CN117850284A - Intelligent control system and method for top drive - Google Patents

Intelligent control system and method for top drive Download PDF

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Publication number
CN117850284A
CN117850284A CN202211219858.8A CN202211219858A CN117850284A CN 117850284 A CN117850284 A CN 117850284A CN 202211219858 A CN202211219858 A CN 202211219858A CN 117850284 A CN117850284 A CN 117850284A
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China
Prior art keywords
top drive
torque
module
control
drilling
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CN202211219858.8A
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Inventor
张尧
王博
杨泉水
楚飞
陈鹏
谭帅
周泽人
孙艳辉
周磊
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China National Petroleum Corp
CNPC Engineering Technology R&D Co Ltd
Beijing Petroleum Machinery Co Ltd
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China National Petroleum Corp
CNPC Engineering Technology R&D Co Ltd
Beijing Petroleum Machinery Co Ltd
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Priority to CN202211219858.8A priority Critical patent/CN117850284A/en
Publication of CN117850284A publication Critical patent/CN117850284A/en
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

The invention discloses a top drive intelligent control system and a method, which belong to the technical field of oil and gas drilling, wherein the system comprises a top drive state signal input module, a drilling machine state signal input module, an underground tool state signal input module, a data storage module, a central processing unit, a top drive control signal output module and a man-machine operation interface, wherein the top drive state signal input module, the drilling machine state signal input module and the underground tool state signal input module are respectively connected with the data storage module, the data storage module is connected with the central processing unit, and the central processing unit is respectively connected with the top drive control signal output module and the man-machine operation interface. The invention also provides a top drive intelligent control method. The technical scheme of the invention improves the automation level of top drive control, simplifies the top drive operation, has the characteristic of safe operation, and is suitable for popularization and application.

Description

Intelligent control system and method for top drive
Technical Field
The invention relates to the technical field of oil and gas drilling, in particular to a top drive intelligent control system and method.
Background
The top drive is a short term of top drive drilling device, and can directly rotate a drill rod from the upper space of a derrick, and downwards feed the drill rod along a special guide rail to finish various drilling operations such as rotary drilling of the drill rod, circulating drilling fluid, connecting a stand column, screwing and unscrewing, chamfering and the like. The device can obviously improve the capacity and efficiency of drilling operation, and becomes a standard product in the petroleum drilling industry. Along with the development of the drilling process and the improvement of the automation of drilling equipment, the top drive control system needs to be more and more automated and intelligent, such as the requirement on the accurate control of a lifting ring, the requirement on the accurate control of the rotation speed torque and the rotation angle of the top drive, the requirement on the linkage of the top drive and other equipment, and the like. These controls include automatic control of the power tap in the top drive, automatic control of the pipe handling device, and coordinated control of the power tap and the pipe handling device.
In the prior art, the driller mainly relies on the driller to manually operate, for example, when the driller grabs or pushes the drilling tool, the driller firstly operates the lifting ring to rotate to a proper angle and then operates the lifting ring to incline to a proper position, so that the operation of grabbing or pushing the drilling tool is completed. All rely on subjective judgments of the driller throughout the operation, and if the judgments are inaccurate, adjustments need to be made repeatedly. When the shackle is assembled and disassembled, the driller is required to operate the locking pin of the rotary head, clamp the back-up wrench and control the output torque of the motor, so that the steps are more and the time is long. Manual operation is closely related to the experience and training level of the driller, and due to unfamiliar equipment, operational failures, and even safety problems, occur. In addition, a new technology is frequently provided for top drive, but the situation that a driller cannot well utilize because of insufficient training is also unfavorable for popularization and use of the new technology. Therefore, it is necessary to design a top drive intelligent control system and method, which can monitor the state of the top drive comprehensively, judge the working condition of the top drive autonomously, propose the corresponding operation proposal according to the working condition, and implement automatically after the driller confirms.
At present, the patents of the top drive control method at home and abroad are divided into two types, namely integral control and functional control.
The integral control is mainly used for controlling each function of the top drive, and can be divided into local control and remote control according to the installation position of the control box. The control system can control all functions of the top drive, after an operator gives an operation instruction manually, the top drive executes corresponding actions according to the given operation instruction, and the operator can operate locally in a driller room or remotely in a safe area. All functions of the top drive are manually controlled by operators, and the functions of automatic control or linkage control are not provided. The patent applied according to this mode is mainly:
the invention patent CN 108089506A top drive well drilling control optimizing device is essentially a remote control device, and the remote control top drive executes corresponding actions through instructions given by operators.
Secondly, aiming at a certain working condition, the single function of the top drive is controlled. The identification of the working condition is mainly judged by an operator according to experience. When the operator recognizes that the drilling operation is under a certain working condition, the corresponding function is started, so that the top drive is in a certain special running state, and the drilling operation under the working condition is facilitated. Whether the working condition can be identified, whether the corresponding function should be started or not is mainly dependent on the degree of understanding of the equipment and the drilling process by an operator, the top drive cannot be automatically identified, and whether the corresponding function should be started or not. The patent applied according to this mode mainly has the following items:
The invention patent CN 112360426A discloses a drilling top drive control system and a drilling top drive control method, which are used for controlling a top drive under certain specific working conditions. Mainly aims at a top drive drilling control system and a method for avoiding stick-slip and drill sticking phenomena.
The invention patent CN 113950219A discloses an intelligent anti-collision controller for a top drive, which is used for detecting the running position of the top drive and achieving the purpose of preventing collision.
Disclosure of Invention
The invention aims to provide a top drive intelligent control system and method, which utilize various collected information to realize the purposes of judging the top drive working condition, giving corresponding operation suggestions according to the working condition and controlling the top drive to automatically finish the operation. The automation level of the top drive control is improved, the top drive operation is simplified, the influence caused by manual experience is reduced, and the safety of the top drive operation and operation is improved.
