深井和大位移井套管磨损规律试验及磨损程度预测
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摘要
在大量的深井、超深井、大斜度井和大位移井的钻探过程中，每口井均不同程度存在着套管磨损问题。套管磨损后其承载能力降低，给后续的钻完井、采油及修井带来重大影响，有时可使一口几乎要完成的井报废。准确预测套管的磨损程度对深井和大位移井的设计及钻井施工具有重要意义。针对国内外套管磨损预测及相关技术存在的主要问题，拟以套管磨损规律的研究为基础，以套管磨损程度预测及剩余强度计算作为研究目标，具体内容如下：
综合套管磨损井状况、井场监测和井下工况模拟试验的分析结果，初步探讨了套管的磨损机理。得出套管磨损是以静载荷为基础，切削磨损、黏着磨损、磨粒磨损和接触疲劳等形式共存的磨损机制。非加重钻井液介质中套管以切削磨损和疲劳磨损为主；加重介质中加重剂能减少钻杆对套管的直接犁削作用，但会增大磨粒磨损和疲劳磨损；高接触压力下，铁矿粉还会加大套管的黏着磨损。
利用钻杆/套管摩擦磨损试验机试验分析了接触力、钻井液加重剂和套管材质等因素对套管磨损的影响规律。得出套管磨损率与接触力呈现近似线性关系，接触力增大，摩擦系数总体上有增大的趋势；含重晶石加重剂的钻井液介质对套管有明显的减磨作用，重晶石和铁矿粉以适当的比例混合可使套管磨损率减小至最低水平；套管具有较高硬度的前提下，提高其抗拉强度有利于降低套管磨损。在此基础上，统计得出了套管磨损效率的参数数据和经验公式。
在考虑钻柱的刚度和屈曲的基础上，推导出深井和大位移井的钻柱拉力—扭矩方程；建立了基于能量原理的套管磨损程度预测模型并编制了预测软件。可以预测包括钻进、起下钻具等作业过程在内的，不同的套管柱层次、钻具组合、井眼轨迹、钻井液类型、钻井参数等情况下的全井段不同井深所对应的套管磨损量。示例计算的结果表明，软件减少了人为的估计误差，预测值准确可靠。
以有限元分析为主导并结合试验验证，研究了磨损套管的剩余抗挤强度。得出套管磨损最严重部位首先发生屈服，逐步发展成“塑性铰”，最后造成整体结构失稳。抗挤强度随套管磨损壁厚、磨损半径和轴向载荷分别呈现指数、幂函数、线性趋势变化；以非磨损套管和偏心圆筒的抗挤强度计算为基础，建立了磨损套管抗挤强度的计算模型。“割缝环”解析法分析了磨损套管的抗内压强度。
论文研究成果对套管柱强度优化设计、套管减磨设计、井下安全评估等都具有实际应用价值，并且为更深入地分析套管磨损机理提供了参考。
During drilling process of a great number of deep wells, super-deep wells, highlydeviated wells and extended reach wells, casing pipe wear problem exists in differentdegree. After casing pipes are worn, their bearing capacity gets reduced, causing asignificant impact on subsequently drilling wells, extracting oil and repairing wells.Sometimes it can make an almost finished well discarded. Accurately predicting weardegree of casing pipes is of important significance on design of deep wells and extendedreach wells as well as drilling construction. The subject planed to adopt the research inwear rule of casing pipes as foundation and adopt prediction of wear degree of casingpipes and calculation of residual intensity as research objectives as for the wear predictionof casing pipes home and abroad along with major problems that relevant technologiesmet. Details are as follow:
By integrating analyzing results of simulation experiments of casing wear wellcondition, well site monitoring and working condition in the well, mechanism of casingpipe abrasion was preliminarily discussed and concluded that casing wear was based onstatic load and was a kind of abrasion mechanism coexisting with cutting wear, adhesionwear, abrasive wear and contact fatigue wear etc. In non-weighted drilling fluid medium,cutting wear was the main form of casing pipe’s wearing; In weighted drilling fluidmedium，abrasive wear and fatigue wear were main forms of casting pipe’s wearing;Heavy weight additive could reduce drill stem’s direct cutting effects on the casing pipe,while it would increase fatigue wear; Compared with barite heavy weight additive, highload of hematite powder would also increase casing pipe’s adhesion wear.
