CN116537738A - Direct-fired nitrogen injection foam well cementation equipment and control method thereof - Google Patents
Direct-fired nitrogen injection foam well cementation equipment and control method thereof Download PDFInfo
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- CN116537738A CN116537738A CN202310522412.0A CN202310522412A CN116537738A CN 116537738 A CN116537738 A CN 116537738A CN 202310522412 A CN202310522412 A CN 202310522412A CN 116537738 A CN116537738 A CN 116537738A
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- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 title claims abstract description 526
- 229910052757 nitrogen Inorganic materials 0.000 title claims abstract description 259
- 239000006260 foam Substances 0.000 title claims abstract description 98
- 238000002347 injection Methods 0.000 title claims abstract description 25
- 239000007924 injection Substances 0.000 title claims abstract description 25
- 238000000034 method Methods 0.000 title claims description 17
- 239000007788 liquid Substances 0.000 claims abstract description 318
- 238000005187 foaming Methods 0.000 claims abstract description 213
- 239000004568 cement Substances 0.000 claims abstract description 89
- 239000002002 slurry Substances 0.000 claims abstract description 71
- 238000002309 gasification Methods 0.000 claims abstract description 60
- 238000002156 mixing Methods 0.000 claims abstract description 15
- 238000006073 displacement reaction Methods 0.000 claims description 46
- 238000007599 discharging Methods 0.000 claims description 21
- 229910001873 dinitrogen Inorganic materials 0.000 claims description 8
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 238000002485 combustion reaction Methods 0.000 claims description 3
- 239000012530 fluid Substances 0.000 claims description 3
- 230000001276 controlling effect Effects 0.000 description 22
- 238000010276 construction Methods 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 239000007789 gas Substances 0.000 description 5
- 230000001105 regulatory effect Effects 0.000 description 5
- 230000008569 process Effects 0.000 description 4
- 230000002265 prevention Effects 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 239000004088 foaming agent Substances 0.000 description 2
- 239000000295 fuel oil Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 210000002569 neuron Anatomy 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000004321 preservation Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005465 channeling Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000005536 corrosion prevention Methods 0.000 description 1
- 238000013480 data collection Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
- B28C5/381—Producing cellular concrete
- B28C5/386—Plants; Systems; Methods
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- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Feeding, Discharge, Calcimining, Fusing, And Gas-Generation Devices (AREA)
Abstract
The invention provides direct-fired nitrogen injection foam well cementation equipment, which comprises: the liquid nitrogen gasification system is used for receiving liquid nitrogen from a liquid nitrogen source and converting the liquid nitrogen into high-pressure nitrogen; the foaming liquid supply system is used for storing and supplying foaming liquid; the foam generator is used for receiving and mixing the foaming liquid, the high-pressure nitrogen and the cement slurry from the cement slurry source to form foam cement slurry; the data acquisition system is used for acquiring real-time state data of the liquid nitrogen gasification system and the foaming liquid supply system; the control system is used for setting the densities of foam cement slurries under different well sections and target state data of the liquid nitrogen gasification system and the foaming liquid supply system, and adjusting the working states of the liquid nitrogen gasification system and the foaming liquid supply system by combining the real-time state data and the target state data of the liquid nitrogen gasification system and the foaming liquid supply system and the set densities of the foam cement slurries.
Description
Technical Field
The invention relates to the technical field of foam cement slurry well cementation, in particular to direct-fired nitrogen injection foam well cementation equipment and a control method thereof.
Background
Cement leakage is one of the general problems faced in the field of cementing. With the deep exploration and development degree in China, the leakage ratio of the well cementation cement also has a trend of sharply increasing. In order to improve the well cementation quality and reduce the risk of annular pressure, urgent needs are provided for low-density cement well cementation. Compared with the conventional cement, the foam cement slurry has the advantages of leakage prevention, channeling prevention, displacement efficiency improvement due to the characteristics of low density, high strength and the like.
Currently, there are two ways to prepare foamed cement slurries, namely chemical foaming and physical foaming.
For chemical foaming, a certain amount of foaming agent is mixed into dry cement, and after the cement and water are mixed and stirred, the foaming agent reacts with certain chemical components in cement paste to generate gas which is distributed in the cement so as to form foam cement. Because the gas generation amount is small, the density of the foam cement slurry is difficult to be greatly reduced in a high-pressure environment in the pit, and the density of the foam cement slurry cannot be adjusted at any time in site construction. At present, chemical foaming is mainly used in China.
In the physical foaming, foam cement slurry is produced by mixing foam liquid and cement slurry or directly filling gas into cement slurry containing the foam liquid. The method has the problems that the foam liquid and the cement paste are separated or can not be effectively mixed together due to low foam pressure and high cement paste pressure, and the high-pressure work of cementing in an oil field is difficult to meet.
Thus, methods for aerated preparation of foamed cement are receiving increasing attention. The nitrogen is stable in chemical property, does not react with other substances generally, can play roles of isolation, flame retardance, explosion prevention and corrosion prevention, has little damage to a reservoir, and is a preferable inflation medium for foam cement.