The invention provides a top drive control method which considers parameters such as top drive height, suspended weight, drilling pressure, pumping pressure, rotating speed, torque, angle and the like, and automatically controls multiple operations of top drive. The system control object comprises a pipe processing device and a power tap, the linkage control of the two parts can be realized, and the system can identify the current working condition of the top drive through the obtained parameters; and recommending the driller to use the corresponding function according to the current working condition, and automatically controlling the top drive to operate the corresponding function after the driller is confirmed. The function of automatic control comprises the positioning of the hanging ring, the automatic screwing-off of the top drive, the automatic release of reactive torque of the top drive and the control of the rotating speed and torque of the top drive. In order to better use the control system, a signal processing and transmitting device and a using method of the whole system are designed. Embodiments of the present invention are implemented as follows:
In one aspect, an embodiment of the invention provides a top drive intelligent control system, which comprises a top drive state signal input module, a drilling machine state signal input module, an underground tool state signal input module, a data storage module, a central processing unit, a top drive control signal output module and a man-machine operation interface, wherein the top drive state signal input module, the drilling machine state signal input module and the underground tool state signal input module are respectively connected with the data storage module, the data storage module is connected with the central processing unit, and the central processing unit is respectively connected with the top drive control signal output module and the man-machine operation interface;
the top drive state signal input module, the drilling machine state signal input module and the downhole tool state signal input module are used for obtaining parameter signals related to drilling;
the data storage module is used for storing signals obtained by the top drive state signal input module, the drilling machine state signal input module and the downhole tool state signal input module;
the central processing unit is used for reading data and identifying the current working condition of the top drive through a built-in algorithm;
the man-machine operation interface is used for displaying recommended top drive operation;
The top drive control signal output module is used for outputting recommended top drive operation.
Further, the drilling-related parameter signals comprise signals of various control commands of a top drive, top drive rotating speed, top drive torque, top drive rotating angle, tool face, pump pressure, drilling pressure, hanging weight, top drive height and the like.
Further, the system also comprises a data acquisition module, a database, a working condition identification module and a control module.
Still further, the data acquisition module includes a top drive status data acquisition module, a rig status data acquisition module, a downhole tool status data acquisition module, and other status data acquisition modules.
Still further, the operating mode identification module includes stick-slip operating mode identification module, locked rotor operating mode identification module and directional operating mode identification module.
Still further, the control module includes a power faucet control module, a pipe handling device control module, and a top drive automation control module.
Further, the top drive control signal output module comprises a digital quantity output module and an analog quantity output module.
The digital quantity output module is used for controlling forward and reverse rotation of the top drive, forward and backward tilting of the lifting ring, forward and reverse rotation of the rotating head, clamping and loosening of the backup wrench, braking of the band-type brake and the like; the digital quantity output module can output a 24VDC signal and can also be connected with the top drive controller in a communication mode;
The analog output module is used for controlling the rotation speed of the top drive, limiting torque of the top drive, rotation angle of the top drive and the like; the analog output module can output 0-10V voltage signals, 4-20mA current signals, 0-20mA current signals and the like, and can also be connected with the top drive controller in a communication mode;
on the other hand, the embodiment of the invention provides a top drive intelligent control method, which comprises the steps of controlling automatic top drive screwing-on, controlling automatic top drive screwing-off and controlling automatic top drive drilling rod grabbing;
the control method for realizing automatic top drive buckling comprises the following steps:
step one: forward spin-buckle; the method specifically comprises three steps, namely, step A, a system control top drive rotates according to a preset rotating speed; step B, judging whether the top drive main shaft and the drill rod are connected or not by detecting the actual torque of the top drive, and stopping the turnbuckle after the turnbuckle torque is reached; step C, completing forward turnbuckle, and sending a turnbuckle completion signal;
step two: clamping the back tongs; the method specifically comprises three steps, namely, a step A, wherein a system controls a back-up wrench to clamp a drill rod; step B, detecting whether the back-up wrench is clamped or not through a sensor arranged on a hydraulic pipeline of the top drive back-up wrench, and considering that the back-up wrench is clamped after the back-up wrench pressure is larger than a threshold value set by a system and is kept for a certain time; step C, controlling the back tongs to keep a clamping state, and sending out a clamping signal;
Step three: the top drives the fastening buckle; the method specifically comprises three steps, namely, step A, controlling a top motor by a system, and setting output torque according to the screwing torque; step B, detecting whether the actual torque of the top drive reaches the set buckling torque; step C, after the torque reaches the buckling torque, sending out a buckling torque reaching signal;
step four: finishing buckling; the method specifically comprises three steps, namely, step A, gradually reducing the top drive output torque according to a curve set by a system until the torque is 0; step B, controlling the top drive to loosen the back tongs; step C, completing an automatic buckling function and sending out a buckling completion signal;
the control method for realizing the automatic shackle of the top drive comprises the following steps:
step one: clamping the back tongs; the method specifically comprises three steps, namely, a step A, wherein a system controls a back-up wrench to clamp a drill rod; step B, detecting whether the back-up wrench is clamped or not through a sensor arranged on a hydraulic pipeline of the top drive back-up wrench, and considering that the back-up wrench is clamped after the back-up wrench pressure is larger than a threshold value set by a system and is kept for a certain time; step C, controlling the back tongs to keep a clamping state, and sending out a clamping signal;
step two: top drive shackle; the method specifically comprises three steps, namely, step A, controlling a top motor by a system, and setting output torque according to the screwing torque; step B, detecting whether the actual torque of the top drive reaches the set buckling torque; step C, after the torque reaches the buckling torque, sending out a buckling torque reaching signal;
Step three: reverse spin-fastening; the method specifically comprises three steps, namely, step A, reversely rotating a system control top drive according to a preset rotating speed; step B, judging whether the reverse turnbuckle is completed or not by detecting the rotation number of the top drive, and stopping the turnbuckle after the preset reverse turnbuckle number is reached; step C, finishing the top drive turnbuckle, and sending a turnbuckle finishing signal;
step four: finishing buckling; the method specifically comprises three steps, namely, step A, gradually reducing the top drive output torque according to a curve set by a system until the torque is 0; step B, controlling the top drive to loosen the back tongs; step C, completing an automatic buckling function and sending out a buckling completion signal;
the control method for realizing automatic grabbing of the drill rod by the top drive comprises the following steps:
step one: judging the position; the method specifically comprises three steps, namely, step A, judging the height and lifting speed of a top drive through the top drive position of a drilling machine after starting a function; detecting whether the top drive reaches a preset height or not, and detecting whether the lifting of the top drive is stopped or not at the same time; step B, the top drive height accords with a preset value, and after lifting is stopped, top drive in-place information is sent out; step C, detecting the position of the drill rod through a sensor on the top drive, and calculating and determining the angle and the inclination angle of the top drive rotating head to be rotated;
Step two: controlling a hanging ring; the method specifically comprises seven steps, wherein in the step A, the top drive rotary head is controlled to rotate; step B, detecting whether the top drive rotating head is in place; step C, after rotating in place, sending out a rotating in place signal; step D, the system controls the top drive hanging ring to incline forwards; step E, detecting whether the inclined position of the hanging ring reaches a preset value or not; step F, after the hanging ring reaches a preset position, sending out an inclination in-place signal; g, positioning the hanging ring is completed, and sending out a completion signal; the control of the hanging ring must be in the order of rotating first, rotating in place and then tilting so as to ensure the safety in the rotating process.
