复杂环境下水泥环全生命周期密封完整性研究进展与展望

丁士东; 陆沛青; 郭印同; 李早元; 卢运虎; 周仕明

doi:10.11911/syztjs.2023076

复杂环境下水泥环全生命周期密封完整性研究进展与展望

丁士东^{1, 2,},
陆沛青^{1, 2},
郭印同³,
李早元⁴,
卢运虎⁵,
周仕明^{1, 2}

1.
页岩油气富集机理与有效开发国家重点实验室, 北京 102206
2.
中石化石油工程技术研究院有限公司, 北京 102206
3.
中国科学院武汉岩土力学研究所, 湖北武汉 430071
4.
西南石油大学研究生院, 四川成都 610500
5.
中国石油大学（北京）石油工程学院, 北京 102249

基金项目: 国家自然科学基金企业创新发展联合基金项目“复杂环境下水泥环全生命周期密封理论与控制方法”（编号：U22B6003）资助

详细信息

作者简介:
丁士东（1967—），男，江苏金湖人，1990年毕业于石油大学（华东）钻井工程专业，2007 年获中国石油大学（北京）油气井工程专业博士学位，正高级工程师，国家“百千万人才工程” 入选者，国家有突出贡献中青年专家，主要从事石油工程技术研究和相关管理工作。系本刊编委。E-mail：dingsd.sripe@sinopec.com。

中图分类号: TE256⁺.9；TE26
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出版历程
- 收稿日期: 2023-02-15
- 修回日期: 2023-06-20
- 网络出版日期: 2023-07-05
- 刊出日期: 2023-08-24

Progress and Prospect on the Study of Full Life Cycle Sealing Integrity of Cement Sheath in Complex Environments

DING Shidong^{1, 2,},
LU Peiqing^{1, 2},
GUO Yintong³,
LI Zaoyuan⁴,
LU Yunhu⁵,
ZHOU Shiming^{1, 2}

1.
State Key Laboratory of Shale Oil and Gas Enrichment Mechanisms and Effective Development, Beijing, 102206, China
2.
Sinopec Research Institute of Petroleum Engineering, Co., Ltd., Beijing, 102206, China
3.
Institute of Rock and Soil Mechanics, Chinese Academy of Sciences, Wuhan, Hubei, 430071, China
4.
Graduate School, Southwest Petroleum University, Chengdu, Sichuan, 610500, China
5.
College of Petroleum Engineering, China University of Petroleum (Beijing), Beijing, 102249, China