The existing preparation device of aerated foam cement does not monitor and adjust parameters such as density of foam cement slurry, liquid nitrogen and discharge capacity of foaming liquid, pressure, temperature and the like in real time, so that the produced foam cement slurry cannot meet construction requirements, and further the well cementation cost is increased and even the well cementation fails.
Disclosure of Invention
The invention provides direct-fired nitrogen injection foam well cementation equipment and a control method thereof, which solve the problems that in the prior art, parameters such as density of foam cement slurry, liquid nitrogen and discharge capacity, pressure, temperature and the like of foaming liquid are not monitored and regulated in real time, so that the produced foam cement slurry cannot meet construction requirements, and further the well cementation cost is increased, even the well cementation fails and the like.
The technical scheme of the invention is realized as follows:
according to one aspect of the present invention, there is provided a direct-fired nitrogen injection foam cementing apparatus comprising:
the liquid nitrogen gasification system is used for receiving liquid nitrogen from a liquid nitrogen source and converting the liquid nitrogen into high-pressure nitrogen;
the foaming liquid supply system is used for storing and supplying foaming liquid;
the foam generator is used for receiving and mixing the foaming liquid, the high-pressure nitrogen and the cement slurry from the cement slurry source to form foam cement slurry;
the data acquisition system is used for acquiring real-time state data of the liquid nitrogen gasification system and the foaming liquid supply system;
the control system is used for setting the densities of foam cement slurries under different well sections and target state data of the liquid nitrogen gasification system and the foaming liquid supply system, and adjusting the working states of the liquid nitrogen gasification system and the foaming liquid supply system by combining the real-time state data and the target state data of the liquid nitrogen gasification system and the foaming liquid supply system and the set densities of the foam cement slurries.
According to the invention, dynamic parameters of nitrogen, foaming liquid and cement slurry are acquired in real time through the data acquisition system, and the working states of the liquid nitrogen gasification system and the foaming liquid supply system are adjusted through the control system, so that parameters such as the displacement, pressure and temperature of the nitrogen and the foaming liquid are always maintained within the set parameter ranges, and the produced foaming cement slurry can meet the construction requirements.
As a preferable scheme of the invention, the liquid nitrogen gasification system comprises a direct-fired evaporator and a first plunger pump, wherein an output port of the direct-fired evaporator is connected with a foam generator, and an input port of the direct-fired evaporator is connected with a liquid nitrogen source through the first plunger pump; the direct-fired evaporator is provided with a plurality of burners, and an ignition device of each burner is connected with a control system; the direct-fired evaporator is used for gasifying liquid nitrogen, so that the gasification speed of the liquid nitrogen is greatly improved, large-displacement gas discharge can be realized, and the control range of nitrogen displacement is wide. Therefore, the control requirement on the density of the foam cement slurry can be met by controlling the discharge capacity of high-pressure nitrogen.
As a preferable scheme of the invention, the foaming liquid supply system comprises a foaming liquid storage box, wherein an output port of the foaming liquid storage box is connected with a foam generator through a second plunger pump, and a booster pump is arranged on a pipeline connecting the foaming liquid storage box and the second plunger pump; the discharge capacity of foaming liquid can be adjusted through the second plunger pump, and the suction pressure of the foaming liquid can be adjusted through the booster pump, so that the discharge capacity and the suction pressure of the foaming liquid can always meet the actual demands.
As a preferable scheme of the invention, the foam generator comprises a mixing cavity, wherein the mixing cavity is connected with two input pipelines and an output pipeline, the two input pipelines are respectively used for inputting high-pressure nitrogen and cement slurry containing foaming liquid, and the output pipeline is used for outputting mixed foam cement slurry; the cement slurry containing foaming liquid and high-pressure nitrogen are respectively conveyed into a mixing cavity of the foam generator in a high-pressure injection mode through two input pipelines, and the foaming cement slurry is directly formed through the spiral block disturbance and impact action in the mixing cavity of the foam generator and is output through the output pipeline.
As a preferred aspect of the present invention, the data acquisition system at least includes one or more of the following sensors:
the density sensor is used for collecting density data of cement paste;
the flow sensor is used for collecting the discharge capacity of the foaming liquid and the nitrogen discharge capacity;
the pressure sensor is used for collecting the discharge pressure of the foaming liquid, the suction pressure of the foaming liquid and the discharge pressure of nitrogen;
and the temperature sensor is used for collecting the nitrogen discharge temperature and the temperature of the main combustion chamber.