Further, the method also comprises the step of identifying the top drive locked rotor, wherein the locked rotor working condition identification software module of the control system is used for identifying the locked rotor working condition, and the input data comprises parameters such as the actual top drive torque T, the top drive rotating speed n, the identification period T, the top drive height h and the like. The identification module records data according to the identification period T, and calculates according to a formula to obtain deltaT=T 2 -T 1 ，Δn＝n 2 -n 1 The system judges according to the value of delta T and delta n and the values of T and n at the current moment, when the delta T is continuously in a positive value and the delta n is in a negative value and reaches a plurality of identification periods T, the system considers that the top drive is about to be blocked, marks that the top drive is in a blocking early warning state at the moment, and when the top drive torque value T reaches a set torque and the actual top drive rotation speed n approaches 0 in the blocking early warning state, the system identifies that blocking occurs at the moment. After the locked-rotor, the system prompts the driller whether to release the reactive torque or not, and after confirmation, the system executes an automatic reactive torque release program. Automatic release of the reactive torque program, the input data of which include the actual torque T of the top drive act Top drive actual rotation speed n act Top drive set torque T set And top drive set rotational speed n set The method comprises the steps of carrying out a first treatment on the surface of the The output data is the torque T of the top drive set And top drive set rotational speed n set And controlling the top drive output torque and the rotating speed through the top drive control signal output module. Automatic release of reactive torque program by lowering top drive settingsTorque gradually reducing counter torque of downhole locked rotor and simultaneously detecting actual rotation speed n of top drive act When the actual rotation speed n of the top drive is found act < 0, exceeding a certain threshold value, and an in unit time t act When gradually increasing, the torque setting value stops decreasing according to an angle delta n in a unit time t act Determining the response of the system: Δn act When gradually increasing or maintaining, the top drive set torque T is increased set ；Δn act When gradually decreasing, the current top drive set torque T is maintained set ；Δn act Approaching 0 and n act When approaching 0, continuously reducing the top drive set torque T set Until the actual torque T of the top drive act After the torque is less than a certain threshold value, the system automatically releases the reactive torque to finish.
Further, the device also comprises a working condition recognition module for recognizing and processing the excessive friction, the pressure and the tool face deviation during directional drilling, and the input data comprises a pump pressure P through the directional working condition recognition module of the control system Pump with a pump body Rotation angle theta of top drive Top Top drive torque T, weight on bit P WOB And identifying parameters such as the suspension weight, the identification period t, the drill rod length l and the like. During drilling operation, the drill rod can be equivalent to a spring, the rotation angle of the top drive is not identical with the rotation angle of the drill bit, and the rotation angle of the drill bit is related to the torque of the top drive, the length of the drill rod and the rigidity of the drill rod, so that the rotation angle of the drill bit and the rotation angle of the top drive have the following relation: Δθ Drill bit ＝k·l·T·Δθ Top drive The tool face deviation is adjusted through three steps, so that the tool face is kept within an allowable range:
step one: parameters are determined. Inputting parameters such as well depth, a preset tool face, a tool face deviation range, a recognition period and the like, controlling the top drive to rotate forward and backward by the system after the drill bit touches the bottom of the well, and obtaining a basic parameter k value as an initial parameter by detecting parameters such as a top drive rotation angle, the drill bit rotation angle, a top drive torque and the like.
Step two: tool face deviation adjustment: detecting an actual tool face value, calculating according to the rotation angle of the drill bit after the tool face is deviated, calculating the rotation angle of the top drive, and controlling the top drive to rotate according to a preset angle. In the adjustment process, the k value is corrected according to the deviation of the rotation angle of the top drive and the rotation intersection of the drill bit during adjustment.
Step three: finishing tool face deviation adjustment: and detecting an actual tool face value, and completing the tool face adjusting process when the actual tool face is within the deviation range of the preset tool face.
Further, the device also comprises judgment and processing of the conditions of excessive friction and pressure drop, and the input data comprise the weight on bit P through the directional working condition identification module of the control system WOB Pumping pressure, hanging weight, identifying period t, well depth and other parameters. The system processes the conditions of overlarge friction resistance and pressure supporting through three steps:
step one: calculating friction resistance, namely calculating underground friction resistance according to parameters such as the weight of the suspension, the weight of the drill, the identification period and the like, and comparing the underground friction resistance with a preset friction resistance threshold;
step two: and judging the holding pressure according to parameters such as friction resistance, drilling pressure, suspension weight, pumping pressure and the like. Judging whether the pressure is in a supporting pressure state or not;
step three: the friction is reduced, the top drive torsion pendulum control function of the system is started, the friction is reduced, and the pressure bearing condition is relieved.
