PDC钻头钻井提速关键影响因素研究

高德利; 刘维; 万绪新; 郭勇

doi:10.11911/syztjs.2023022

PDC钻头钻井提速关键影响因素研究

doi: 10.11911/syztjs.2023022

1.
石油工程教育部重点实验室（中国石油大学（北京）），北京 102249
2.
中石化胜利石油工程有限公司，山东东营 257000
3.
中国石油新疆油田分公司工程技术研究院，新疆克拉玛依 834000

基金项目: 国家自然科学基金重点项目“复杂结构‘井工厂’立体设计建设基础研究”（编号：52234002）、国家自然科学基金创新研究群体项目“复杂油气井钻井与完井基础研究”（编号：51821092）、中国石油大学（北京）科研启动基金项目“高效钻头的研究”（编号：ZX20190065）联合资助

详细信息

作者简介:
高德利(1958—)，男，山东禹城人，1982年毕业于华东石油学院钻井工程专业，1984年获西南石油学院石油矿场机械专业硕士学位，1990年获石油大学油气田开发工程专业博士学位，教授，中国科学院院士，长期从事复杂油气井工程领域的科学研究与实践。系本刊编委。E-mail: gaodeli@cup.edu.cn。

中图分类号: TE21
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出版历程
- 收稿日期: 2022-12-05
- 修回日期: 2023-02-01
- 网络出版日期: 2023-02-11

Study on Key Factors Influencing the ROP Improvement of PDC Bits

1.
MOE Key Laboratory of Petroleum Engineering, China University of Petroleum (Beijing), Beijing, 102249, China
2.
Sinopec Shengli Oilfield Service Corporation, Dongying, Shandong, 257000, China
3.
Engineering Technology Research Institute, PetroChina Xinjiang Oilfield Company, Karamay, Xinjiang, 834000, China

摘要

摘要:
为了在钻井工程中发挥出PDC钻头的最大功效，通过理论分析、室内试验、案例分析、现场试验等，探讨了高钻压、高转速等钻井参数强化对PDC钻头钻速和磨损的影响规律，同时分析了PDC钻头的磨损机理与过早失效主因。研究结果表明：1）钻压是影响PDC钻头机械钻速的直接和首选因素，当钻头处于高效破岩状态时，无论钻遇一般地层还是硬岩地层，钻压与机械钻速均应呈线性关系；钻遇均质硬岩地层时，建议将200 kN以上高钻压纳入PDC钻头的常规应用参数；2）提高转速可实现钻井提速，虽然高转速会加剧PDC钻头的磨损，但目前切削齿的质量足以满足PDC钻头在高转速（400～500 r/min）下长时间钻进多数地层的需求；3）布齿密度对钻头机械钻速有影响，但并非直接因素，只要“吃得进去，切得下来，排得及时”三者建立动态平衡，即便是高布齿密度PDC钻头也可以实现优快钻进；4）PDC钻头破岩效率越高，钻头磨损会越小，如提高钻压，会增大切削齿吃入深度、减少钻头磨损；5）动态冲击和低效破岩是造成PDC切削齿和钻头过早失效的主因，实现PDC钻头高效钻进的核心是提高破岩效率与抑制钻头振动。该研究结果对PDC钻头合理使用与钻井提速技术创新具有参考意义。
- PDC钻头 /
- 钻井提速 /
- 钻井参数 /
- 硬岩提速 /
- 钻头失效 /
- 切削齿磨损机理
Abstract:
For the maximization of the efficacy of the polycrystalline diamond compact (PDC) bits in drilling engineering, comprehensive research, including theoretical analysis, laboratory test, case study, and on-site trials, was conducted to investigate how a high weight-on-bit (WOB), a high rotary speed, and other optimized drilling parameters work on the rate of penetration (ROP) and the wear of a PDC bit. Furthermore, the wear mechanism of the PDC bit and the primary cause of the premature failure of the bit were analyzed. The results indicated that: 1) The ROP of the PDC bit was directly and primarily affected by the WOB. When the bit was in an efficient rock-breaking state, the WOB was invariably in a linear relationship with the ROP whether the formation encountered was a conventional one or a hard rock formation. Adding a high WOB over 200 kN into the normal pressurization range of the PDC bit was recommended if the formation encountered was a homogeneous hard rock formation. 2) ROP improvement could be achieved by enhancing the rotary speed. Although the wear of the PDC bit could be aggravated by a high rotary speed, the requirement on a PDC bit to penetrate most formations for a long time at a high rotary speed (400–500 r/min) could be readily met by the quality of the currently available PDC cutter. 3) The ROP of the bit was also affected by cutter density, but not in a direct manner. As long as a dynamic balance among “capabilities to bite into the formation, cut the rock, and evacuate the cuttings in time” was reached, the optimized fast drilling could be achieved even by a PDC bit with a high cutter density. 4) The wear of the PDC bit was less severe under the higher rock-breaking efficiency of the bit. The WOB could be enhanced to improve the ROP and reduce bit wear. 5) Dynamic impact and inefficient rock-breaking were considered the primary causes of the premature failure of the PDC cutter and bit. The key for the PDC bit to achieve efficient penetration was improving rock-breaking efficiency and restraining bit vibration. The above results could be used as a reference for the proper utilization of PDC bits and the innovation of ROP improvement technologies.
- PDC bit /
- ROP improvement /
- drilling parameters /
- ROP improvement for hard rock formation /
- bit failure /
- wear mechanism of PDC cutter

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图 1 钻头高效破岩时钻压与机械钻速的关系示意

Figure 1. Relationship between WOB and ROP during efficient rock-breaking of the bit

