Research Progress and the Prospect of Intelligent Drilling and Completion Technologies
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摘要:
智能钻完井技术是钻完井工程与人工智能、大数据、云计算等先进技术的有机融合，可实现油气钻完井过程的精细表征、决策优化和闭环调控，有望大幅提升钻完井效率、储层钻遇率和油气采收率，是油气领域的研究前沿和热点。从工程实际出发构建了油气钻完井人工智能应用场景，根据钻完井工程与人工智能技术的融合深度划分了智能钻完井技术的发展层次；分析了国内外智能钻完井理论与技术的研究现状，结合人工智能技术和钻完井工程的发展趋势提出了中长期发展规划，并凝练了智能钻完井技术研究面临的难题和重点攻关方向，以期为推进我国智能钻完井技术的基础理论研究和推广应用提供参考。
Abstract:Intelligent drilling and completion technologies are the integration of drilling and completion engineering with Artificial Intelligence (AI), Big Data, cloud computing, and other advanced technologies. They can achieve fine characterization, optimal decision-making, and closed-loop control of oil and gas drilling and completion and are expected to significantly improve drilling and completion efficiency, reservoir drilling rate, and oil and gas recovery efficiency. Therefore, they are the research frontier and hot spot in the oil and gas field. In this paper, the application scenario system of AI in oil and gas drilling and completion was constructed from the engineering practice. Then, the development level of intelligent drilling and completion technologies was divided according to the integration degree of drilling and completion engineering with AI. Furthermore, the research status of intelligent drilling and completion theories and technologies both in China and abroad was discussed, with a medium- and long-term development plan being proposed according to the development trend of AI and drilling and completion engineering. Finally, the problems and key directions of intelligent drilling and completion technologies were summarized. The paper serves as a reference for accelerating the basic theoretical research and application of intelligent drilling and completion technologies in China.
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水平井多级滑套分段压裂是低渗透油气藏的主要增产方式之一，其具有效率高、施工连续、增产效果好等优点[1]。双向锚定封隔器是多级滑套分段压裂的核心工具，主要用于完井管柱的送入、双向锚定和重叠段环空的封隔，其性能直接影响压裂施工的成败[2–3]。
