abnormal, and whether the acoustic sensor corresponding to the gate valve has captured a high-frequency continuous fluid cavitation stress wave; if not, continue monitoring. If the pressure sensor detects an abnormal pressure and the acoustic sensor corresponding to the gate valve captures a high-frequency continuous fluid cavitation stress wave, it is determined that a high-pressure leak has occurred on the sealing surface of the corresponding gate valve, and a leak alarm is output. Locate the fault location and perform maintenance on the faulty gate valve.

[0012] Preferably, the fault diagnosis and life prediction process includes the following steps: Determine whether the diversion manifold is in a steady state after grouting; otherwise, skip this data collection and wait for the next cycle. If the manifold is in a steady state after grouting, read the actual opening degree Ua of the corresponding throttle valve, the current flow rate Q of the corresponding throttle valve, and the pressure difference ΔP of the corresponding throttle valve; Input Q and ΔP, and based on the calibration data table, fit the theoretical reference opening Us of the throttle valve under this working condition; Calculate the deviation ΔU between Ua and Us, and then smooth and denoise ΔU. Historical cumulative wear characteristic values ​​are extracted from the database, and a time-wear characteristic value fitting curve is established; Determine whether the inference curve reaches the maximum allowable wear amount; if not, store the wear characteristic value of this time in the database. If the inference curve reaches the maximum permissible wear level, calculate the remaining effective life and record the future time point when the maximum permissible wear level is reached; When the recorded future time point is reached, a replacement or maintenance warning will be issued.

[0013] Preferably, the interlock mechanism determination process includes the following steps: The control system receives gate valve operation commands; Determine whether the main gate valve and the pressure relief gate valve request to open simultaneously. If so, refuse the operation and trigger an alarm; otherwise, proceed to the next judgment logic. Determine whether the bypass gate valve and the pressure relief gate valve request to open simultaneously. If so, refuse the operation and trigger an alarm; otherwise, proceed to the next judgment logic. Determine whether the main grouting gate valve and the bypass grouting gate valve request to open simultaneously. If so, refuse the operation and issue an alarm; otherwise, allow the operation.

[0014] Preferably, the method includes the following steps: The control system receives the grouting command and opens the main grouting gate valve / bypass grouting gate valve; Real-time acquisition of pressure before and after the corresponding throttle valve in the passage, and calculation of pressure difference e; If 0.5MPa < e ≤ 40MPa, the opening of the corresponding throttle valve will dynamically increase as the pressure difference decreases. If e > 40 MPa, control the throttle valve opening to be between 3% and 5%; If e ≤ 0.5 MPa, then lock the throttle valve position.

[0015] Compared with the prior art, the intelligent continuous circulation drilling manifold and its usage method provided in this embodiment of the invention have the following advantages: In this invention, the diversion manifold can automatically realize the grouting work of the main passage and the bypass passage and the switching of the passage. During the switching process, the pressure fluctuation can be reduced by controlling the opening and closing of different gate valves. The built-in interlocking mechanism judgment process can also eliminate operational errors and ensure operational safety. Attached Figure Description

[0016] Figure 1 This is a structural diagram of the intelligent continuous circulation drilling manifold of the present invention; Figure 2 This is a schematic diagram of the usage process of the intelligent continuous circulation drilling manifold of the present invention; Figure 3 This is a schematic diagram of the valve fault diagnosis process for the intelligent continuous circulation drilling manifold of the present invention; Figure 4 This is a schematic diagram of another valve fault diagnosis process for the intelligent continuous circulation drilling manifold of the present invention; Figure 5 This is a schematic diagram of the life prediction process for the throttle valve of the intelligent continuous circulation drilling manifold of the present invention. Figure 6 This is a schematic diagram of the safety interlock mechanism judgment process for the intelligent continuous circulation drilling manifold of the present invention; Figure 7 This is a schematic diagram of the throttle valve opening control method for the intelligent continuous circulation drilling manifold of the present invention.