The system can dynamically adjust the top drive rotating speed according to the change of the rotating speed and the torque during drilling. The input parameters of the device comprise a rotating speed n and a torque T, and the device can identify and process the stick-slip working condition in the drilling process. The identification step mainly comprises the following steps:
step one: recording data of the rotating speed n and the torque T, wherein the recording period is less than or equal to 100ms;
Step two: converting the recorded data signals from time domain to frequency domain to obtain frequency domain signals of 1Hz-10Hz respectively;
step three: the frequency domain signals of the rotating speed n and the torque T are subjected to characteristic comparison, and the signal intensity of 1-10Hz is i respectively 1 ，i 2 ，i 3 …i 10 The weight of each frequency domain signal intensity is k respectively 1 ，k 2 ，k 3 …k 10 Respectively calculating i 1 *k 1 ，i 2 *k 2 ，i 3 *k 3 …i 10 *k 10 According to a built-in algorithm, finally obtaining the intensity value i of the stick-slip working condition; the weight of the frequency domain signal strength can be adjusted by the system parameters.
Step four: and judging whether the top drive soft torque function needs to be started or not according to the intensity value i of the stick-slip working condition, and automatically setting corresponding parameters of the soft torque function.
The embodiment of the invention has the beneficial effects that:
the invention provides a top drive intelligent control system and a top drive intelligent control method, which apply theories such as automatic control and fuzzy control logic, and take parameters such as top drive height, suspended weight, drilling pressure, pumping pressure, rotating speed, torque and angle into consideration. The system control object comprises a pipe processing device and a power tap, and can realize the linkage control of the two parts. The system can identify the current working condition of the top drive through the obtained parameters; and recommending the driller to use the corresponding function according to the current working condition, and automatically controlling the top drive to operate the corresponding function after the driller is confirmed. The functions of automatic control comprise hanging ring positioning, top drive screwing-off, top drive drilling and the like. In order to better use the control system, a signal processing and transmitting device and a using method of the whole system are designed. Aiming at top drives with various types in the market, the system is provided with a universal connection interface and a universal system, and the universality is good.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings that are needed in the embodiments will be briefly described below, it being understood that the following drawings only illustrate some embodiments of the present invention and therefore should not be considered as limiting the scope, and other related 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 top drive intelligent control system of the present invention;
FIG. 2 is a schematic diagram of a software architecture of the top drive intelligent control system of the present invention;
FIG. 3 is a schematic view of an automatic make-up;
fig. 4 is a schematic view of a shackle;
FIG. 5 is a top drive hoist ring automatic control flow chart;
FIG. 6 is a tool face bias adjustment flow chart;
FIG. 7 is a flow chart of friction and underpressure case processing;
FIG. 8 is a flow chart of drilling condition identification and processing;
fig. 9 is a flow chart of an embodiment of the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. The components of the embodiments of the present invention generally described and illustrated in the figures herein can be arranged and designed in a wide variety of different configurations.
Referring to fig. 1 to 2, the top drive intelligent control system of the present invention includes: the system comprises a top drive state signal input module 1, a drilling machine state signal input module 2, a downhole tool state signal input module 3, a data storage module 4, a central processing unit 5, a top drive control signal output module 6 and a man-machine operation interface 7. The invention is an independent device for controlling the top drive, which is connected with a top drive control console through an output module, and the output signals are transmitted to a top drive logic controller through the top drive control console, so that the aim of controlling various functions of the top drive is fulfilled, and the top drive control logic controller is suitable for top drives of different types by changing different top drive control signal output modules.
The software control part of the invention obtains parameter signals related to drilling through a top drive state signal input module 1, a drilling machine state signal input module 2, a downhole tool state signal input module 3 and other state signal input modules 4, and the parameter signals comprise various control commands of a top drive, signals of a top drive rotating speed, a top drive torque, a top drive rotating angle, a tool face, a pump pressure, a bit pressure, a cantilever weight, a top drive height and the like, the obtained signals are stored in a data storage module 4, a central processing unit 5 reads data, a built-in algorithm is used for identifying the working condition of the top drive, the recommended top drive operation is displayed on a man-machine operation interface 7, and after driller confirmation, the top drive control signal output module 6 outputs the signals to control the corresponding actions of the top drive. The system can output multiple paths of signals simultaneously so as to realize the function of controlling multiple actions of the top drive simultaneously.
The system adopts a modularized design, is an independent control system and controls the top drive in parallel with the top drive control console. When the system is used, firstly, the control right of the top drive system is obtained through driller confirmation, and after the control right is obtained, the top drive operation is controlled by the system; the driller can obtain the control right of the top drive at any time, and after the control right is cancelled, the top drive is still controlled by the top drive control console. According to the design of the invention, the system can be suitable for various top drive systems, and different top drive state signal input modules 1 and top drive control signal output modules 6 can be replaced according to different top drive types and different control objects so as to realize the purpose of universality.
The system can realize the linkage control of the power tap and the pipe treatment device. The invention provides a control method for realizing automatic top drive screwing based on the control system, as shown in fig. 3, comprising the following steps:
step one: and (5) forward screwing. The method specifically comprises three steps, namely, step A, the system controls the top drive to rotate at a preset rotating speed (the rotating speed can be set through a man-machine operation interface 7); step B, judging whether the top drive main shaft and the drill rod are connected or not by detecting the actual torque of the top drive, and stopping the spinning after the torque reaches the spinning torque (the torque can be set through a man-machine operation interface 7); step C, completing forward turnbuckle, and sending a turnbuckle completion signal;
Step two: the back tongs are clamped. The method specifically comprises three steps, namely, a step A, wherein a system controls a back-up wrench to clamp a drill rod; step B, detecting whether the back-up wrench is clamped or not through a sensor arranged on a hydraulic pipeline of the top drive back-up wrench, wherein the back-up wrench is considered to be clamped after the pressure of the back-up wrench is larger than a threshold value set by a system (the threshold value can be set through a man-machine operation interface 7) and is maintained for a certain time (the time can be set through the man-machine operation interface 7); and C, controlling the back tongs to keep a clamping state, and sending out a clamping signal.