摘要

摘要:
受井下高温高压、酸性流体、固井后大规模分段压裂、油气开采等诸多因素影响，水泥环密封完整性极易遭受破坏，导致层间窜流、井口带压，甚至引发井喷。目前，以提高水泥环胶结质量为核心的水泥环密封控制技术，已无法满足复杂油气井长效开发需求，而随着深井、超深井与非常规油气井不断增多，未来面临的环境和工况更加复杂，对水泥环密封完整性的要求更高。为此，概述了复杂环境下水泥环全生命周期密封完整性研究进展，分析了目前水泥环密封完整性控制存在的主要问题，指出了未来应解决的基本理论和科学问题，并对未来相关技术进行了展望。研究认为，在持续研究高温高压环境下水泥水化及防窜理论、动载环境下水泥环密封失效规律、酸性环境下水泥石腐蚀机制的基础上，应突出全生命周期控制理念，解决“窜流、损伤、腐蚀”导致水泥环密封失效等关键科学问题，创新以水泥环密封完整性全生命周期监测技术和“防窜流、防损伤、防腐蚀”为核心的水泥环长效密封完整性控制技术，建立复杂环境下水泥环全生命周期密封理论与控制方法，支撑深层与非常规油气资源高效开发。
- 复杂环境 /
- 水泥环 /
- 全生命周期 /
- 密封完整性 /
- 研究进展 /
- 展望
Abstract:
Influenced by many factors such as downhole high temperature and high pressure, acidic fluid, large-scale multi-stage fracturing after cementing, and oil and gas exploitation, the sealing integrity of the cement sheaths is vulnerable to damage, which leads to interlayer channeling, wellhead pressure, and even blowout. At present, the sealing control technology of cement sheaths centered on improving cement sheath cementation quality can no longer meet the demand for long-term development of complex oil and gas wells, and with the increasing number of deep wells, ultra-deep wells, and unconventional oil and gas wells, the environment and working conditions faced in the future will be even more complex, which will require even higher requirements for the sealing integrity of cement sheaths. To this end, the progress of research on the full life circle sealing integrity of cement sheaths in complex environments was reviewed, and the main problems existing in the sealing integrity control of cement sheaths were analyzed. The basic theoretical and scientific problems that should be solved in the future were pointed out, and related technologies were prospected. It is concluded that on the basis of continuous research on the theory of cement slurry hydration and anti-channeling in high-temperature and high-pressure environments, the failure law of cement sheath sealing in dynamic load environments, and the corrosion mechanism of cement stone in acidic environments, it is necessary to highlight the concept of full life cycle control and solve the key scientific problems such as “channeling, damage, and corrosion” leading to the failure of cement sheath sealing. It is also of great significance to innovate full life circle sealing integrity monitoring technology of cement sheaths and long-lasting sealing integrity control technology centered on “anti-channeling, anti-damage, and anti-corrosion” and establish the full life circle sealing theory and control method of cement sheaths in complex environments, so as to support the high-efficiency development of deep and unconventional oil and gas resources.
- complex environment /
- cement sheath /
- full life cycle /
- sealing integrity /
- progress /
- prospect

HTML全文

川渝地区页岩层经历了强烈的后期改造，地质条件相对复杂，页岩分布不稳定，呈现较强的各向异性特征。对于页岩气的勘探开发，井壁取心技术是关键技术之一，页岩气水平井的水平段长达1 000～2 000 m，采用常规钻杆、连续油管难以将取心器准确下至取心位置，且钻井完井工作难度大、耗时长、费用高^[1-2]。针对川渝地区页岩气水平井长水平段取心困难的问题，张宇奇^[3]将井下爬行器与旋转式井壁取心器相结合，设计了一种具备爬行、定位、推靠、取心、储样和解卡等功能的旋转式井壁取心器，可完成水平井水平段、大位移定向井斜井段的取心作业；张朝界等人^[4]用Solidworks软件模拟实际工况，建立了页岩气水平井和取心器的三维模型，利用ADAMS虚拟样机仿真技术，对取心器的爬行能力、过弯能力、负载能力和越障能力进行了模拟分析，结果表明均满足设计要求。

爬行机构作为旋转式井壁取心器的直接驱动装置，其性能决定了取心器能否正常完成井下取心工作。1994年，J. Hallundbæk首先设计了Welltec轮式爬行器^[5]，Sondex公司对轮式爬行器进行了改进，采用了2个扶正机构^[6]；D. Bloom等人^[7]研发了Maxtrac伸缩式爬行器，M. Buyers等人^[8]对其进行了改进，可以蠕动前进。2001年，沈阳工业大学研制了管道爬行器；高进伟等人^[9]根据平行四边形原理设计了爬行及定心装置，解决了爬行器在井下的轴向居中问题；周劲辉等人^[10]研制了水平井自扶正式电缆爬行器；唐德威等人^[11]研制了井下电机驱动爬行器。适用于水平井的爬行器以伸缩式爬行器和轮式爬行器为主，伸缩式爬行器的负载大，但爬行速度较慢；轮式爬行器的爬行速度快，但牵引力较小，仅能完成测井工具的运输，无法携带大段岩心，不适用于川渝地区页岩气水平井长水平段的取心工作。为此，笔者对传统爬行机构进行改进，采用行星齿轮、锥齿轮组合的传动方式，利用正交试验分析方法，分析各因素对支撑臂伸出速度和支撑臂推靠力的影响程度，并对主要结构尺寸进行了优化，降低了支撑臂所需要的推靠力，提高了支撑臂的伸出速度。