[0017] In the diagram: 1. Manifold mud inlet; 2. Electromagnetic flowmeter; 3. Normally open gate valve; 4. Eighth acoustic sensor; 5. Fourth pressure sensor; 6. Main gate valve; 7. First acoustic sensor; 8. Sixth acoustic sensor; 9. Main grouting check valve; 10. Main grouting throttle valve; 11. Fifth acoustic sensor; 12. First pressure sensor; 13. Third pressure sensor; 14. Bypass grouting gate valve; 15. Third acoustic sensor; 16. Bypass grouting throttle valve; 17. Fourth acoustic sensor; 18. Bypass gate valve; 19. Second acoustic sensor; 20. Main grouting gate valve; 21. Seventh acoustic sensor; 22. Pressure relief gate valve; 23. Mud outlet; 24. Second pressure sensor; 25. Bypass grouting check valve; 26. Top drive drilling unit; 27. Circulation sub; 28. Mud tank; 29. ​​Smart connector; 30. Bypass side valve. Detailed Implementation

[0018] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples. The following examples are for illustrative purposes only and are not intended to limit the scope of the invention.

[0019] like Figure 1 As shown, a preferred embodiment of the present invention provides an intelligent continuous circulation drilling manifold, which includes a top drive drilling device 26, a circulation sub 27 and a mud tank 28, including a main passage, a bypass passage, a bypass grouting passage, a main grouting passage and a pressure relief passage.

[0020] The main passage includes a main gate valve 6, which connects to the top drive drilling unit 26 to supply drilling fluid to the drill pipe. The bypass passage includes a bypass gate valve 18, which connects to the circulation sub 27 to supply drilling fluid to the circulation sub 27. The bypass grouting passage includes a bypass grouting gate valve 14, a bypass grouting throttle valve 16, and a bypass grouting check valve 25 connected in sequence. The bypass grouting gate valve 14 connects the main gate valve 6 and the top drive drilling unit 26, and the bypass grouting check valve 25 connects the bypass gate valve 18 and the circulation sub 27. The main grouting passage includes a main grouting gate valve 20, a main grouting throttle valve 10, and a main grouting check valve 9 connected in sequence. The main grouting gate valve 20 connects the bypass valve 18 and the circulation sub 27, and the bypass grouting check valve 25 connects the main gate valve 6 and the top drive drilling unit 26. The pressure relief circuit includes a pressure relief gate valve 22. One end of the pressure relief gate valve 22 is connected to the bypass grouting throttle valve 16 and the main grouting throttle valve 10, and the other end of the pressure relief gate valve 22 is connected to the mud tank 28.

[0021] Specifically, in this embodiment, five channels are provided: a main channel, a bypass channel, a bypass grouting channel, a main grouting channel, and a pressure relief channel. Each channel is connected to the pipeline via a dedicated valve, thereby achieving stable circulation of drilling fluid, channel switching, grouting balance, and pressure relief. During normal drilling, the drilling fluid circulates stably throughout the entire process via the main channel. That is, the drilling fluid flows sequentially through the main gate valve 6 to the top driving drilling device 26 and then flows downward along the drill pipe, ensuring that downhole sand carrying capacity and pressure control meet construction requirements. When connecting or disconnecting single sections or columns, the system can be manually or automatically switched to the bypass channel. That is, the drilling fluid flows through the bypass gate valve 18 to the intelligent connector 29, then to the circulation sub 27, and flows downward to the drill bit through the channel on the side of the circulation sub 27. This ensures uninterrupted circulation of drilling fluid throughout the process, eliminating the need to stop the pump and avoiding potential hazards such as wellbore instability and stuck drill bits due to sand accumulation.

[0022] Furthermore, to avoid problems such as short-term flow interruption in the drilling string circulation and unstable surface and bottom hole pressure due to insufficient drilling fluid filling in idle channels, and to prevent excessive pressure differences between the main and bypass channels during switching, grouting is required in the main or bypass channels before switching. This balances the pressure between the main and bypass channels. During circulation in the main or bypass channel, the bypass grouting line or main grouting line can be opened to divert a small portion of the drilling fluid to the bypass or main channel, thus achieving pressure balance between the main and bypass channels. This ensures no instantaneous flow interruption during channel switching and maintains stable wellhead circulation pressure and bottom hole ECD. Moreover, during grouting, the pressure and flow rate of the drilling fluid in the main and bypass grouting lines can be dynamically controlled by adjusting the opening of the throttle valve. This keeps fluctuations in wellhead pressure and circulation channel flow within a reasonable range, further preventing safety issues caused by drilling fluid pressure fluctuations.

[0023] Furthermore, the pressure relief gate valve 22 of the pressure relief circuit is connected to the mud tank 28, the main grouting throttle valve 10, and the bypass grouting throttle valve 16. After the main passage and bypass passage are switched, the residual mud drilling fluid in the bypass passage and the main grouting passage (or the main passage and the bypass grouting passage) can be depressurized and discharged into the mud tank 28 through the mud discharge outlet 23, so as to avoid excessive drilling fluid remaining in the passage and causing safety problems.