常规双向锚定封隔器在现场应用过程中存在一些问题：操作不当或发生井下落物时可能会提前坐挂、坐封；进行环空封压能力测试时，经常出现高压密封失效的问题；常规双向锚定封隔器多为永久式，一旦坐封将无法解封起出，只能进行套铣或钻除，甚至可能造成油气井报废[4–9]。为了进一步提高双向锚定封隔器的可靠性，笔者研制了可解挂式双向锚定悬挂封隔器，开展了高承载技术、高压密封技术、防提前坐封技术和解挂技术等关键技术研究，并进行了可解挂式双向锚定悬挂封隔器进的性能测试及现场应用，均取得了预期效果。
1. 可解挂双向锚定悬挂封隔器的结构及原理
可解挂双向锚定悬挂封隔器的设计要点为：1）送入工具要具备防提前坐封功能，同时具备机械、液压双作用丢手功能，以确保悬挂封隔器安全下入及顺利丢手；2）采用合金卡瓦，以保证悬挂封隔器的锚定能力，同时增加解挂功能，在出现提前坐挂情况时，确保可解挂并提出封隔器；3）采用整体式卡瓦结构，以增大卡瓦接触面积、降低对套管的损伤，提供重载锚定，并保证在解挂后有效回收卡瓦；4）采用三胶筒结构，以增强对套管的适应性。
基于上述设计要点，研制了用于多级滑套分段压裂的可解挂双向锚定悬挂封隔器，结构如图1所示。该封隔器由送入工具、防提前坐封装置、悬挂封隔单元和解挂单元组成，具备重载锚定、高压封隔、防提前坐封和机械液压双作用丢手等功能。
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图 1 可解挂双向锚定悬挂封隔器结构Figure 1. Structure of detachable bi-directional anchoring suspension packer该封隔器的工作原理是：采用送入工具将锚定封隔器及尾管送至预定位置，投入憋压球进行管内憋压，剪断封隔器启动销钉，液缸推动回接筒挤压胶筒，胶筒挤压卡瓦；卡瓦锚定完成后继续憋压，坐封胶筒；胶筒坐封后起出管串，再次下入回接插头进行回接锁定；解挂时，首先下入解挂工具，解挂工具与封隔器锚定，然后上提管串，回接筒不再挤压胶筒和卡瓦，胶筒及卡瓦复位，实现解挂。
2. 封隔器关键技术研究
2.1 高承载技术
分段压裂施工过程中，锚定封隔器首先要具备尾管悬挂功能，同时要防止压裂过程中井底高压导致的管串向上窜动，因此，封隔器要具备双向锚定功能。封隔器的锚定卡瓦主要有分瓣式和整体式2种，相较于分瓣式卡瓦，整体式卡瓦与套管内壁的接触面积更大，轴向应力分布更加合理，可以降低对套管的损伤。
常规永久式锚定封隔器无解挂功能，一旦出现提前坐挂情况，必须能够快速钻除，因此一般采用铸铁制造整体卡瓦。由于铸铁的强度和硬度偏低，卡瓦锚定效果不理想，存在锚定能力低的问题。为提高卡瓦锚定效果，同时保证解挂后有效复位，选用合金钢制造卡瓦，并采用整体式卡瓦结构（见图2）。卡瓦设多条应力槽，坐挂时卡瓦扩张支撑井壁，解挂后复位。通过结构设计和材料热处理工艺优化，可提高锚定性能和下入安全性能。
该封隔器要求卡瓦重载锚定解挂后可进行回收，卡瓦本体具备较高韧性的同时，卡瓦牙要具备较高的耐磨性和硬度，因此选用20CrMnTi钢作为制造卡瓦的材料，进行后期热处理，采用局部渗碳回火处理方式，使卡瓦肋部获得大量的回火马氏体组织、齿部获得大量的淬火马氏体组织，在保证卡瓦本体具有较高韧性的同时，保证卡瓦牙具有较高的硬度，以满足卡瓦的锚定性能、耐冲击性能和可回收性能要求。
采用有限元方法研究整体式卡瓦在压裂施工过程中的性能，分析卡瓦结构、卡瓦材料等对卡瓦坐挂、解挂性能的影响。根据卡瓦的工作原理，建立有限元模型，并对其边界进行处理：1）约束卡瓦，使其只具有沿周向运动的自由度；2）建立卡瓦与锥套、卡瓦与套管内壁、锥套与本体之间的接触。制造卡瓦的材料为20CrMnTi钢，本体及套管的材料为35CrMo合金结构钢（见表1）。分别在卡瓦两侧施加约束，分析卡瓦受力及变形情况。压裂时胶筒需要承受70 MPa的压差，由卡瓦进行锚定。因此，从卡瓦上端面施加671.3 kN的压力，计算卡瓦受力。
表 1 整体式卡瓦材料的参数Table 1. Materials parameters of integrated slip材料 弹性模量/GPa 泊松比 屈服强度/MPa 20CrMnTi 207 0.25 850 35CrMo 206 0.30 758 根据第四强度理论计算von Mises应力，结果如图3所示。扩张过程中最大受力位置位于卡瓦肋部，应力为257.5 MPa，满足设计安全系数大于2.0的要求，卡瓦受力较为均匀。
2.2 高压密封技术
分段压裂施工时施工压力较高，为保护上层套管，降低施工风险，防止环空压力传递至井口，需要对套管重叠段进行封隔，要求封隔器具备高压密封性能。
传统双向锚定封隔器胶筒大多采用一体式胶筒，通过挤压胶筒，使其变形与外层套管产生接触应力，实现环空封隔。这种胶筒结构简单，胶筒较短，如果封隔井段出现固相沉积或者套管变形，容易封压失效，因此其井况适应性较差，密封可靠性不高。
可解挂双向锚定封隔器采用三胶筒密封结构，胶筒之间采用V形配合，两两保护（见图4）。胶筒采用2种不同硬度的橡胶，中间胶筒硬度较低，作为主要的密封部件；两侧胶筒硬度较高，保护中间胶筒的同时，进行双重密封。为防止坐封及密封过程中胶筒挤压外凸，胶筒两侧有防突环，防突环周向有多条割缝，胶筒坐封过程中紧贴胶筒外侧，保护胶筒。为防止因防突环遇阻引起的胶筒提前坐封，防突环与锥套采用了一体化设计。