1. 爬行机构传动方案设计

取心器的爬行轮要求有足够的扭矩和正压力，以克服摩擦阻力、井下水平段及造斜段电缆拖拽力和井下流体阻力，而爬行轮的扭矩需要液压或电机来提供。由于整体尺寸的限制，要求爬行轮的转动速度及转矩较高，且因井下温升问题无法使用液压驱动来提供动力，只能用电机驱动爬行轮转动。为了满足取心直径要求，所选择电机的直径不能太大；考虑整个取心器系统需要地面提供电力，要求地面采用高压输电方式进行供电，相应地需要选择高压电机；由于尺寸控制，电机转速越高，电机尺寸越小。综合考虑，选择特制高速电机。

取心器的前进动力由爬行轮提供，需要选择多种传动方式来实现电机与爬行轮之间的传动。行星齿轮减速器具有同轴向输出扭矩、轴向尺寸小和传动比大等特点，而且体积微小，可适用于精密仪器、电动装置、操作机构和取心器系统等设备；蜗轮蜗杆传动结构紧凑，单级传动比大，工作较稳定，但安装精度要求高，不适合用于爬行轮传动；带传动适用于高速传动，且安装时需要一定预紧力，无法在爬行轮传动过程中使用。因此，选择行星齿轮作为主要动力传动，搭配可以改变传动方向的锥齿轮，驱动电机的动力经过行星齿轮减速器、锥齿轮、链传动和行星爬行轮到达爬行轮，从而实现取心器的爬行功能。设计的爬行机构传动方案见图1。

图 1 爬行机构传动设计方案

Figure 1. Transmission design of the crawling mechanism

下载: 全尺寸图片幻灯片

2. 爬行机构优化设计

爬行臂作为爬行机构的主要部件，一方面可以作为传动机架，把锥齿轮的动力通过链传动传递到爬行轮上；另一方面，爬行臂作为伸出部分，其末端装配爬行轮，与支撑臂相互配合，完成爬行轮的压紧工作。支撑臂作为支撑调节机构，对运动状态进行微调，达到取心器所需要的预压力。所以，二者作为爬行机构的主要部件，其结构尺寸和结构强度对整个机构的性能影响非常大。

2.1 爬行臂和支撑臂受力分析

爬行臂和支撑臂的受力如图2所示（O为爬行臂铰接点，C为爬行轮中心）。

图 2 爬行臂和支撑臂力学分析

Figure 2. Mechanical analysis of the crawling arm and supporting arm

下载: 全尺寸图片幻灯片

根据几何关系，可得^[12]：

$\sin \alpha = \frac{{D - d}}{{2a}}$

(1)

$\sin \beta = \frac{{D - d + 2{{b}}\sin \alpha + 2e}}{{2c}}$

(2)

式中：D为井筒直径，mm；a，b为爬行臂CA段和OC段的长度，爬行臂OA的长度为a+b，mm；c为支撑臂AB的长度，mm；d为爬行轮直径，mm；e为支撑臂铰接点与轴线的偏心距，mm；α为爬行臂转角，（°）；β为支撑臂转角，（°）

对爬行臂和支撑臂进行受力分析，可得平衡方程：

$\left\{ \begin{array}{l} {F_0}\sin \alpha + {F_B}\cos \beta = F_{\rm{N}} \\ {F_0}\cos \alpha + {F_B}\sin \beta = 0 \end{array} \right.$

(3)