Step three: the top drive is tightly buckled. The method specifically comprises three steps, namely, step A, controlling a top motor by a system, and setting output torque according to the screwing torque; step B, detecting whether the actual torque of the top drive reaches the set buckling torque; and C, after the torque reaches the buckling torque, sending out a buckling torque reaching signal.
Step four: and finishing buckling. The method specifically comprises three steps, namely, step A, gradually reducing the top drive output torque according to a curve set by a system until the torque is 0; step B, controlling the top drive to loosen the back tongs; and step C, completing an automatic buckling function and sending out a buckling completion signal.
The system can realize the linkage control of the power tap and the pipe processing device. The invention provides a control method for realizing top drive automatic shackle based on the control system, which comprises the following steps as shown in fig. 4:
Step one: the back tongs are clamped. The method specifically comprises three steps, namely, a step A, wherein a system controls a back-up wrench to clamp a drill rod; step B, detecting whether the back-up wrench is clamped or not through a sensor arranged on a hydraulic pipeline of the top drive back-up wrench, wherein the back-up wrench is considered to be clamped after the pressure of the back-up wrench is larger than a threshold value set by a system (the threshold value can be set through a man-machine operation interface 7) and is maintained for a certain time (the time can be set through the man-machine operation interface 7); and C, controlling the back tongs to keep a clamping state, and sending out a clamping signal.
Step two: and (5) top drive shackle. The method specifically comprises three steps, namely, step A, controlling a top motor by a system, and setting output torque according to the screwing torque; step B, detecting whether the actual torque of the top drive reaches the set buckling torque; and C, after the torque reaches the buckling torque, sending out a buckling torque reaching signal.
Step three: and (5) reversely screwing. The method specifically comprises three steps, namely, step A, the system controls the top drive to reversely rotate according to a preset rotating speed (the rotating speed can be set through a man-machine operation interface 7); step B, judging whether the reverse turnbuckle is completed or not by detecting the rotation number of the top drive, and stopping the turnbuckle after the preset reverse turnbuckle number (the number of the turnbuckle can be set through a man-machine operation interface 7); step C, finishing the top drive turnbuckle, and sending a turnbuckle finishing signal;
Step four: and finishing buckling. The method specifically comprises three steps, namely, step A, gradually reducing the top drive output torque according to a curve set by a system until the torque is 0; step B, controlling the top drive to loosen the back tongs; and step C, completing an automatic buckling function and sending out a buckling completion signal.
The invention provides a control method for automatically grabbing a drill rod by a top drive based on the control system, which comprises the following steps as shown in fig. 5:
step one: and (5) judging the position. The method specifically comprises three steps, namely, step A, judging the height and lifting speed of a top drive through the top drive position of a drilling machine after starting a function; detecting whether the top drive reaches a preset height or not, and detecting whether the lifting of the top drive is stopped or not at the same time; step B, the top drive height accords with a preset value, and after lifting is stopped, top drive in-place information is sent out; and C, detecting the position of the drill rod through a sensor on the top drive, and calculating and determining the angle and the inclination angle of the top drive rotating head to be rotated.
Step two: and (5) controlling the hanging ring. The method specifically comprises seven steps, wherein in the step A, the top drive rotary head is controlled to rotate; step B, detecting whether the top drive rotating head is in place; step C, after rotating in place, sending out a rotating in place signal; step D, the system controls the top drive hanging ring to incline forwards; step E, detecting whether the inclined position of the hanging ring reaches a preset value or not; step F, after the hanging ring reaches a preset position, sending out an inclination in-place signal; and G, finishing positioning the hanging ring and sending a finishing signal. The control of the hanging ring must be in the order of rotating first, rotating in place and then tilting so as to ensure the safety in the rotating process.
The system has the recognition and treatment of complex working conditions during top drive drilling, and can recognize and treat the top drive locked-rotor working conditions. The method comprises the steps of identifying the top drive locked rotor, and identifying the locked rotor working condition of the control system through a locked rotor working condition identification software module, wherein input data comprise parameters such as the actual torque T of the top drive, the rotating speed n of the top drive, an identification period T, the height h of the top drive and the like. The identification module records data according to the identification period T, and calculates according to a formula to obtain deltaT=T 2 -T 1 ，Δn＝n 2 -n 1 The system judges according to the values of delta T and delta n and the values of T and n at the current moment,when the delta T is continuously in a positive value, and the delta n is in a negative value and reaches a plurality of recognition periods T, the system considers that the top drive is about to be blocked, the top drive is marked to be in a blocking early warning state at the moment, when the top drive torque value T reaches a set torque in the blocking early warning state, and when the actual top drive rotating speed n approaches 0, the system recognizes that the blocking occurs at the moment. After the locked-rotor, the system prompts the driller whether to release the reactive torque or not, and after confirmation, the system executes an automatic reactive torque release program. Automatic release of the reactive torque program, the input data of which include the actual torque T of the top drive act Top drive actual rotation speed n act Top drive set torque T set And top drive set rotational speed n set The method comprises the steps of carrying out a first treatment on the surface of the The output data is the torque T of the top drive set And top drive set rotational speed n set The top drive output torque and the rotating speed are controlled by the top drive control signal output module 6. Automatic release reactive torque program, gradually reducing the reactive torque of the downhole locked rotor by reducing the top drive set torque, and simultaneously detecting the actual rotation speed n of the top drive act When the actual rotation speed n of the top drive is found act < 0, exceeds a certain threshold value (which can be set by the human-machine interface 7), and an in unit time t act When gradually increasing, the torque setting value stops decreasing according to an angle delta n in a unit time t act Determining the response of the system: Δn act When gradually increasing or maintaining, the top drive set torque T is increased set ；Δn act When gradually decreasing, the current top drive set torque T is maintained set ；Δn act Approaching 0 and n act When approaching 0, continuously reducing the top drive set torque T set Until the actual torque T of the top drive act After a certain threshold value (the threshold value can be set by the man-machine operation interface 7), the system automatically releases the reactive torque to finish.