[0024] In some embodiments, the main passage includes a first acoustic sensor 7 for monitoring the status of the main gate valve 6; the bypass passage includes a second acoustic sensor 19 for monitoring the status of the bypass gate valve 18; the bypass grouting passage includes a third acoustic sensor 15 and a fourth acoustic sensor 17, the third acoustic sensor 15 for monitoring the status of the bypass grouting gate valve 14 and the fourth acoustic sensor 17 for monitoring the status of the bypass grouting check valve 25; the main grouting passage includes a fifth acoustic sensor 11 and a sixth acoustic sensor 8, the fifth acoustic sensor 11 for monitoring the status of the main grouting gate valve 20 and the sixth acoustic sensor 8 for monitoring the status of the main grouting check valve 9; and the pressure relief passage includes a seventh acoustic sensor 21 for monitoring the status of the pressure relief gate valve 22.

[0025] Specifically, in this embodiment, corresponding acoustic sensors are provided for the main gate valve 6, bypass gate valve 18, bypass grouting gate valve 14, bypass grouting check valve 25, main grouting gate valve 20, main grouting check valve 9, and pressure relief gate valve 22. These acoustic sensors can monitor and reflect the working status of each valve and provide data support for the control system during the inspection process before the diversion manifold is put into operation. This allows the control system to determine whether there is any valve abnormality. If a valve abnormality is found, an alarm can be issued in a timely manner to remind the staff to repair or replace the corresponding valve, thereby ensuring the smooth operation of subsequent drilling fluid circulation.

[0026] In some embodiments, the main passage includes a first pressure sensor 12, which is disposed between the main gate valve 6 and the drill pipe to monitor the pressure status of the main passage; the bypass passage includes a second pressure sensor 24, which is disposed between the bypass gate valve 18 and the drill pipe to monitor the pressure status of the bypass passage; and the pressure relief passage includes a third pressure sensor 13, which is connected to the pressure relief gate valve 22 to monitor the pressure status of the pressure relief passage.

[0027] Specifically, in this embodiment, pressure sensors are installed in the main passage, bypass passage, and pressure relief passage. The pressure sensors can monitor the pressure in the main passage, bypass passage, and pressure relief passage. The control system can determine which passage is malfunctioning based on abnormal pressure. Then, in conjunction with the acoustic sensor described above, it can accurately determine which gate valve and which section of pipeline is leaking abnormally, thereby precisely locating the fault point and facilitating subsequent maintenance work.

[0028] Furthermore, in some other embodiments, the pressure difference across the throttle valve can be used to determine whether there is an abnormal pressure in the grouting circuit, for both the main grouting circuit and the bypass grouting circuit. In other embodiments, multiple pressure sensors can be used as needed, which will not be elaborated further here.

[0029] In some embodiments, the system also includes a manifold mud inlet 1, an electromagnetic flowmeter 2, and a normally open gate valve 3 connected in sequence. The other end of the normally open gate valve 3 is connected to a main gate valve 6 and a bypass gate valve 18, respectively. The normally open gate valve 3 is connected to an eighth acoustic sensor 4 and a fourth pressure sensor 5. The eighth acoustic sensor 4 is used to monitor the status of the normally open gate valve 3, and the fourth pressure sensor 5 is used to monitor the mud input pressure.

[0030] Specifically, in this embodiment, external drilling fluid is introduced into the branch manifold through the manifold inlet. The drilling fluid then passes sequentially through the electromagnetic flowmeter 2 and the normally open gate valve 3. Under normal drilling conditions, the main gate valve 6 is open, and the bypass gate valve 18 is closed. The drilling fluid enters the top-drive drilling device 26 through the main gate valve 6 and is then fed into the well, ensuring stable drilling operations. In the case of connecting a new drill string, after the drill pipe is seated, the connector automatically engages with the bypass side valve 30. Then, various pressure sensors monitor the pressure at each point to ensure it is normal, and various acoustic sensors determine whether each gate valve is leak-free. When the pressure at each point is normal and all gate valves are functioning normally, the bypass grouting gate valve 14 can be slowly opened, and the bypass grouting throttle valve 16 begins grouting into the bypass passage at its minimum opening. As the pressure difference between the main passage and the bypass passage decreases, the opening of the bypass grouting throttle valve 16 can be dynamically increased to ensure a smooth rise in pipeline pressure in the bypass passage and prevent water hammer during grouting. Once the pressure in the main and bypass passages is nearly balanced, the bypass gate valve 18 can be opened to establish a dual-passage circulation. Then, the main gate valve 6 is slowly closed, and the pressure relief gate valve 22 is opened to drain the residual drilling fluid and mud from the main passage through the mud discharge outlet 23. After depressurization, the pressure relief gate valve 22 can be closed. After confirming that there are no abnormalities in the pressure at any point, the drill rig is instructed to connect a new stand. After the new stand is connected, the main passage circulation can be switched back through reverse operation, and the connecting connector will automatically disengage, thus resuming normal drilling.