式中：F₀为爬行臂正压力，N；F_B为支撑臂B点推靠力，N；F_N为爬行轮所受正压力，N。

由此，得到支撑臂和爬行臂的力矩公式为：

$\left\{ \begin{array}{l} F_{\rm{N}} {{a}}\cos \alpha - ({F_0}\sin \alpha + {F_A}\cos \alpha ) (a + b)\sin\alpha = 0 \\ {F_A}c\sin \alpha \sin \beta - {F_A}c\cos \alpha \cos \beta = 0 \end{array} \right.$

(4)

式中：F_A为A点的推靠力，N。

由于支撑臂上A点和B点的力在各自方向上的分力大小相同、方向相反，联立式（3）和式（4）可得：

$\left\{ \begin{array}{l} {F_0}\cos \alpha = {F_A}\sin \alpha = {F_B}\sin \beta \\ {F_A}\cos \alpha + {F_0}\sin \alpha = F_{\rm{N}} \\ F_{\rm{N}} a\cos\alpha - (a + b) {F_A}\sin \alpha (\cos\alpha \tan\beta + \sin\alpha ) = 0 \end{array} \right.$

(5)

则爬行轮所受摩擦力f_P为：

${f_{\rm{P}}} = \mu F_{\rm{N}} = \frac{{\mu ({{a}} + b)(\tan\alpha + \tan\beta )}}{a}{F_B}\sin \beta$

(6)

式中：μ为爬行器与井壁的摩擦系数，理论上可取0.5；f_P为爬行轮所受摩擦力，N。

取心器所需要的总推进力为6 000 N，爬行轮设计为2组，每组有3个爬行轮，则单个爬行轮所要达到的正压力为1 000 N。

2.2 爬行臂优化分析

在液压缸推力的作用下滑块移动，推动支撑臂伸出，爬行臂绕O点旋转，带动爬行轮压靠在井壁上（见图3）。爬行机构的基本性能参数是爬行轮的正压力及其工作效率。工作效率主要取决于支撑臂的伸出速度，支撑臂的伸出速度由滑块位移决定，爬行臂长度a+b、支撑臂长度c、爬行臂转角α和偏心距e等因素都会对其产生影响。将这4个影响因素确定为优化变量，建立爬行机构的优化设计函数。

图 3 爬行机构运动简图

Figure 3. Kinematic sketch of the crawling mechanism

下载: 全尺寸图片幻灯片

根据几何关系，可得：

$\left\{ \begin{array}{l} s = {s_A} + \sqrt {{c^2} - {{\left[ {\left( {a + b} \right)\sin \alpha + e} \right]}^2}} \\ s = \left( {a + b} \right) - \left( {a + b} \right)\cos \alpha + c\cos \psi \\ e = c\sin \psi \end{array} \right.$

(7)

式中：s_A为滑块位移，mm；s为滑块右死点距铰接点A的水平距离，mm； $\psi$ 为支撑臂初始转角，（°）。

化简式（7），可得滑块位移s_A的计算式：

${s_A}{\rm{ = }}c\cos \psi {\rm{ - }}\sqrt {{c^2} - {{\left[ {\left( {a + b} \right)\sin \alpha + e} \right]}^2}} {\rm{ + }}\left( {a + b} \right)\left( {{\rm{1 - }}\cos \alpha } \right)$

(8)

式（8）对时间求导，可得支撑臂伸出速度v_A的计算式：

${v_A} = (a + b)\sin \alpha - e + \frac{{\left[ {\left( {a + b} \right)\sin \alpha + e} \right] \left( {a + b} \right)\cos \alpha }}{{\sqrt {{c^2} - {{\left[ {\left( {a + b} \right)\sin \alpha + e} \right]}^2}} }}$

(9)

式中：v_A为支撑臂的伸出速度，mm/s

根据式（6），可得爬行轮所受正压力F_N为:

$F_{\rm{N}} = \frac{{({{a}} + b)(\tan\alpha + \tan\beta )}}{a}{F_B}\sin \beta$

(10)