The system can identify and handle the conditions of excessive friction, pressure and tool face deviation in directional drilling, as shown in fig. 6. Identification of conditions during directional drilling, the input data of which comprises a pump pressure P through a directional condition identification module of a control system Pump with a pump body Rotation angle theta of top drive Top Top drive torque T, weight on bit P WOB And identifying parameters such as the suspension weight, the identification period t, the drill rod length l and the like. During drilling operation, the drill rod and the like can be used for drillingThe spring is effectively formed, the rotation angle of the top drive is not identical with the rotation angle of the drill bit, the rotation angle of the drill bit is related to the torque of the top drive, the length of the drill rod and the rigidity of the drill rod, and therefore, the rotation angle of the drill bit and the rotation angle of the top drive have the following relation: Δθ Drill bit ＝k·l·TΔθ Top drive . The system adjusts the tool face bias through three steps to keep the tool face within the allowable range:
step one: parameters are determined. Inputting parameters such as well depth, a preset tool face, a tool face deviation range, a recognition period and the like, controlling the top drive to rotate forward and backward by the system after the drill bit touches the bottom of the well, and obtaining a basic parameter k value as an initial parameter by detecting parameters such as a top drive rotation angle, the drill bit rotation angle, a top drive torque and the like.
Step two: tool face deviation adjustment: detecting an actual tool face value, calculating according to the rotation angle of the drill bit after the tool face is deviated, calculating the rotation angle of the top drive, and controlling the top drive to rotate according to a preset angle. In the adjustment process, the k value is corrected according to the deviation of the rotation angle of the top drive and the rotation intersection of the drill bit during adjustment.
Step three: finishing tool face deviation adjustment: and detecting an actual tool face value, and completing the tool face adjusting process when the actual tool face is within the deviation range of the preset tool face.
The judgment and treatment of the excessive friction and the pressure drop condition are shown in fig. 7. The input data comprises the weight on bit P through the directional working condition identification module of the control system WOB Pumping pressure, hanging weight, identifying period t, well depth and other parameters. The system processes the conditions of overlarge friction resistance and pressure supporting through three steps:
step one: calculating friction resistance, namely calculating underground friction resistance according to parameters such as the weight of the suspension, the weight of the drill, the identification period and the like, and comparing the underground friction resistance with a preset friction resistance threshold;
step two: and judging the holding pressure according to parameters such as friction resistance, drilling pressure, suspension weight, pumping pressure and the like. Judging whether the pressure is in a supporting pressure state or not;
step three: the friction is reduced, the top drive torsion pendulum control function of the system is started, the friction is reduced, and the pressure bearing condition is relieved.
The system can dynamically adjust the top drive rotating speed according to the change of the rotating speed and the torque during drilling, and the process is shown in fig. 8. The input parameters of the device comprise a rotating speed n and a torque T, and the device can identify and process the stick-slip working condition in the drilling process. The identification step mainly comprises the following steps:
Step one: recording data of the rotating speed n and the torque T, wherein the recording period is less than or equal to 100ms;
step two: converting the recorded data signals from time domain to frequency domain to obtain frequency domain signals of 1Hz-10Hz respectively;
step three: performing characteristic comparison on frequency domain signals of the rotating speed n and the torque T to obtain an intensity value i of a stick-slip working condition;
step four: and judging whether the top drive soft torque function needs to be started or not according to the intensity value i of the stick-slip working condition, and automatically setting corresponding parameters of the soft torque function.
Examples
As shown in fig. 9, in this embodiment, the top drive status signal input module 1, the data storage module 4, and the central processing unit 5 are installed in a top drive control room, the top drive control signal output module 6 and the man-machine operation interface 7 are installed on a top drive console, and the drilling machine status input module 2 and the downhole tool status input module 3 are installed in a driller room. The modules are connected and data exchanged by adopting a field bus. Data are collected through each input module and stored in the data storage module, and after data processing is carried out through the central processing unit, automatic control is carried out on the top drive.
When the drilling operation is carried out, the system monitors parameters of the top driving force tap part, including parameters such as rotation speed, torque, angle, suspended weight, pump pressure and the like, and when the working conditions such as locked rotor, stick-slip, pressure supporting and the like are monitored, corresponding processing modes are respectively started through the methods shown in the figures 6 to 8, and the control parameters such as rotation speed, torque, angle and the like of the top driving are adjusted through the top driving control signal output module 6. The top drive control signal output module 6 may be controlled in various manners, such as voltage signals, current signals, communication signals, and selection of output signals, and during system installation, the selection is made according to the type of top drive to be controlled.
When the tripping operation is carried out, the system monitors parameters of the top drive pipe treatment device part, including parameters such as top drive height, rotating head rotating angle, hanging ring inclination angle and the like, and the working conditions such as top drive on-off, drilling tool grabbing and the like are controlled by the method described in fig. 3-5. The top drive control signal output module 6 can control the forward and backward tilting signals of the lifting ring of the top drive, the rotating head rotating signals, the backup pliers clamping and loosening signals, and the top drive can be controlled by outputting 24VDC signals or communication signals. The control mode is selected according to the type of the controlled top drive when the system is installed.
It is to be understood that the above-described embodiments of the present invention are merely illustrative of or explanation of the principles of the present invention and are in no way limiting of the invention. Accordingly, any modification, equivalent replacement, improvement, etc. made without departing from the spirit and scope of the present invention should be included in the scope of the present invention. Furthermore, the appended claims are intended to cover all such changes and modifications that fall within the scope and boundary of the appended claims, or equivalents of such scope and boundary.