As a preferable scheme of the invention, the control system is used for setting the density of foam cement slurry, the target discharge capacity of foaming liquid, the target discharge capacity of nitrogen, the target suction pressure range of the foaming liquid, the limit discharge pressure of the foaming liquid and the limit discharge pressure of the nitrogen and the target discharge temperature of the nitrogen under different well sections, and
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding first plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the rotation speed of a corresponding second plunger pump in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
The control system can timely and accurately adjust the rotating speed of the first plunger pump when the set nitrogen displacement changes so as to ensure that the nitrogen displacement reaches the set requirement; when the set displacement of the foaming liquid changes, the rotating speed of the second plunger pump can be timely and accurately adjusted so as to ensure that the displacement of the foaming liquid reaches the set requirement; when the temperature of the nitrogen outlet is too high or too low, the working states of the plurality of combustors can be automatically controlled, and the stability of the nitrogen discharge temperature is maintained; the whole control system only needs to set parameters, can be automatically controlled and adjusted to a set range, is simple to operate, and greatly saves labor intensity.
Specifically, the formula for calculating the number of burner operations in a liquid nitrogen gasification system is:
ΔE＝E n -E n-1
wherein CV n Representing a current cycle period output; CV (CV) n-1 An output representing a last cycle period; k (K) P Representing the proportional gain; e (E) n Indicating the deviation of the measured nitrogen discharge temperature and the target discharge temperature in the current cycle period; e (E) n-1 Indicating the deviation between the measured nitrogen discharge temperature and the target discharge temperature in the previous cycle; e (E) n-2 Indicating the deviation between the measured nitrogen discharge temperature and the target discharge temperature in the last cycle period; k (K) I Representing the integral gain; Δt represents a cycle period; k (K) D Representing differential gain;
according to the proportional relation between the output of the current cycle period and the number of the burners, the working number of the burners is obtained through conversion as follows:
k＝CV n ·m/100
wherein m is the total number of burners; CV (CV) n The value of (2) is 0-100, and the number k of burners is 0-m.
Further, if k is calculated to be a fraction and k is between i and i+1, wherein i is an integer between 0 and m-1; setting a time period T and dividing T into 10 parts, each part being Δt, the number of required burners being i+1 in a time interval of 0 to nxΔt, and the number of required burners being i in a time interval of nxΔt/to T; where n= (k-i) ×10. By calculating the number of distributed burners by the above method, the nitrogen gas discharge temperature can be stably controlled within the preset range.
According to another aspect of the present invention, there is provided a control method of a direct-fired nitrogen injection foam cementing apparatus, comprising the steps of:
setting target state data of a liquid nitrogen gasification system and a foaming liquid supply system under different well sections and density of foam cement slurry, wherein the target state data at least comprises one or more of nitrogen target discharge capacity, nitrogen target discharge temperature, nitrogen limit discharge pressure, foaming liquid target discharge capacity, foaming liquid target suction pressure range and foaming liquid limit discharge pressure;
collecting real-time state data of a liquid nitrogen gasification system and a foaming liquid supply system; the real-time state data at least comprises one or more of measured nitrogen displacement, measured nitrogen discharge temperature, measured nitrogen discharge pressure, measured foaming liquid displacement, measured foaming liquid suction pressure and measured foaming liquid discharge pressure;
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding first plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the rotation speed of a corresponding second plunger pump in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
Advantageous effects
Compared with the prior art, the invention has the beneficial effects that: according to the invention, the dynamic parameters of nitrogen, foaming liquid and cement slurry are acquired in real time through the data acquisition system, and the working states of the liquid nitrogen gasification system and the foaming liquid supply system are adjusted through the control system; when the set displacement of the foaming liquid changes, the rotating speed of the second plunger pump can be timely and accurately adjusted so as to ensure that the displacement of the foaming liquid reaches the set requirement; when the temperature of the nitrogen outlet is too high or too low, the working states of the plurality of combustors can be automatically controlled, and the stability of the nitrogen discharge temperature is maintained; the whole control system only needs to set parameters, and can always maintain the parameters such as the displacement, the pressure, the temperature and the like of the nitrogen and the foaming liquid within the set parameter range through automatic control, so that the produced foam cement slurry can meet the construction requirements.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a system architecture of a direct-fired nitrogen injection foam cementing apparatus of the present invention;
fig. 2 is a schematic flow chart of a control method of the direct-fired nitrogen injection foam well cementation equipment.
Detailed Description
The technical solutions of the present invention will be clearly and completely described in conjunction with the embodiments of the present invention, and it is apparent that the described embodiments are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Referring to fig. 1, this embodiment provides a direct-fired nitrogen injection foam cementing apparatus, comprising:
the liquid nitrogen gasification system is used for receiving liquid nitrogen from a liquid nitrogen source and converting the liquid nitrogen into high-pressure nitrogen;
the liquid nitrogen gasification system comprises a high-pressure pipe direct-fired evaporator and a first plunger pump, wherein an output port of the direct-fired evaporator is connected with the foam generator, and an input port of the direct-fired evaporator is connected with a liquid nitrogen source through the first plunger pump; the direct-fired evaporator is provided with a plurality of burners, and an ignition device of each burner is connected with a control system; the evaporator is also provided with a fan, and the nitrogen discharge temperature can be controlled within a preset range by adjusting the speed of the fan and the oil injection quantity of the burner; the high-pressure pipe is heated by heat generated by fuel oil, liquid nitrogen in the high-pressure pipe coil is converted into high-pressure nitrogen, the liquid nitrogen is gasified by the direct-fired evaporator, the gasification speed of the liquid nitrogen is greatly improved, large-displacement gas discharge can be realized, and the control range of nitrogen discharge is wide. Therefore, the control requirement on the density of the foam cement slurry can be met by controlling the discharge capacity of high-pressure nitrogen.