[0031] Furthermore, it should be noted that in this embodiment, the control system actually comprises two parts: a central control unit for the manifold and an explosion-proof control cabinet for the manifold. The central control unit includes a control console and a manifold computer. The control console also includes an emergency stop button. The control console directly interlocks the gate valves and throttle valves of the shunt manifold in the field equipment via an independent 24V emergency stop hard-wired circuit, thereby enabling direct control of the opening and closing states of each gate valve and throttle valve in emergency situations, ensuring equipment and operational safety. The explosion-proof control cabinet for the manifold includes an industrial switch, a PLC controller, and an edge gateway. Under normal operating conditions, the control signals from the control console are sent to the gate valves and throttle valves of the shunt manifold through the industrial switch to control their operating states. Simultaneously, the shunt manifold is electrically connected to the PLC controllers of the field equipment via the PLC controller. The PLC controllers of the field equipment collect pressure data from various pressure sensors. This pressure data is transmitted through the PLC controller to the industrial switch, and then through the industrial switch to the manifold computer, facilitating the manifold computer's monitoring of the pressure and operating states at various points in the shunt manifold. The edge gateway connects to the various acoustic sensors in the manifold via a high-speed acquisition link. The acoustic signals monitored by the acoustic sensors are then transmitted to the manifold computer via the edge gateway and the industrial switch. Combined with the pressure data described earlier, the manifold computer can more comprehensively monitor the safety status of the manifold.

[0032] like Figure 2 As shown, the present invention also provides a method for using an intelligent continuous circulation drilling manifold, for use in the intelligent continuous circulation drilling manifold described above, comprising the following steps: The control system controls the diversion manifold to sequentially execute the interlock mechanism judgment process and the fault diagnosis and life prediction process to determine whether the safety operation logic is met and whether each gate valve is normal. If the safety operation logic or the gate valve is abnormal, the operation is refused and an alarm is triggered. If the safe operation logic is met and all gate valves are functioning normally, open the bypass grouting gate valve 14, and dynamically grout the bypass path until it is balanced with the main path. Then, open the bypass gate valve 18 to form a dual-path circulation. Next, close the main gate valve 6 and release the residual pressure in the main path and bypass grouting path to complete the switching. Continuously circulate the connection to the column; or... Open the main grouting gate valve 20, and perform dynamic grouting in the main passage until the main passage and the bypass passage are balanced. Then open the main gate valve 6 to form a dual-passage circulation. Then close the bypass gate valve 18 and release the residual pressure in the bypass passage and the main grouting passage to complete the switching and continue drilling.

[0033] Specifically, in actual operation, the control system first needs to determine whether the operation command meets the safety operation logic, and then check whether each gate valve is in normal condition. When the operation meets the safety operation logic and all gate valves are normal, the main passage and bypass passage can be switched. In the case of connecting a new column, the circulation needs to be switched from the main passage to the bypass passage. The bypass grouting gate valve 14 can be opened slowly, and the bypass grouting throttle valve 16 starts grouting into the bypass passage at the minimum opening. As the pressure difference between the main passage and the bypass passage decreases, the opening of the bypass grouting throttle valve 16 can be dynamically increased to ensure that the pipeline pressure in the bypass passage rises smoothly and avoids grouting water hammer. When the pressure in the main passage and the bypass passage is nearly balanced, the bypass gate valve 18 can be opened to establish a dual-pass circulation, and then the main passage gate valve 6 can be closed slowly, and the pressure relief gate valve 22 can be opened to release the residual mud drilling fluid in the main passage, thereby completing the passage switching. Then, the drilling platform can be prompted to connect a new column.