Claims (11)

1. The top drive intelligent control system is characterized by comprising a top drive state signal input module, a drilling machine state signal input module, an underground tool state signal input module, a data storage module, a central processing unit, a top drive control signal output module and a man-machine operation interface, wherein the top drive state signal input module, the drilling machine state signal input module and the underground tool state signal input module are respectively connected with the data storage module, the data storage module is connected with the central processing unit, and the central processing unit is respectively connected with the top drive control signal output module and the man-machine operation interface;
the top drive state signal input module, the drilling machine state signal input module and the downhole tool state signal input module are used for obtaining parameter signals related to drilling;
the data storage module is used for storing signals obtained by the top drive state signal input module, the drilling machine state signal input module and the downhole tool state signal input module;
the central processing unit is used for reading data and identifying the current working condition of the top drive through a built-in algorithm;
the man-machine operation interface is used for displaying recommended top drive operation;
The top drive control signal output module is used for outputting recommended top drive operation.
2. The top drive intelligent control system of claim 1, wherein the drilling-related parameter signals comprise top drive control commands, top drive rotational speed, top drive torque, top drive rotational angle, toolface, pump pressure, weight on bit, weight on weight, top drive height signals.
3. The top drive intelligent control system of claim 1, further comprising a data acquisition module, a database, a condition identification module, and a control module.
4. The top drive intelligent control system of claim 3, wherein the data acquisition module comprises a top drive status data acquisition module, a rig status data acquisition module, a downhole tool status data acquisition module, and other status data acquisition modules.
5. The top drive intelligent control system of claim 3, wherein the condition identification module comprises a stick-slip condition identification module, a locked-rotor condition identification module, and a directional condition identification module.
6. A top drive intelligent control system according to claim 3, wherein the control modules comprise a power faucet control module, a pipe handling device control module, and a top drive automation control module.
7. The top drive intelligent control system of claim 1, wherein the top drive control signal output module comprises a digital quantity output module and an analog quantity output module;
the digital quantity output module is used for controlling forward and reverse rotation of the top drive, forward and backward tilting of the lifting ring, forward and reverse rotation of the rotating head, clamping and loosening of the backup wrench, braking of the band-type brake, and outputting a 24VDC signal or connecting with the top drive controller in a communication mode;
the analog output module is used for controlling the rotation speed of the top drive, limiting torque of the top drive and rotation angle of the top drive, outputting 0-10V voltage signals, 4-20mA current signals and 0-20mA current signals by the analog output module, or connecting with the top drive controller in a communication mode.
8. The intelligent control method for the top drive is characterized by comprising the control of automatic top drive screwing-on, the control of automatic top drive screwing-off and the control of automatic top drive grabbing of a drill rod;
the control method for realizing automatic top drive buckling comprises the following steps:
step one: forward spin-buckle; the method specifically comprises three steps, namely, step A, a system control top drive rotates according to a preset rotating speed; step B, judging whether the top drive main shaft and the drill rod are connected or not by detecting the actual torque of the top drive, and stopping the turnbuckle after the turnbuckle torque is reached; step C, completing forward turnbuckle, and sending a turnbuckle completion signal;
Step two: clamping the back tongs; the method specifically comprises three steps, namely, a step A, wherein a system controls a back-up wrench to clamp a drill rod; step B, detecting whether the back-up wrench is clamped or not through a sensor arranged on a hydraulic pipeline of the top drive back-up wrench, and considering that the back-up wrench is clamped after the back-up wrench pressure is larger than a threshold value set by a system and is kept for a certain time; step C, controlling the back tongs to keep a clamping state, and sending out a clamping signal;
step three: the top drives the fastening buckle; the method specifically comprises three steps, namely, step A, controlling a top motor by a system, and setting output torque according to the screwing torque; step B, detecting whether the actual torque of the top drive reaches the set buckling torque; step C, after the torque reaches the buckling torque, sending out a buckling torque reaching signal;
step four: finishing buckling; the method specifically comprises three steps, namely, step A, gradually reducing the top drive output torque according to a curve set by a system until the torque is 0; step B, controlling the top drive to loosen the back tongs; step C, completing an automatic buckling function and sending out a buckling completion signal;
the control method for realizing the automatic shackle of the top drive comprises the following steps:
step one: clamping the back tongs; the method specifically comprises three steps, namely, a step A, wherein a system controls a back-up wrench to clamp a drill rod; step B, detecting whether the back-up wrench is clamped or not through a sensor arranged on a hydraulic pipeline of the top drive back-up wrench, and considering that the back-up wrench is clamped after the back-up wrench pressure is larger than a threshold value set by a system and is kept for a certain time; step C, controlling the back tongs to keep a clamping state, and sending out a clamping signal;
Step two: top drive shackle; the method specifically comprises three steps, namely, step A, controlling a top motor by a system, and setting output torque according to the screwing torque; step B, detecting whether the actual torque of the top drive reaches the set buckling torque; step C, after the torque reaches the buckling torque, sending out a buckling torque reaching signal;
step three: reverse spin-fastening; the method specifically comprises three steps, namely, step A, reversely rotating a system control top drive according to a preset rotating speed; step B, judging whether the reverse turnbuckle is completed or not by detecting the rotation number of the top drive, and stopping the turnbuckle after the preset reverse turnbuckle number is reached; step C, finishing the top drive turnbuckle, and sending a turnbuckle finishing signal;
step four: finishing buckling; the method specifically comprises three steps, namely, step A, gradually reducing the top drive output torque according to a curve set by a system until the torque is 0; step B, controlling the top drive to loosen the back tongs; step C, completing an automatic buckling function and sending out a buckling completion signal;
the control method for realizing automatic grabbing of the drill rod by the top drive comprises the following steps:
step one: judging the position; the method specifically comprises three steps, namely, step A, judging the height and lifting speed of a top drive through the top drive position of a drilling machine after starting a function; detecting whether the top drive reaches a preset height or not, and detecting whether the lifting of the top drive is stopped or not at the same time; step B, the top drive height accords with a preset value, and after lifting is stopped, top drive in-place information is sent out; step C, detecting the position of the drill rod through a sensor on the top drive, and calculating and determining the angle and the inclination angle of the top drive rotating head to be rotated;
Step two: controlling a hanging ring; the method specifically comprises seven steps, wherein in the step A, the top drive rotary head is controlled to rotate; step B, detecting whether the top drive rotating head is in place; step C, after rotating in place, sending out a rotating in place signal; step D, the system controls the top drive hanging ring to incline forwards; step E, detecting whether the inclined position of the hanging ring reaches a preset value or not; step F, after the hanging ring reaches a preset position, sending out an inclination in-place signal; g, positioning the hanging ring is completed, and sending out a completion signal; the control of the hanging ring must be in the order of rotating first, rotating in place and then tilting so as to ensure the safety in the rotating process.