The foaming liquid supply system is used for storing and supplying foaming liquid;
the foaming liquid supply system comprises a foaming liquid storage tank, an output port of the foaming liquid storage tank is connected with a foam generator through a second plunger pump, and a booster pump is arranged on a pipeline connecting the foaming liquid storage tank and the second plunger pump; the discharge capacity of foaming liquid can be adjusted through the second plunger pump, and the suction pressure of the foaming liquid can be adjusted through the booster pump, so that the discharge capacity and the suction pressure of the foaming liquid can always meet the actual demands.
In the specific implementation process, the inside of foaming liquid storage box is equipped with the heater for heat up to the foaming liquid, foaming liquid storage box outside is equipped with the heat preservation, heater and heat preservation can accelerate the foaming liquid configuration to guarantee that the temperature of the foaming liquid of output is in certain within range.
A foam generator for receiving and mixing a foaming liquid, high pressure nitrogen and cement slurry from a cement slurry source (cement slurry is provided by a cement pump truck) to form a foamed cement slurry;
the foam generator comprises a mixing cavity, wherein the mixing cavity is connected with two input pipelines and one output pipeline, the two input pipelines are respectively used for inputting high-pressure nitrogen and cement slurry containing foaming liquid (one input pipeline is used for pre-mixing the foaming liquid and the cement slurry to form the cement slurry containing the foaming liquid), and the output pipeline is used for outputting the mixed foam cement slurry; the cement slurry containing foaming liquid and high-pressure nitrogen are respectively conveyed into a mixing cavity of the foam generator in a high-pressure injection mode through two input pipelines, and the foaming cement slurry is directly formed through the spiral block disturbance and impact action in the mixing cavity of the foam generator and is output through the output pipeline.
The data acquisition system is used for acquiring real-time state data of the liquid nitrogen gasification system and the foaming liquid supply system;
the data acquisition system comprises a plurality of high-pressure pipelines and a plurality of low-pressure pipelines, wherein the high-pressure pipelines are arranged in the high-pressure pipeline and the low-pressure pipeline respectively:
the density sensor is used for collecting density data of cement paste;
the flow sensor is used for collecting the discharge capacity of the foaming liquid and the nitrogen discharge capacity;
the pressure sensor is used for collecting the discharge pressure of the foaming liquid, the suction pressure of the foaming liquid and the discharge pressure of nitrogen;
the temperature sensor is used for collecting the nitrogen discharge temperature and the temperatures of the multiple combustion chambers;
the control system comprises a microcontroller and is used for setting target state data of the liquid nitrogen gasification system and the foaming liquid supply system and density of foam cement slurry under different well sections, and adjusting working states of the liquid nitrogen gasification system and the foaming liquid supply system by combining real-time state data of the liquid nitrogen gasification system and the foaming liquid supply system, the target state data and the set density of the foam cement slurry.
The sensor can monitor the density, flow, temperature, pressure and other parameters of each fluid in real time, display and control the parameters by the microcontroller, and adjust the parameters in time so as to realize the configuration and output of the foam cement slurry with high efficiency, high quality and accuracy.
The microcontroller realizes man-machine communication with a man-machine interface through an industrial Ethernet port, thereby being convenient for remote input of operation parameters and real-time procedure control; the human-computer interface can set function keys for workers to use according to the needs, for example, related settings for calibration are carried out on a calibration screen through keys on the human-computer interface; control modes or operation parameters or operation start or stop operation are set on the main screen through keys on the human-computer interface.
In the specific implementation process, the control system is used for setting the density of the foam cement slurry, the target discharge capacity of the foaming liquid and the target discharge capacity of the nitrogen, the limit discharge pressure of the foaming liquid and the limit discharge pressure of the nitrogen and the target discharge temperature of the nitrogen under different well sections, and
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm; because the nitrogen temperature has a large influence on the volume of bubbles in the foam cement slurry, the nitrogen temperature can have a large influence on the density of the foam cement slurry, and therefore, the accurate control of the nitrogen discharge temperature is important for adjusting the density of the foam cement slurry;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the corresponding plunger pump rotating speed in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
According to the embodiment, dynamic parameters of nitrogen, foaming liquid and cement slurry are collected in real time through the data collection system, and working states of the liquid nitrogen gasification system and the foaming liquid supply system are adjusted through the control system; when the set displacement of the foaming liquid changes, the rotating speed of the second plunger pump can be timely and accurately adjusted so as to ensure that the displacement of the foaming liquid reaches the set requirement; when the temperature of the nitrogen outlet is too high or too low, the working states of the plurality of combustors can be automatically controlled, and the stability of the nitrogen discharge temperature is maintained; the whole control system only needs to set parameters, and can always maintain the parameters such as the displacement, the pressure, the temperature and the like of the nitrogen and the foaming liquid within the set parameter range through automatic control, so that the produced foam cement slurry can meet the construction requirements.