[0034] After the new support column is installed, the circulation needs to be switched from the bypass path back to the main path. At this time, the control system also needs to determine whether the operation command meets the safety operation logic, and then check whether each gate valve is in normal condition. When the operation meets the safety operation logic and each gate valve is normal, the main grouting gate valve 20 can be slowly opened, and the main grouting throttle valve 10 can start grouting into the main path at the minimum opening. As the pressure difference between the main path and the bypass path decreases, the opening of the main grouting throttle valve 10 can be dynamically increased to ensure that the pipeline pressure in the main path rises smoothly and avoids grouting water hammer. When the pressure in the main path and the bypass path is nearly balanced, the main gate valve 6 can be opened to establish a dual-path circulation, and then the bypass gate valve 18 can be slowly closed, and the pressure relief gate valve 22 can be opened to release the residual mud drilling fluid in the bypass path, thereby completing the path switching, and finally the drilling work can continue.

[0035] like Figure 3 As shown, in some embodiments, the fault diagnosis and life prediction process includes the following steps: The control system issues valve opening and closing commands and records the opening degree and output torque timing of each valve in real time.

[0036] Determine whether there is a sudden spike in torque that deviates from the historical normal threshold.

[0037] If the torque suddenly spikes without deviating from the historical normal threshold, the valve opening and closing will be completed normally.

[0038] If the torque suddenly spikes and changes dramatically, deviating from the historical normal threshold, a mechanical jamming fault is identified, and an alarm is issued.

[0039] Specifically, before actual use, the mechanical jamming status of each gate valve needs to be checked. After the control system issues the valve opening and closing command, the sensors on each valve will record and upload the valve opening degree and output torque timing in real time. The control system then compares the uploaded valve opening degree and output torque timing with the previously recorded historical normal thresholds and determines whether there is a sudden spike in torque that deviates from the historical normal threshold. If no spike occurs, the status of each valve continues to be monitored. If a spike occurs, it indicates that the valve has a mechanical jamming fault, and an alarm needs to be issued to remind workers to carry out timely inspection and maintenance.

[0040] like Figure 4 As shown, in some embodiments, the fault diagnosis and life prediction process includes the following steps: After all gate valves are closed and the pipeline is depressurized, the monitoring data of the first pressure sensor 12, the second pressure sensor 24, the third pressure sensor 13, and the acoustic sensors corresponding to each gate valve are retrieved.

[0041] Determine if the pressure of each pressure sensor is abnormal, and whether the acoustic sensor corresponding to the gate valve has captured a high-frequency continuous fluid cavitation stress wave; if not, continue monitoring.

[0042] If the pressure sensor detects an abnormal pressure and the acoustic sensor corresponding to the gate valve captures a high-frequency continuous fluid cavitation stress wave, it is determined that a high-pressure leak has occurred on the sealing surface of the corresponding gate valve, and a leak alarm is output.

[0043] Locate the fault location and perform maintenance on the faulty gate valve.

[0044] Specifically, before actual use, it is necessary to check whether each valve has high-pressure puncture leakage to ensure the safety of subsequent work. In this embodiment, the pressure status of the main passage, bypass passage, and pressure relief passage is first monitored by the first pressure sensor 12, the second pressure sensor 24, and the third pressure sensor 13, respectively. The pressure status of the two grouting passages can be monitored by the pressure sensors built into the throttle valves. When an abnormal pressure is detected downstream of the pipeline, the acoustic sensors corresponding to each valve in the corresponding passage can be checked. If the acoustic sensor simultaneously captures a high-frequency continuous fluid cavitation stress wave, it indicates that a high-pressure puncture leakage fault has occurred on the sealing surface of the valve corresponding to the acoustic sensor. The control system then outputs a puncture leakage alarm signal and simultaneously triggers hardware protection to stop the valve motor to ensure safety and facilitate subsequent inspection and maintenance. The puncture leakage alarm signal will trigger a fault alarm and prompt, allowing staff to obtain fault information and locate the fault point, thereby facilitating quick inspection and maintenance of the faulty valve.

[0045] like Figure 5As shown, in some embodiments, the fault diagnosis and life prediction process includes the following steps: Determine whether the diversion manifold is in a steady state after grouting. If not, skip this data collection and wait for the next cycle.

[0046] If the manifold is in a steady state after grouting, then read the actual opening degree Ua of the corresponding throttle valve, the current flow rate Q of the corresponding throttle valve, and the pressure difference △P of the corresponding throttle valve.