根据几何关系及式（1）、式（2），可得：

$\sin \beta = \frac{{\left( {{{a + b}}} \right)\sin \alpha + e}}{c}$

(11)

$\tan \beta = \frac{{(a + b)\sin \alpha + e}}{{\sqrt {{c^2} - {{\left[ {(a + b)\sin \alpha + e} \right]}^2}} }}$

(12)

将式（11）、式（12）代入式（10），可得到支撑臂推靠力F_B：

$\begin{array}{l} \qquad\qquad\qquad\qquad\qquad {F_B} = \\ \dfrac{ ac{F_{\rm{N}} }}{{({{a + b}})\left(\tan \alpha {{ + }}\dfrac{{(a + b)\sin \alpha + e}}{{\sqrt {{c^2} - {{[(a + b)\sin \alpha + e]}^2}} }}\right)[(a + b)\sin \alpha + e]}} \end{array}$

(13)

式（9）和式（13）即为爬行机构的多目标优化函数，利用正交试验分析法对其进行分析，可得到支撑臂及爬行臂有关参数的优化解。

影响支撑臂伸出速度和推靠力的因素包括爬行臂长度a+b、支撑臂长度c、爬行臂转角α和偏心距e。已知爬行轮直径为60 mm，取心器适用于ϕ200.0 mm的水平井，可以确定各影响因素的参数水平（见表1）。

表 1 正交试验各因素的水平

Table 1. Factor level of the orthogonal test

水平	因素
水平	a/mm	b/mm	c/mm	e/mm	α/（°）
1	75	20	100	5	30
2	80	25	115	8	35
3	102	28	130	12	40
4	120	30	140	15	45

下载: 导出CSV

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根据表1设计的正交试验方案，共进行16次试验，结果见表2。

表 2 正交试验方案及结果

Table 2. Plan and results of the orthogonal test

序号	因素					v_A/ （mm·s^–1）	F_B/N
序号	a/mm	b/mm	c/mm	e/mm	α/（°）	v_A/ （mm·s^–1）	F_B/N
1	75	20	100	5	30	43.034	1 476.282
2	75	25	115	8	35	49.923	948.763
3	75	28	130	12	40	54.784	760.183
4	75	30	140	15	45	59.831	613.171
5	80	20	115	12	45	59.442	546.541
6	80	25	100	15	40	53.611	401.823
7	80	28	140	5	35	57.392	1 244.544
8	80	30	130	8	30	47.480	1 326.465
9	102	20	130	15	35	55.684	817.832
10	102	25	140	12	30	52.055	1 222.991
11	102	28	100	8	45	102.036	29.503
12	102	30	115	5	40	80.807	473.042
13	120	20	140	8	40	82.741	673.195
14	120	25	130	5	45	98.571	404.759
15	120	28	115	15	30	60.058	582.237
16	120	30	100	12	35	78.109	143.874

下载: 导出CSV

| 显示表格

为了确定上述各因素对试验指标的影响，将求解的指标进行极差计算，即可找出各因素的主次顺序及优化组合，结果见表3和表4。正交试验各指标的平均值用k_i（i=1，2，3，4）表示，其中i表示每个变量的因素水平顺序，将各指标平均值进行极差处理。极差R表示目标量变化的最大范围，可以用来表征不同变量对指标值的影响程度。指标值越大，此变量对目标函数的影响程度越大，需要重点考虑；指标值越小，此变量对目标函数的影响越小，可优先满足其他指标后再进行考虑^[13-14]。

表 3 支撑臂伸出速度极差分析结果

Table 3. The extension speed range analysis of the supporting arm

参数	不同因素水平对应的支撑臂伸出速度v_A /（mm·s^–1）
参数	a	b	c	e	α
k₁	51.799	60.225	69.197	69.951	50.657
k₂	54.481	63.540	62.558	70.545	60.277
k₃	72.645	68.568	64.130	61.098	67.985
k₄	79.870	66.557	63.005	57.296	79.970
R	28.071	8.343	6.639	13.249	29.313