Specifically, the formula for calculating the number of burner operations in a liquid nitrogen gasification system is:
ΔE＝E n -E n-I
wherein CV n Representing a current cycle period output; CV (CV) n-1 An output representing a last cycle period; k (K) P Representing the proportional gain; e (E) n Indicating the deviation of the measured nitrogen discharge temperature and the target discharge temperature in the current cycle period; e (E) n-1 Indicating the deviation between the measured nitrogen discharge temperature and the target discharge temperature in the previous cycle; e (E) n-2 Indicating the deviation between the measured nitrogen discharge temperature and the target discharge temperature in the last cycle period; k (K) I Representing the integral gain; Δt represents a cycle period; k (K) D Representing differential gain;
according to the proportional relation between the output of the current cycle period and the number of the burners, the working number of the burners is obtained through conversion as follows:
k＝DV n m/100, where m is the total number of burners, in this example taken as 8; CV (CV) n The number k of burners is 0 to 8.
If the number k of the burners is calculated to be between 7 and 8, let n= (k-7) ×10, set a time period T, and divide T into 10 parts, each of which is Δt, the number of required burners is 8 in the time interval of 0 to nxΔt, and the number of required burners is 7 in the time interval of nxΔt/to T;
if the number k of the burners is calculated to be between 6 and 7, let n= (k-6) ×10, set a time period T, and divide T into 10 parts, each of which is Δt, the number of required burners is 7 in the time interval of 0 to nxΔt, and the number of required burners is 6 in the time interval of nxΔt/to T;
if the number k of the burners is calculated to be between 5 and 6, let n= (k-5) ×10, set a time period T, and divide T into 10 parts, each of which is Δt, the number of required burners is 6 in the time interval of 0 to nxΔt, and the number of required burners is 5 in the time interval of nxΔt/to T;
if the number k of the burners is calculated to be between 4 and 5, let n= (k-4) ×10, set a time period T, and divide T into 10 parts, each of which is Δt, the number of required burners is 5 in the time interval of 0 to nxΔt, and the number of required burners is 4 in the time interval of nxΔt/to T;
if the number k of the burners is calculated to be between 3 and 4, let n= (k-3) ×10, set a time period T, and divide T into 10 parts, each of which is Δt, the number of required burners is 4 in the time interval of 0 to nxΔt, and the number of required burners is 3 in the time interval of nxΔt/to T;
if the number k of the burners is calculated to be between 2 and 3, let n= (k-2) x 10, set a time period T, and divide T into 10 parts, each part being Δt, the number of required burners being 3 in the time interval of 0 to nxΔt, and the number of required burners being 2 in the time interval of nxΔt/to T;
if the number k of the burners is calculated to be between 1 and 2, let n= (k-1) ×10, set a time period T, and divide T into 10 parts, each of which is Δt, the number of required burners is 2 in the time interval of 0 to nxΔt, and the number of required burners is 1 in the time interval of nxΔt/to T;
if the number k of burners is calculated to be between 0 and 1, let n=k×10, set the time period T, and divide T into 10 parts, each part being Δt, the number of burners required is 1 in the time interval of 0 to nxΔt, and the number of burners required is 0 in the time interval of nxΔt/to T.
As shown in fig. 2, the embodiment also provides a control method of the direct-fired nitrogen injection foam well cementation equipment, which comprises the following steps:
setting target state data of a liquid nitrogen gasification system and a foaming liquid supply system under different well sections and density of foam cement slurry, wherein the target state data at least comprises one or more of nitrogen target discharge capacity, nitrogen target discharge temperature, nitrogen limit discharge pressure, foaming liquid target discharge capacity, foaming liquid target suction pressure range and foaming liquid limit discharge pressure;
collecting real-time state data of a liquid nitrogen gasification system and a foaming liquid supply system; the real-time state data at least comprises one or more of measured nitrogen displacement, measured nitrogen discharge temperature, measured nitrogen discharge pressure, measured foaming liquid displacement, measured foaming liquid suction pressure and measured foaming liquid discharge pressure;
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding first plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the rotation speed of a corresponding second plunger pump in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
As shown in fig. 2, the automatic control method of the direct nitrogen injection foam well cementation device provided by the embodiment includes the following steps:
setting target state data of a liquid nitrogen gasification system and a foaming liquid supply system under different well sections and density of foam cement slurry, wherein the target state data at least comprises one or more of nitrogen target discharge capacity, nitrogen target discharge temperature, nitrogen limit discharge pressure, foaming liquid target discharge capacity, foaming liquid target suction pressure range and foaming liquid limit discharge pressure;
collecting real-time state data of a liquid nitrogen gasification system and a foaming liquid supply system; the real-time state data at least comprises one or more of measured nitrogen displacement, measured nitrogen discharge temperature, measured nitrogen discharge pressure, measured foaming liquid displacement, measured foaming liquid suction pressure and measured foaming liquid discharge pressure;
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding first plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the rotation speed of a corresponding second plunger pump in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
The control process of the well cementation equipment of the embodiment is as follows:
the human-computer interface can set function keys for workers to use according to the needs, for example, related settings for calibration are carried out on a calibration screen through keys on the human-computer interface; control modes or operation parameters or operation start or stop operation are set on the main screen through keys on the human-computer interface.