Drill rod/casing pipe frictional wear testing machine was utilized to analyze the effectrule which made by contact force, drilling fluid heavy weight additive and casing pipequality on casing pipe wear. It was concluded that wear rate of casing pipe and contactforce took on approximate linear relation. When contact force strengthened, frictionalcoefficient tended to increase; drilling fluid medium containing barite aggravating agenthad evident wear decreasing effect on casing pipe, mixture of barite and hematite power at proper ratio of 2:1 could reduce casing pipe’s wear to its lowest level; at the premise ofhigh hardness, improving casing pipe’s tensile strength could benefit the reduction of itswear. Based on that, parameter data and empirical formula were reached through statistics.
On the basis of taking stiffness and buckling of drill column into account,tension—torque equation of drill column in deep well and extended reach well wasobtained; prediction model of wear degree of casing pipe based on energy principle wasestablished and forecast software was prepared. Wearing capacity of casing pipecorresponding to different well depths in all well sections could be predicted under suchcircumstances as layer of different casing strings, combination of drilling tools, well boretrack, type of drilling fluid and drilling parameter etc, including such operation process asdrilling and pulling out drilling tools etc. The calculated result through examples denotedthat software reduces artificial error of estimation, and predicted value was accurate andreliable.
The residual collapsing strength of worn casing pipe was researched by thefinite-element analysis and verification of tests. It concluded that the yielding occurredfirst at the gravest worn part of the casing pipe, developing into“plastic hinge”gradually,and causing the instable overall structure at last. The collapsing strength respectivelypresented changes of indexes, power function and linear trend with wear wall thickness,wear radius and axial load of the casing pipe. A computation model of collapsing strengthof worn casing pipe was established based on collapsing strength calculation of non-wearcasing pipe and eccentric cylinder. Internal pressure strength of worn casing pipe wasanalyzed in“slot cutting”analysis method.
Research result of the thesis has practical application value in strength optimizationdesign of casing string, wear-reducing design of casing pipe and safety assessment underwells etc, and provides references for further analyzing wear mechanism of casing pipes.
综合套管磨损井状况、井场监测和井下工况模拟试验的分析结果，初步探讨了套管的磨损机理。得出套管磨损是以静载荷为基础，切削磨损、黏着磨损、磨粒磨损和接触疲劳等形式共存的磨损机制。非加重钻井液介质中套管以切削磨损和疲劳磨损为主；加重介质中加重剂能减少钻杆对套管的直接犁削作用，但会增大磨粒磨损和疲劳磨损；高接触压力下，铁矿粉还会加大套管的黏着磨损。
利用钻杆/套管摩擦磨损试验机试验分析了接触力、钻井液加重剂和套管材质等因素对套管磨损的影响规律。得出套管磨损率与接触力呈现近似线性关系，接触力增大，摩擦系数总体上有增大的趋势；含重晶石加重剂的钻井液介质对套管有明显的减磨作用，重晶石和铁矿粉以适当的比例混合可使套管磨损率减小至最低水平；套管具有较高硬度的前提下，提高其抗拉强度有利于降低套管磨损。在此基础上，统计得出了套管磨损效率的参数数据和经验公式。
在考虑钻柱的刚度和屈曲的基础上，推导出深井和大位移井的钻柱拉力—扭矩方程；建立了基于能量原理的套管磨损程度预测模型并编制了预测软件。可以预测包括钻进、起下钻具等作业过程在内的，不同的套管柱层次、钻具组合、井眼轨迹、钻井液类型、钻井参数等情况下的全井段不同井深所对应的套管磨损量。示例计算的结果表明，软件减少了人为的估计误差，预测值准确可靠。
以有限元分析为主导并结合试验验证，研究了磨损套管的剩余抗挤强度。得出套管磨损最严重部位首先发生屈服，逐步发展成“塑性铰”，最后造成整体结构失稳。抗挤强度随套管磨损壁厚、磨损半径和轴向载荷分别呈现指数、幂函数、线性趋势变化；以非磨损套管和偏心圆筒的抗挤强度计算为基础，建立了磨损套管抗挤强度的计算模型。“割缝环”解析法分析了磨损套管的抗内压强度。
论文研究成果对套管柱强度优化设计、套管减磨设计、井下安全评估等都具有实际应用价值，并且为更深入地分析套管磨损机理提供了参考。
During drilling process of a great number of deep wells, super-deep wells, highlydeviated wells and extended reach wells, casing pipe wear problem exists in differentdegree. After casing pipes are worn, their bearing capacity gets reduced, causing asignificant impact on subsequently drilling wells, extracting oil and repairing wells.Sometimes it can make an almost finished well discarded. Accurately predicting weardegree of casing pipes is of important significance on design of deep wells and extendedreach wells as well as drilling construction. The subject planed to adopt the research inwear rule of casing pipes as foundation and adopt prediction of wear degree of casingpipes and calculation of residual intensity as research objectives as for the wear predictionof casing pipes home and abroad along with major problems that relevant technologiesmet. Details are as follow:
By integrating analyzing results of simulation experiments of casing wear wellcondition, well site monitoring and working condition in the well, mechanism of casingpipe abrasion was preliminarily discussed and concluded that casing wear was based onstatic load and was a kind of abrasion mechanism coexisting with cutting wear, adhesionwear, abrasive wear and contact fatigue wear etc. In non-weighted drilling fluid medium,cutting wear was the main form of casing pipe’s wearing; In weighted drilling fluidmedium，abrasive wear and fatigue wear were main forms of casting pipe’s wearing;Heavy weight additive could reduce drill stem’s direct cutting effects on the casing pipe,while it would increase fatigue wear; Compared with barite heavy weight additive, highload of hematite powder would also increase casing pipe’s adhesion wear.
Drill rod/casing pipe frictional wear testing machine was utilized to analyze the effectrule which made by contact force, drilling fluid heavy weight additive and casing pipequality on casing pipe wear. It was concluded that wear rate of casing pipe and contactforce took on approximate linear relation. When contact force strengthened, frictionalcoefficient tended to increase; drilling fluid medium containing barite aggravating agenthad evident wear decreasing effect on casing pipe, mixture of barite and hematite power at proper ratio of 2:1 could reduce casing pipe’s wear to its lowest level; at the premise ofhigh hardness, improving casing pipe’s tensile strength could benefit the reduction of itswear. Based on that, parameter data and empirical formula were reached through statistics.
On the basis of taking stiffness and buckling of drill column into account,tension—torque equation of drill column in deep well and extended reach well wasobtained; prediction model of wear degree of casing pipe based on energy principle wasestablished and forecast software was prepared. Wearing capacity of casing pipecorresponding to different well depths in all well sections could be predicted under suchcircumstances as layer of different casing strings, combination of drilling tools, well boretrack, type of drilling fluid and drilling parameter etc, including such operation process asdrilling and pulling out drilling tools etc. The calculated result through examples denotedthat software reduces artificial error of estimation, and predicted value was accurate andreliable.
The residual collapsing strength of worn casing pipe was researched by thefinite-element analysis and verification of tests. It concluded that the yielding occurredfirst at the gravest worn part of the casing pipe, developing into“plastic hinge”gradually,and causing the instable overall structure at last. The collapsing strength respectivelypresented changes of indexes, power function and linear trend with wear wall thickness,wear radius and axial load of the casing pipe. A computation model of collapsing strengthof worn casing pipe was established based on collapsing strength calculation of non-wearcasing pipe and eccentric cylinder. Internal pressure strength of worn casing pipe wasanalyzed in“slot cutting”analysis method.
Research result of the thesis has practical application value in strength optimizationdesign of casing string, wear-reducing design of casing pipe and safety assessment underwells etc, and provides references for further analyzing wear mechanism of casing pipes.
引文
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