[0047] Input Q and ΔP, and based on the calibration data table, fit the theoretical reference opening Us of the throttle valve under this operating condition.

[0048] Calculate the deviation ΔU between Ua and Us, and then smooth and denoise ΔU.

[0049] Historical cumulative wear characteristic values ​​are extracted from the database, and a time-wear characteristic value fitting curve is established.

[0050] Determine whether the inference curve reaches the maximum allowable wear amount; if not, store the wear characteristic value in the database.

[0051] If the inference curve reaches the maximum permissible wear level, calculate the remaining effective life and record the future time point at which the maximum permissible wear level is reached.

[0052] When the recorded future time point is reached, a replacement or maintenance warning will be issued.

[0053] Specifically, for predicting the service life of throttle valves, this embodiment uses an opening deviation judgment method based on operating condition benchmark comparison for judgment and prediction. First, it is necessary to confirm whether there are drastic fluctuations in the flow rate and pressure at various points in the corresponding grouting path after grouting. If there are drastic fluctuations, it indicates that the current grouting path is unstable and not suitable for predicting the throttle valve's service life. In this case, the current data collection is skipped, and data collection is waited for the next grouting cycle. When the corresponding grouting path is in a stable state after grouting, the current actual opening Ua, current flow rate Q, and current pressure difference ΔP of the corresponding throttle valve can be obtained. Then, the current flow rate Q and current pressure difference ΔP are combined with the calibration data table to fit the theoretical benchmark opening Us of the corresponding throttle valve in a healthy state under this operating condition. The deviation value ΔU between Ua and Us is then calculated, which is the wear amount. Then, the average value of the most recent ΔU is taken to smooth and remove noise. Finally, the historical cumulative wear feature values ​​are extracted, and a time-wear feature value fitting curve is established. Finally, the system checks whether the time-wear characteristic value fitting curve reaches the maximum permissible wear level. If not, the wear characteristic value is stored in the database for future reference. If the maximum permissible wear level is reached, the remaining effective lifespan of the corresponding throttle valve is calculated. When the throttle valve reaches its remaining effective lifespan, i.e., when it reaches the predicted future time point of maximum permissible wear, the control system issues a replacement or maintenance warning to remind personnel to repair or replace the throttle valve in a timely manner. Understandably, the control system will provide multiple lifespan predictions and suggested maintenance times between these future time points.

[0054] like Figure 6 As shown, in some embodiments, the interlock mechanism determination process includes the following steps: The control system receives gate valve operation commands.

[0055] Determine whether the main gate valve 6 and the pressure relief gate valve 22 request to open simultaneously. If so, refuse the operation and trigger an alarm; otherwise, proceed to the next judgment logic.

[0056] Determine whether the bypass gate valve 18 and the pressure relief gate valve 22 request to open simultaneously. If so, refuse the operation and issue an alarm; otherwise, proceed to the next judgment logic.

[0057] Determine whether the main grouting gate valve 20 and the bypass grouting gate valve 14 request to open simultaneously. If so, refuse the operation and issue an alarm; otherwise, allow the operation.

[0058] Specifically, to ensure the drilling fluid flows along the pre-set pipeline and avoid safety issues, the interlocking mechanism of the diversion manifold needs to be checked before actual use. The main gate valve 6 and the pressure relief gate valve 22 cannot be opened simultaneously; otherwise, the drilling fluid will flow from the pressure relief gate valve 22 into the mud tank 28, severely affecting the flow rate and pressure of the drilling fluid flowing into the top-driven drilling rig 26. The same principle applies to the bypass gate valve 18 and the pressure relief gate valve 22. Simultaneously, the main grouting gate valve 20 and the bypass grouting valve 14 cannot be opened simultaneously to prevent the drilling fluid from circulating between the main grouting line and the bypass grouting line.

[0059] like Figure 7 As shown, in some embodiments, the following steps are also included: The control system receives the grouting command and opens the main grouting gate valve 20 / bypass grouting gate valve 14; Real-time acquisition of pressure before and after the corresponding throttle valve in the passage, and calculation of pressure difference e; If 0.5MPa < e ≤ 40MPa, the opening of the corresponding throttle valve will dynamically increase as the pressure difference decreases. If e > 40MPa, control the opening of the corresponding throttle valve to be between 3% and 5%; If e≤0.5MPa, lock the throttle valve position.