By means of software program settings, the microprocessor can control the following operations:
the microprocessor measures the nitrogen discharge pressure through the pressure sensor, and automatically enters the equipment protection state after the nitrogen discharge pressure exceeds the set nitrogen discharge pressure limit: the nitrogen and foaming liquid supply was stopped and an overpressure indication was given.
The microprocessor measures the discharge pressure of the foaming liquid through the pressure sensor, and automatically enters the equipment protection state after the discharge pressure of the foaming liquid exceeds the preset pressure limit of the foaming liquid: the nitrogen and foaming liquid supply was stopped and an overpressure indication was given.
The microprocessor detects that the liquid nitrogen inhalation temperature is higher than the set saturation temperature through the temperature sensor, and gives an alarm and prompts.
The microprocessor controls the start/stop of the liquid nitrogen pump motor by operating the liquid nitrogen pump motor on a human-computer interface; when the liquid nitrogen pump is started, the prompt beside the rotating speed of the liquid nitrogen pump correspondingly changes into 'running'; after stopping the liquid nitrogen pump, the prompt beside the liquid nitrogen pump speed correspondingly changes into stop: at liquid nitrogen pump motor panel switch in remote control, motor operation and rotational speed control are automatic control, and after the button operation began, microprocessor can be according to setting for nitrogen gas discharge capacity, and the nitrogen gas flow automatic regulating rotational speed that control mode and the nitrogen gas flowmeter of liquid nitrogen pump motor measured maintains nitrogen gas discharge capacity at the setting value, and the concrete mode is: the microprocessor takes the nitrogen flow measured by the nitrogen flow meter as a feedback value, takes the set nitrogen flow as a set value, and controls the rotating speed of the liquid nitrogen pump motor through a single neuron PID. When the liquid nitrogen pump is under manual control, an increasing/decreasing button appears on the right side of the rotating speed of the motor of the liquid nitrogen pump, and the increasing/decreasing button is required to be clicked on a screen to increase/decrease the rotating speed of the motor so as to control the nitrogen discharge.
The microprocessor controls the starting/stopping of the foaming liquid pump motor by operating the starting/stopping of the foaming liquid pump motor on a human-computer interface; when the foam liquid pump is started, the prompt beside the motor speed of the foam liquid pump correspondingly changes into running; after the motor of the foam liquid pump is stopped, the prompt beside the motor speed of the foam liquid pump correspondingly changes into stop: when the panel switch of the foaming liquid pump motor is in remote control, the motor operates and the rotating speed is controlled to be controlled automatically, after key operation is started, the microprocessor takes the set foaming liquid flow as a set value, the foaming liquid flow measured by the foaming liquid flow meter is taken as a feedback value, the rotating speed is automatically regulated through a single neuron PID, and the foaming liquid flow is maintained at the set value. When the control is under manual control, an up/down button appears on the right side of the rotation speed of the motor of the foam liquid pump, and the up/down button needs to be clicked on a screen to increase/decrease the rotation speed of the motor to control the flow.
The microprocessor controls the starting/stopping of the feeding pump motor by operating the starting/stopping of the feeding pump motor on a human-computer interface; when the motor is started, the prompt beside the motor speed of the liquid feeding pump correspondingly changes into running; after the upper liquid pump motor is stopped, the prompt beside the rotating speed of the upper liquid pump motor correspondingly changes into stop: after the operation of the key is started, the microprocessor sets the liquid level of the foaming liquid tank as a set value, the liquid level measured by the liquid level meter of the foaming liquid tank as a feedback value, and the rotating speed of the motor of the liquid feeding pump is regulated through the traditional PID control, so that the liquid level of the liquid feeding pump tank is maintained at the set value. When the manual control is performed, an up/down button appears at the right side of the rotating speed of the motor of the liquid pump, and the up/down button needs to be clicked on a screen to increase/decrease the rotating speed of the motor to control the liquid level.