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图 2 岩性和齿形对钻压与机械钻速之间关系曲线的影响

Figure 2. Effects of lithology and cutter shape on relationship curve between WOB and ROP

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图 3 “异常”因素作用时钻压与机械钻速的关系示意

Figure 3. Relationship between WOB and ROP under influences of “abnormal” factors

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图 4 脱钴PDC切削齿的磨损面积与其行进距离的关系

Figure 4. Relationship between wear area and travel distance of leached PDC cutter

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图 5 相同进尺下PDC钻头吃入深度与切削齿行进距离的关系

Figure 5. Relationship between cut depth of PDC bit and travel distance of cutter under the same drilling footage

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图 6 相同进尺下PDC钻头吃入深度与切削齿磨损体积的对应关系

Figure 6. Relationship between the wear volume loss of PDC cutter and the cut depth under the same footage

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图 7 转速对PDC切削齿磨损体积的影响

Figure 7. Effect of rotary speed on wear volume of PDC cutter

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图 8 胜利油田罗家区块二开钻井指标

Figure 8. Drilling data from Luojia block in Shengli Oilfield

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图 9 NPD的耐磨性和抗冲击性测试示意

Figure 9. Wear resistance and impact resistance tests of nano-polycrystalline diamond (NPD)

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图 10 135°斧形齿钻遇花岗岩时发生冲击失效

Figure 10. Impact-induced failure of 135° axe-shaped teeth when encountering granite

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图 11 PDC钻头的破岩、耐用、稳定一体化综合评价体系示意

Figure 11. Comprehensive evaluation system integrating rock-breaking efficiency, durability, and stability of PDC bit

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图 12 PDC切削齿聚晶金刚石层的横截面

Figure 12. Cross-sections of polycrystalline diamond layer of PDC cutter

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图 13 脱钴和未脱钴PDC切削齿的磨损体积与行进距离的关系

Figure 13. Relationships between wear volumes and travel distances of leached and non-leached PDC cutters

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图 14 抗冲击性测试后的未脱钴PDC切削齿形貌

Figure 14. Morphology of non-leached PDC cutter after impact resistance test

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图 15 PDC切削齿的典型出井状况

Figure 15. Typical dull conditions of PDC cutters pulled out of hole

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图 16 X射线检测的PDC切削齿脱钴深度

Figure 16. Leached depth of PDC cutters detected by X-ray

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图 17 未脱钴PDC切削齿的出井形貌

Figure 17. Morphology of non-leached PDC cutters pulled out of hole

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图 18 与图7对应的切削齿磨口形貌

Figure 18. Wear scar morphology of PDC cutter corresponding to Fig.7

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表 1 VTL试验参数

Table 1. Vertical turning lathe (VTL) test parameters

试验编号	每圈吃入深度/mm	总的行进距离/m	切削深度/ mm	线速度/ （m·min⁻¹）
#1	0.5	68 097	60	100
#2	1.0	34 049
#3	1.5	22 699
#4	2.0	17 024
#5	2.5	13 619
#6	3.0	11 350
#7	1.0	34 049	60	20
#8		34 049		60
#9		34 049		100
#10		34 049		140

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表 2 高速螺杆与常规螺杆参数对比

Table 2. Parameter comparison between high-speed motor and conventional motor

螺杆类型	钻压/kN	工作排量/ （L·min⁻¹）	输出扭矩/（N·m）	顶驱转速 / （r·min⁻¹）	钻头转速 / （r·min⁻¹）
ϕ172.0 mm高速螺杆	60～100	2200	8869	60～80	380～400
ϕ172.0 mm常规螺杆	60～150	2200	12750	60～80	220～240

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表 3 玛南风城组不同钻具组合的钻井指标

Table 3. Drilling performances of various bottom-hole assemblies in Fengcheng Formation on southern slope of Mahu Sag

试验井	钻头	井下动力钻具	单趟平均进尺/m	平均机械钻速/（m·h⁻¹）	井型	完钻时间
JL53井	牙轮钻头、PDC钻头、复合钻头		<50	<1.3	直井	2020年
JL56井	异形齿PDC钻头	常规螺杆	88	2.0	直井	2020年
MH48井	孕镶钻头	涡轮	193	1.8	直井	2020年
MN520井	PDC钻头	旋导	86	1.2	水平井造斜段	2021年
MN520井	PDC钻头	高速螺杆	578	4.8	水平井水平段	2021年
MN272井	PDC钻头	高速螺杆	1008	8.2	水平井水平段	2022年

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表 4 胜利油田常规钻井参数与强化钻井参数对比

Table 4. Comparison of conventional and enhanced drilling parameters in Shengli Oilfield

钻井参数类型	钻压/kN	顶驱转速 /（r·min⁻¹）	排量/（L·s⁻¹）	泵压/MPa	提速工具
常规钻井参数	40～80	70	40	15	螺杆
强化钻井参数	100～120	70～80	>70	>20	大扭矩螺杆

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表 5 美国FORGE 78B-32井TKC83型PDC钻头钻井指标

Table 5. Drilling data of TKC83 PDC bit in FORGE Well 78B-32

趟钻数	钻头直径/mm	入井井深/m	进尺/m	平均机械钻速/（m·h⁻¹）	钻压/kN	顶驱转速/（r·min⁻¹）	排量/（L·s⁻¹）	钻遇岩性
7	269.9	1 112.8	643.1	20.4	295	40.0	51.7	花岗闪长岩
9	269.9	1 774.2	267.9	22.3	295	50.0	50.5	花岗闪长岩
13	269.9	2 055.0	265.5	21.2	295	45.0	52.4	花岗闪长岩
14	269.9	2 320.5	270.4	22.5	295	50.0	52.4	花岗闪长岩

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