[0060] Specifically, when grouting is required in the main or bypass passages, the grouting speed needs to be controlled to avoid excessive pressure fluctuations. In this embodiment, the opening of the throttle valve is adjusted based on the pressure before and after the throttle valve in the grouting path to control the grouting speed. Specifically, when the pressure difference is between 0.5 MPa and 40 MPa, the throttle valve opening is increased as the pressure difference gradually decreases, either linearly or curvilinearly. When the pressure difference is greater than 40 MPa, the throttle valve opening needs to be reduced as much as possible to avoid excessive pressure fluctuations that could damage the pipeline and valves. When the pressure difference is less than 0.5 MPa, the throttle valve can be locked at its maximum opening to increase the grouting speed. Of course, it is understood that the throttle valve opening control and pressure difference standards may vary depending on the actual construction conditions, and the throttle valve opening adjustment can be driven by a servo motor.

[0061] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several improvements and substitutions without departing from the technical principles of the present invention, and these improvements and substitutions should also be considered within the scope of protection of the present invention.

Claims

1. An intelligent continuous circulation drilling manifold, comprising a top drive drilling unit, a circulation sub, and a mud tank, characterized in that, include: The main passage includes a main gate valve connected to the top drive drilling unit to input drilling fluid into the drill pipe; A bypass passage, the bypass passage including a bypass gate valve connected to a circulation sub to introduce drilling fluid into the circulation sub; A bypass grouting path, comprising a bypass grouting gate valve, a bypass grouting throttle valve, and a bypass grouting check valve connected in sequence, wherein the bypass grouting gate valve is connected to the main gate valve and the top drive drilling device, and the bypass grouting check valve is connected to the bypass gate valve and the circulation sub. The main grouting circuit includes a main grouting gate valve, a main grouting throttle valve, and a main grouting check valve connected in sequence. The main grouting gate valve is connected to the bypass gate valve and the circulation sub, and the bypass grouting check valve is connected to the main gate valve and the top drive drilling device. The pressure relief circuit includes a pressure relief gate valve, one end of which is connected to the bypass grouting throttling valve and the main grouting throttling valve, and the other end of which is connected to the mud tank.

2. The intelligent continuous circulation drilling manifold according to claim 1, characterized in that, The main passage includes a first acoustic sensor, which is used to monitor the status of the main gate valve. The bypass path includes a second acoustic sensor, which is used to monitor the status of the bypass gate valve. The bypass grouting path includes a third acoustic sensor and a fourth acoustic sensor. The third acoustic sensor is used to monitor the status of the bypass grouting gate valve, and the fourth acoustic sensor is used to monitor the status of the bypass grouting check valve. The main grouting circuit includes a fifth acoustic sensor and a sixth acoustic sensor. The fifth acoustic sensor is used to monitor the status of the main grouting gate valve, and the sixth acoustic sensor is used to monitor the status of the main grouting check valve. The pressure relief circuit includes a seventh acoustic sensor, which is used to monitor the status of the pressure relief gate valve.

3. The intelligent continuous circulation drilling manifold according to claim 2, characterized in that, The main passage includes a first pressure sensor, which is disposed between the main gate valve and the drill pipe to monitor the pressure status of the main passage; The bypass passage includes a second pressure sensor, which is disposed between the bypass gate valve and the drill pipe to monitor the pressure status of the bypass passage; The pressure relief circuit includes a third pressure sensor, which is connected to the pressure relief gate valve to monitor the pressure status of the pressure relief circuit.

4. The intelligent continuous circulation drilling manifold according to claim 3, characterized in that, It also includes a manifold mud inlet, an electromagnetic flowmeter and a normally open gate valve connected in sequence, with the other end of the normally open gate valve connected to the main gate valve and the bypass gate valve respectively; The normally open gate valve is connected to an eighth acoustic sensor and a fourth pressure sensor. The eighth acoustic sensor is used to monitor the status of the normally open gate valve, and the fourth pressure sensor is used to monitor the mud input pressure.