下载: 导出CSV

| 显示表格

表 4 支撑臂推靠力极差分析结果

Table 4. The push-the-bit force range analysis of the supporting arm

参数	不同因素水平对应的支撑臂推靠力F_B/N
参数	a	b	c	e	α
k₁	949.550	878.460	512.870	899.650	1 151.990
k₂	879.325	744.580	637.650	744.480	788.750
k₃	635.830	374.120	827.310	668.400	577.040
k₄	451.000	638.910	938.470	603.750	398.490
R	498.550	504.340	425.600	295.900	753.500

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根据多目标优化理论，对2个目标量v_A和F_B进行分析，得出各因素的影响程度：各因素对目标函数v_A的影响程度从大到小的顺序为α，a，e，b和c；对目标函数F_B的影响程度从大到小的顺序为α，b，a，c和e。比较2组目标函数的优化值，可首先确定α，a和b的优化解分别为45°，120 mm和30 mm。通过比较影响程度的大小，得到e的优化解为8 mm，根据爬行臂长度确定c的优化解为140 mm。

为了确定求得的优化解对爬行机构试验指标的影响，将优化解代入原目标函数，并与优化前各结构尺寸的试验指标进行对比，结果见表5。

表 5 优化前后试验指标对比

Table 5. Comparison between test indicators before and after optimization

优化前后	a/mm	b/mm	c/mm	e/mm	α/（°）	v_A/（mm·s^–1）	F_B/N
优化前	75	20	100	5	30	43.034	1 259.222
	80	25	115	8	35	52.829	893.596
	102	28	130	12	40	72.393	554.946
	120	30	140	15	45	92.284	339.869
优化后	120	30	140	8	45	99.060	408.230

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从表5可以看出，根据正交试验结果优选出的结构尺寸可以降低支撑臂所需推靠力，提高支撑臂伸出速度，说明可以使用正交试验方法优化爬行机构的结构尺寸，优化结果满足要求。

2.3 爬行机构结构设计

根据爬行臂和支撑臂的优化设计结果，对爬行机构的各零部件进行设计、选型、强度校核和刚度校核，使用Solidworks软件对其进行建模和虚拟装配，得到了爬行机构的三维模型，如图4所示。

图 4 爬行机构的三维模型

Figure 4. Three-dimensional model of the crawling mechanism

下载: 全尺寸图片幻灯片

3. 结　论

1）根据页岩气井旋转式井壁取心器的工作要求，设计了一种由行星齿轮、锥齿轮组合传动的新型爬行机构，能够带动整个取心器行进。

2）根据机械动力学原理，建立了爬行机构正压力、支撑臂伸出速度、支撑臂推靠力与爬行臂及支撑臂结构尺寸的函数方程。

3）爬行臂转角对支撑臂伸出速度和推靠力影响最大。爬行臂转角优化后，可以降低支撑臂所需推靠力，提高支撑臂伸出速度，优化结果满足要求。

图 1 典型水泥浆“液–固”态转化期的典型微观结构

Figure 1. Typical microstructure during the "liquid-solid" state transition of typical cement slurry

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图 2 高温循环载荷下的水泥石偏应力–应变曲线^[17]

Figure 2. Stress-strain curve of cement stone under cyclic loading at high temperature

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图 3 防腐水泥浆体系设计思路

Figure 3. Design idea of anticorrosive cement slurry system

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图 4 用于修正测井方法的全尺寸固井水泥环模拟井群

Figure 4. Full-size cementing ring simulation of a well cluster for modified logging methods

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1. 爬行机构传动方案设计
2. 爬行机构优化设计
2.1 爬行臂和支撑臂受力分析
2.2 爬行臂优化分析
2.3 爬行机构结构设计
3. 结　论

复杂环境下水泥环全生命周期密封完整性研究进展与展望

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