Development and Field Test of a Non-Planar Cutter PDC Bit with Convex Ridges
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摘要:
常规PDC钻头在钻进塔里木油田库车山前巨厚砾石层时存在破岩效率低、机械钻速慢和钻井周期长等问题，分析认为，砾石对常规PDC钻头的平面齿产生较大冲击力导致切削齿崩齿或严重磨损是钻速低的主要原因。为此，设计了一种凸脊型非平面齿，并研制了配套PDC钻头，将钻头破岩方式由常规PDC钻头的面切削转变为线压裂和面挤压，大大提高了钻头破岩效率。室内试验表明，凸脊型非平面齿具有良好的抗冲击性能与抗研磨性能，抗冲击性能是平面齿的10倍以上。2只凸脊型非平面齿PDC钻头在库车山前地区博孜区块某井砾石层井段进行了现场试验，创造了机械钻速最高、单只钻头进尺最长的区块纪录，与邻井常规PDC钻头相比，进尺提高1.5倍以上，平均机械钻速提高64%以上，提速效果明显。研究与试验表明，凸脊型非平面齿PDC钻头能够较好地满足库车山前巨厚砾石层高效钻进的要求，可为库车山前深层天然气的高效勘探开发提供了技术支持。
Abstract:When conventional PDC bits are used to drill into the massive gravel layer at the Kuqa Piedmont, challenges such as low rock breaking efficiency, low ROP and long drilling cycle are encountered. A deeper analysis concluded that the large impact of gravels on the planar tooth of conventional PDC bits, as well as the further tooth breakage or severe wear are the main reasons of low penetration rate. Therefore, a convex ridge non-planar cutter was designed, and the matched PDC bit was developed to transform the traditional face cutting into linear fracturing and face crushing methods, which greatly improves the rock breaking efficiency of bit. The lab tests suggest that the convex ridge non-planar cutter had good impact resistance and anti-abrasive performance, and the impact resistance was 10 times that of the planar tooth. Two convex ridge non-planar tooth PDC bits have been tested in the gravel interval of a well in the Bozi Block, creating a record of the highest ROP and the longest single bit footage in this block. Compared with the conventional PDC bits in adjacent wells, the footage was increased by more than 1.5 times, and the average ROP increased over 64%, with obvious effect of raising the penetration rate. Research and tests indicated that the ridge non-planar cutter PDC bit could meet the requirements of drilling in the massive gravel layer of Kuqa Piedmont effectively, and provide technical supports for the efficient exploration & development of deep natural gas in this area.
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Keywords:
- gravel layer /
- rate of penetration /
- non-planar cutter /
- PDC bit /
- rock-breaking mechanism /
- Bozi Block /
- Tarim Oilfield
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图 2 金刚石复合片切削齿受冲击损伤而出现断裂面
Figure 2. Fracture surface of PDC cutters due to impact damage
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图 5 非平面齿切削砂岩、泥岩示意
Figure 5. Schematic of cutting sandstone and mudstone by non-planar cutter
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图 7 抗研磨性能试验中平面齿和凸脊型非平面齿失效后的磨损状况
Figure 7. Wear status of planar tooth and non-planar convex ridge tooth in anti-wear performance test
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图 8 2只凸脊型非平面齿PDC钻头的冠部设计
Figure 8. Crown design of two convex ridge non-planar tooth PDC bits
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图 9 试验井钻头进尺和机械钻速统计结果
Figure 9. Statistical results of bit footage and ROP in test wells
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图 11 邻井B钻头进尺和机械钻速统计结果
Figure 11. Statistical results of bit footage and ROP in adjacent Well B
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图 10 邻井A钻头进尺和机械钻速统计结果
Figure 10. Statistical results of bit footage and ROP in adjacent Well A
表 1 抗研磨性能试验中平面齿和凸脊型非平面齿的切削距离对比
Table 1 Comparison of cutting distances between the planar cutter and convex ridge type non-planar cutter in the anti-wear performance test
切削齿 失效前切削距离/m 提高幅度，% 平面齿 凸脊型非平面齿 样品1 7 259.10 13 170.37 81.4 样品2 8 379.19 12 739.85 52.0 样品3 7 681.57 12 954.17 68.6 
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