9. The intelligent control method of the top drive according to claim 8, further comprising the step of identifying the locked rotor of the top drive, wherein the data input by the locked rotor condition identification software module of the control system comprises the actual torque T of the top drive, the rotating speed n of the top drive, the identification period T and the height h of the top drive; the identification module records data according to the identification period T, and calculates according to a formula to obtain deltaT=T 2 -T 1 ，Δn＝n 2 -n 1 The system judges according to the value of delta T and delta n and the values of T and n at the current moment, when the delta T is continuously in a positive value and the delta n is in a negative value and reaches a plurality of identification periods T, the system considers that the top drive is about to be blocked, marks the state in which the top drive is in a blocking early warning state at the moment, and when the top drive torque value T reaches a set torque and the actual top drive rotation speed n approaches 0 in the blocking early warning state, the blocking is identified at the moment; after locked-rotor, the system prompts the driller whether to release the reactive torque or not, and after confirmation, the system executes an automatic reactive torque release program; automatic release of the reactive torque program, the input data of which include the actual torque T of the top drive act Top drive actual rotation speed n act Top drive set torque T set And top drive set rotational speed n set The method comprises the steps of carrying out a first treatment on the surface of the The output data is the torque T of the top drive set And top drive set rotational speed n set The top drive is controlled by the top drive control signal output moduleOutputting torque and rotating speed; automatic release reactive torque program, gradually reducing the reactive torque of the downhole locked rotor by reducing the top drive set torque, and simultaneously detecting the actual rotation speed n of the top drive act When the actual rotation speed n of the top drive is found act < 0, exceeding a certain threshold value, and an in unit time t act When gradually increasing, the torque setting value stops decreasing according to an angle delta n in a unit time t act Determining the response of the system: Δn act When gradually increasing or maintaining, the top drive set torque T is increased set ；Δn act When gradually decreasing, the current top drive set torque T is maintained set ；Δn act Approaching 0 and n act When approaching 0, continuously reducing the top drive set torque T set Until the actual torque T of the top drive act After the torque is less than a certain threshold value, the system automatically releases the reactive torque to finish.
10. The intelligent control method for top drive of claim 8, further comprising identifying and processing conditions of excessive friction, holding pressure and tool face deviation during directional drilling, identifying conditions during directional drilling, and inputting data including pump pressure P via a directional condition identification module of the control system Pump with a pump body Rotation angle theta of top drive Top Top drive torque T, weight on bit P WOB The suspension weight, the identification period t and the length l of the drill rod; during drilling operation, the drill rod is equivalent to a spring, the rotation angle of the top drive is not identical with the rotation angle of the drill bit, the rotation angle of the drill bit is related to the torque of the top drive, the length of the drill rod and the rigidity of the drill rod, and the rotation angle of the drill bit and the rotation angle of the top drive have the following relation: Δθ Drill bit ＝k·l·T·Δθ Top drive The tool face deviation is adjusted through three steps, so that the tool face is kept within an allowable range:
step one: determining parameters; inputting well depth, a preset tool face and a tool face deviation range, identifying a period, controlling a top drive to rotate forward and backward by a system after a drill bit touches a well bottom, and obtaining a basic parameter k value as an initial parameter by detecting a top drive rotation angle, the drill bit rotation angle and a top drive torque;
step two: tool face deviation adjustment: detecting an actual tool face value, calculating a top drive rotation angle according to the rotation angle of a drill bit after deviation of the tool face occurs, and controlling the top drive to rotate according to a preset angle; in the adjustment process, correcting the k value according to the deviation of the rotation angle of the top drive and the rotation intersection of the drill bit during adjustment;
Step three: finishing tool face deviation adjustment: and detecting an actual tool face value, and completing the tool face adjusting process when the actual tool face is within the deviation range of the preset tool face.
11. The intelligent control method of top drive of claim 8, further comprising determining and processing conditions of excessive friction and pressure drop, wherein the input data comprises weight on bit P via the directional condition identification module of the control system WOB Pumping pressure and hanging weight, identifying period t and well depth; the system processes the conditions of overlarge friction resistance and pressure supporting through three steps:
step one: calculating friction resistance, namely calculating underground friction resistance according to the suspension weight, the bit pressure and the identification period, and comparing the underground friction resistance with a preset friction resistance threshold;
step two: judging the holding pressure according to friction, drilling pressure, hanging weight and pumping pressure; judging whether the pressure is in a supporting pressure state or not;
step three: the friction is reduced, the top drive torsion pendulum control function of the system is started, the friction is reduced, and the pressure bearing condition is relieved;
the system can dynamically adjust the top drive rotating speed according to the change of rotating speed and torque during drilling; the input parameters comprise a rotating speed n and a torque T, and the stick-slip working conditions in the drilling process are identified and processed; the identification step mainly comprises the following steps:
Step one: recording data of the rotating speed n and the torque T, wherein the recording period is less than or equal to 100ms;
step two: converting the recorded data signals from time domain to frequency domain to obtain frequency domain signals of 1Hz-10Hz respectively;
step three: performing characteristic comparison on frequency domain signals of the rotating speed n and the torque T to obtain an intensity value i of a stick-slip working condition;
step four: and judging whether the top drive soft torque function needs to be started or not according to the intensity value i of the stick-slip working condition, and automatically setting corresponding parameters of the soft torque function.
CN202211219858.8A 2022-09-30 2022-09-30 Intelligent control system and method for top drive Pending CN117850284A (en)

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Application Number Priority Date Filing Date Title
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