5. A method for using an intelligent continuous circulation drilling manifold, for use with the intelligent continuous circulation drilling manifold as described in claim 4, characterized in that, Includes the following steps: The control system controls the diversion manifold to sequentially execute the interlock mechanism judgment process and the fault diagnosis and life prediction process to determine whether the safety operation logic is met and whether each gate valve is normal. If the safety operation logic or the gate valve is abnormal, the operation is refused and an alarm is triggered. If the safe operation logic is met and all gate valves are functioning normally, open the bypass grouting gate valve, and dynamically grout the bypass path until it is balanced with the main path. Then, open the bypass gate valve to form a dual-path circulation. Finally, close the main gate valve and release the residual pressure in both the main and bypass grouting paths to complete the switching process. Continuously cycle the connection to the column; or... Open the main grouting gate valve and dynamically grout the main passage until the main passage and the bypass passage are balanced. Then open the main gate valve again to form a dual-passage circulation. Then close the bypass gate valve and release the residual pressure in the bypass passage and the main grouting passage to complete the switching and continue drilling.

6. The method for using the intelligent continuous circulation drilling manifold according to claim 5, characterized in that, The fault diagnosis and life prediction process includes the following steps: The control system issues valve opening and closing commands and records the opening degree and output torque timing of each valve in real time. Determine whether there is a sudden spike in torque that deviates from the historical normal threshold. If the torque suddenly spikes without deviating from the historical normal threshold, the valve opening and closing will be completed normally. If the torque suddenly spikes and changes dramatically, deviating from the historical normal threshold, a mechanical jamming fault is identified, and an alarm is issued.

7. The method for using the intelligent continuous circulation drilling manifold according to claim 6, characterized in that, The fault diagnosis and life prediction process includes the following steps: After all gate valves are closed and the pipeline is depressurized, the monitoring data of the first pressure sensor, the second pressure sensor, the third pressure sensor, and the acoustic sensor corresponding to each gate valve are retrieved. Determine if the pressure of each pressure sensor is abnormal, and whether the acoustic sensor corresponding to the gate valve has captured a high-frequency continuous fluid cavitation stress wave; if not, continue monitoring. If the pressure sensor detects an abnormal pressure and the acoustic sensor corresponding to the gate valve captures a high-frequency continuous fluid cavitation stress wave, it is determined that a high-pressure leak has occurred on the sealing surface of the corresponding gate valve, and a leak alarm is output. Locate the fault location and perform maintenance on the faulty gate valve.

8. The method for using the intelligent continuous circulation drilling manifold according to claim 7, characterized in that, The fault diagnosis and life prediction process includes the following steps: Determine whether the diversion manifold is in a steady state after grouting; otherwise, skip this data collection and wait for the next cycle. If the manifold is in a steady state after grouting, read the actual opening degree Ua of the corresponding throttle valve, the current flow rate Q of the corresponding throttle valve, and the pressure difference ΔP of the corresponding throttle valve; Input Q and ΔP, and based on the calibration data table, fit the theoretical reference opening Us of the throttle valve under this working condition; Calculate the deviation ΔU between Ua and Us, and then smooth and denoise ΔU. Historical cumulative wear characteristic values ​​are extracted from the database, and a time-wear characteristic value fitting curve is established; Determine whether the inference curve reaches the maximum allowable wear amount; if not, store the wear characteristic value of this time in the database. If the inference curve reaches the maximum permissible wear level, calculate the remaining effective life and record the future time point when the maximum permissible wear level is reached; When the recorded future time point is reached, a replacement or maintenance warning will be issued.

9. The method of using the intelligent continuous circulation drilling manifold according to claim 5, characterized in that, The interlock mechanism determination process includes the following steps: The control system receives gate valve operation commands; Determine whether the main gate valve and the pressure relief gate valve request to open simultaneously. If so, refuse the operation and trigger an alarm; otherwise, proceed to the next judgment logic. Determine whether the bypass gate valve and the pressure relief gate valve request to open simultaneously. If so, refuse the operation and trigger an alarm; otherwise, proceed to the next judgment logic. Determine whether the main grouting gate valve and the bypass grouting gate valve request to open simultaneously. If so, refuse the operation and issue an alarm; otherwise, allow the operation.

10. The method of using the intelligent continuous circulation drilling manifold according to claim 5, characterized in that, Includes the following steps: The control system receives the grouting command and opens the main grouting gate valve / bypass grouting gate valve; Real-time acquisition of pressure before and after the corresponding throttle valve in the passage, and calculation of pressure difference e; If 0.5MPa < e ≤ 40MPa, the opening of the corresponding throttle valve will dynamically increase as the pressure difference decreases. If e > 40MPa, control the opening of the corresponding throttle valve to be between 3% and 5%; If e≤0.5MPa, lock the throttle valve position.

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