The microprocessor controls the starting/stopping of the booster pump motor by operating the booster pump motor on the human-computer interface; when the booster pump is started, the prompt beside the motor rotating speed of the booster pump correspondingly changes into running; after the motor of the booster pump is stopped, the prompt beside the rotating speed of the motor of the booster pump correspondingly changes into stop: when the panel switch of the motor of the booster pump is in remote control, the motor operates and is automatically controlled, after key operation is started, the microprocessor can set the suction pressure range of the foam liquid pump and the pressure measured by the foam liquid suction pressure sensor, and after the set pressure is lower than the set pressure range, the rotating speed of the motor is increased; the pressure is higher than the set pressure range, the motor rotating speed of the foaming liquid booster pump is automatically regulated by reducing the motor rotating speed, and the foaming liquid suction pressure is maintained in the set range. When the control is performed manually, an up/down button appears on the right side of the rotating speed of the motor, and the up/down button needs to be clicked on a screen to increase/decrease the rotating speed so as to control the suction pressure of the foaming liquid.
The microprocessor controls the start/stop of the evaporator fan motor by operating the evaporator fan motor on a human-machine interface; when the motor is started, the prompt beside the rotating speed of the fan motor of the evaporator correspondingly changes into running; after the evaporator fan motor is stopped, the prompt beside the rotation speed of the evaporator fan motor correspondingly becomes 'stop': when the panel switch of the evaporator fan motor is in remote control, the motor runs and is automatically controlled, and after key operation starts, the microprocessor automatically controls the rotating speed of the evaporator fan motor according to the current state of the burner: when igniting, a set rotating speed (lower rotating speed) is given; after ignition is successful, a set rotating speed (higher rotating speed) is given, the two set rotating speeds are used as set rotating speeds, the monitored rotating speed of the motor is used as a feedback rotating speed, and the control voltage is calculated through single-neuron PID control to control the rotating speed of the fan motor of the evaporator. When the manual control is performed, an up/down button appears on the right side of the motor rotation speed, and the up/down button needs to be clicked on a screen to increase/decrease the rotation speed of the fan motor of the evaporator.
The microprocessor fires and the main fires of the evaporator by operating the evaporator on a man-machine interface: after the evaporator switch is automatically controlled by a program and key operation is started, the microprocessor takes the set discharge temperature as a set value, the liquid nitrogen pump discharge temperature sensor collects the liquid nitrogen discharge temperature as a feedback value, and the number of main burners required is calculated through incremental PID control to control the fuel oil electromagnetic valves of 8 burners.
The microprocessor reads the temperature of the foaming liquid tank through a foaming liquid tank temperature sensor, and after the temperature is lower than a set temperature range, the microprocessor turns on a heater to heat; and after the set temperature range is reached, the heater is turned off to stop heating.
When the operation is started, the sensor collects all data and transmits the data to the microprocessor, and the data are displayed on a human-computer interface; an operator inputs operation data according to the process requirements through keys of a human-computer interface; the microprocessor automatically controls each executing mechanism; and sending out an operation stopping command through a key on a human-computer interface to stop operation, so that the operation of the nitrogen injection foam well cementation equipment is accurately, dynamically and comprehensively automatically controlled.
The foregoing description of the preferred embodiments of the invention is not intended to be limiting, but rather is intended to cover all modifications, equivalents, alternatives, and improvements that fall within the spirit and scope of the invention.
Claims (9)
1. A direct-fired nitrogen injection foam cementing apparatus, comprising:
the liquid nitrogen gasification system is used for receiving liquid nitrogen from a liquid nitrogen source and converting the liquid nitrogen into high-pressure nitrogen;
the foaming liquid supply system is used for storing and supplying foaming liquid;
the foam generator is used for receiving and mixing the foaming liquid, the high-pressure nitrogen and the cement slurry from the cement slurry source to form foam cement slurry;
the data acquisition system is used for acquiring real-time state data of the liquid nitrogen gasification system and the foaming liquid supply system;
the control system is used for setting the densities of foam cement slurries under different well sections and target state data of the liquid nitrogen gasification system and the foaming liquid supply system, and adjusting the working states of the liquid nitrogen gasification system and the foaming liquid supply system by combining the real-time state data and the target state data of the liquid nitrogen gasification system and the foaming liquid supply system and the set densities of the foam cement slurries.
2. The direct-fired nitrogen injection foam well cementation equipment according to claim 1, wherein the liquid nitrogen gasification system comprises a direct-fired evaporator and a first plunger pump, an output port of the direct-fired evaporator is connected with the foam generator, and an input port of the direct-fired evaporator is connected with a liquid nitrogen source through the first plunger pump; the direct-fired evaporator is provided with a plurality of burners, and the ignition device of the burners is connected with a control system.
3. The direct-fired nitrogen injection foam well cementation device according to claim 1, wherein the foaming liquid supply system comprises a foaming liquid storage tank, an output port of the foaming liquid storage tank is connected with the foam generator through a second plunger pump, and a booster pump is arranged on a pipeline connecting the foaming liquid storage tank with the second plunger pump.
4. A direct-fired nitrogen injection foam cementing apparatus according to claim 1, wherein the foam generator comprises a mixing chamber connected with two input pipes for inputting high pressure nitrogen and cement slurry containing foaming liquid, respectively, and an output pipe for outputting the mixed foam cement slurry.
5. The direct-fired nitrogen injection foam cementing apparatus of claim 1, wherein said data acquisition system comprises at least one or more of the following sensors:
the density sensor is used for collecting density data of cement paste;
the flow sensor is used for collecting the discharge capacity of the foaming liquid and the nitrogen discharge capacity;
the pressure sensor is used for collecting the discharge pressure of the foaming liquid, the suction pressure of the foaming liquid and the discharge pressure of nitrogen;
and the temperature sensor is used for collecting the nitrogen discharge temperature and the temperature of the main combustion chamber.
6. The direct-fired nitrogen injection foam cementing apparatus according to claim 1, wherein the control system is configured to set the density of foam cement slurry, the target displacement of foaming fluid, the target displacement of nitrogen gas, the ultimate discharge pressure of foaming fluid and the ultimate discharge pressure of nitrogen gas, and the ultimate discharge temperature of nitrogen gas at different well sections, and
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding first plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the rotation speed of a corresponding second plunger pump in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
7. The direct-fired nitrogen injection foam cementing apparatus of claim 6 wherein the formula for calculating the number of burner operations in a liquid nitrogen gasification system is:
ΔE＝E n -E n-1
wherein CV n An output representing a current cycle period; CV (CV) n-1 An output representing a last cycle period; k (K) P Representing the proportional gain; e (E) n Indicating the measured nitrogen discharge temperature and target discharge temperature during the current cycleDeviation of (2); e (E) n-1 Indicating the deviation between the measured nitrogen discharge temperature and the target discharge temperature in the previous cycle; e (E) n-2 Indicating the deviation between the measured nitrogen discharge temperature and the target discharge temperature in the last cycle period; k (K) I Representing the integral gain; Δt represents a cycle period; k (K) D Representing differential gain;
according to the proportional relation between the output of the current cycle period and the number of the burners, the working number of the burners is obtained through conversion as follows:
k＝CV n ·m/100
wherein m is the total number of burners; CV (CV) n The value of (2) is 0-100, and the number k of burners is 0-m.
8. A direct-fired nitrogen injection foam cementing apparatus according to claim 7, wherein if k is calculated as a fraction and k is between i and i+1, wherein i is an integer between 0 and m "1; setting a time period T and dividing T into 10 parts, each part being Δt, the number of required burners being i+1 in a time interval of 0 to nxΔt, and the number of required burners being i in a time interval of nxΔt/to T; where n= (k-i) ×10.
9. The control method of the direct-fired nitrogen injection foam well cementation equipment is characterized by comprising the following steps of:
setting target state data of a liquid nitrogen gasification system and a foaming liquid supply system under different well sections and density of foam cement slurry, wherein the target state data at least comprises one or more of nitrogen target discharge capacity, nitrogen target discharge temperature, nitrogen limit discharge pressure, foaming liquid target discharge capacity, foaming liquid target suction pressure range and foaming liquid limit discharge pressure;
collecting real-time state data of a liquid nitrogen gasification system and a foaming liquid supply system; the real-time state data at least comprises one or more of measured nitrogen displacement, measured nitrogen discharge temperature, measured nitrogen discharge pressure, measured foaming liquid displacement, measured foaming liquid suction pressure and measured foaming liquid discharge pressure;
according to the current actually measured nitrogen discharge temperature and the target discharge temperature, calculating the corresponding working quantity of the burner in the liquid nitrogen gasification system through an incremental PID control algorithm;
adjusting the target discharge capacity of foaming liquid and nitrogen according to the set densities of foam cement slurries under different well sections;
according to the set target nitrogen displacement and the actual measured displacement, controlling the rotating speed of a corresponding first plunger pump in the liquid nitrogen gasification system to adjust the nitrogen displacement;
controlling the rotation speed of a corresponding second plunger pump in the foaming liquid supply system to adjust the foaming liquid discharge capacity according to the set foaming liquid target discharge capacity and the actually measured foaming liquid discharge capacity;
controlling the foaming liquid supply system to output the highest discharging pressure of the foaming liquid according to the set foaming liquid limit discharging pressure and the actually measured foaming liquid discharging pressure;
and controlling the highest discharge pressure of the nitrogen output by the liquid nitrogen gasification system according to the set nitrogen limit discharge pressure and the actual measured nitrogen discharge pressure.
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| CN202310522412.0A CN116537738A (en) | 2023-05-05 | 2023-05-05 | Direct-fired nitrogen injection foam well cementation equipment and control method thereof |
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| CN202310522412.0A CN116537738A (en) | 2023-05-05 | 2023-05-05 | Direct-fired nitrogen injection foam well cementation equipment and control method thereof |
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