2.3 防提前坐封技术
压裂管柱入井后会因与井壁磕碰或者落物等原因导致封隔器提前坐挂，为保证下入安全，设计了防提前坐封装置，既能保证封隔器不会提前坐挂，又能保证封隔器到位后正常坐挂、坐封。
防提前坐封装置位于回接筒和送入工具之间，结构如图5所示。其左端的支撑爪连接送入工具本体，其右端支撑挡块连接回接筒，确保回接筒的运动与坐封工具同步，即使回接筒外部环空出现落物并遇阻，也不会提前坐封。封隔器达到预定位置坐挂坐封时，管内憋压坐封，剪断启动销钉，液缸推动支撑组件向右移动，支撑爪和支撑挡块回收，送入工具和回接筒之间产生相对轴向运动，防提前坐封装置不再起作用。
2.4 解挂技术
封隔器入井过程中若中途遇阻并提前坐挂坐封，可下入专门的解挂工具将封隔器解挂解封。设计的解挂工具结构如图6所示，初始状态下，由解挂套和支撑卡簧支撑封隔器及尾管，当解挂工具下至封隔器位置，其外表面的马牙扣与封隔器回接筒锚定。解挂工具伸缩定位块与封隔器的解挂套锚定。上提管串，剪断解挂剪钉，解挂套与支撑卡簧产生相对运动，支撑卡簧失去支撑后回收，不再对封隔器产生锁紧作用，封隔器本体可以上下移动，胶筒和卡瓦回弹，实现解挂。该解挂形式不受压差和尾管悬重的影响，同时不影响压裂施工作业[10]。
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图 6 可解挂式双向锚定封隔器与解挂工具的结构Figure 6. Structure of the detachable bi-directional anchoring packer and detachment tool3. 封隔器性能测试
为了验证可解挂双向锚定悬挂封隔器的性能，模拟现场环境，分别进行了锚定性能、封压性能、防提前坐封装置性能和整机解挂解封性能测试。
3.1 封隔器锚定性能
为了测试封隔器锚定单元的锚定性能，研制了锚定性能测试装置。卡瓦外径为149.0 mm，试验套管内径为159.0 mm。采用机械加载坐挂，坐挂载荷为120 kN，坐挂后卸载，环空加压检测卡瓦锚定性能，加载至1 200 kN，保持30 min（见图7），卡瓦无滑移。对支撑封头反向加载1 200 kN，保持30 min，卡瓦滑移2.0 mm，满足性能要求。卸载，卡瓦回弹，回弹后外径151.0 mm，满足设计要求。
3.2 封隔器密封性能
为了测试封隔器锚定单元的密封性能，研制了密封性能测试装置。封隔器胶筒外径148.0 mm，试验套管内径为159.0 mm。试验装置上下各有一个加压封头，可分别进行加压，采用机械加载方式坐封胶筒。为模拟现场井况，将试验装置放入到加热装置中，加热至80 ℃，机械加载49 kN，完成坐封。之后环空加压，逐级加压至35，50，70和80 MPa，稳压15 min无压降（见图8）。泄压后，逐级加温至100，120，140和160 ℃，保温10 h，分别从两端加压，均能实现80 MPa密封，共密封34 h。泄压、卸载，胶筒回弹，检测胶筒外径为152.0 mm，满足设计要求。
3.3 防提前坐封装置性能
模拟现场施工中的遇阻井况，测试防提前坐封装置对封隔器的保护作用。将封隔器底部进行固定，加工工装单独支撑回接筒部分，采用拉伸试验机推动回接筒，检测防提前坐封装置抗剪性能。装置加载载荷分别为20，50，100，200，300和500 kN，封隔器均未坐封。试验结果表明，防提前坐封装置可有效保护封隔器，即使在遇阻500 kN的情况下封隔器仍不会坐封。管内憋压15 MPa，封隔器开始正常坐封，防提前坐封装置失效。
3.4 封隔器解挂解封性能
为模拟现场封隔器解挂、解封操作，在模拟试验井进行入井性能测试。试验套管内径为159.0 mm，封隔器最大外径为152.0 mm。利用管串将封隔器下至预定位置，管内憋压至25 MPa，先坐挂坐封，正转机械丢手，起出送入工具。下入解挂工具至封隔器位置，悬重减小50 kN时解挂工具与封隔器锚定；上提解挂工具，至悬重增大200 kN时剪断解挂剪钉；继续缓慢上提，将封隔器起出井口，顺利实现解挂、解封。
4. 现场应用
可解挂双向锚定悬挂封隔器在鄂尔多斯盆地20多口井进行了应用，均顺利实现坐挂、坐封，并对环空起到有效的密封作用，确保了压裂施工作业的正常进行，解决了常规双向锚定封隔器存在的密封失效和提前坐挂等问题。下面以X67井为例介绍可解挂双向锚定悬挂封隔器的应用情况。
X67井位于鄂尔多斯盆地伊陕斜坡东北部，完钻井深4 112.00 m，水平段长1 200.00 m，上层套管为ϕ177.8 mm套管，尾管为ϕ114.3 mm套管，悬挂器下深2 597.00 m，可解挂双向锚定悬挂封隔器下入位置的井斜角为43°左右，共完成12段的分段压裂。下入送入管柱前采用刮管器进行刮管，然后采用通井规通井，下入送入管柱投入憋压球，依次憋压至15，20，25和28 MPa并稳压5 min，完成可解挂双向锚定悬挂封隔器的坐挂、坐封，验挂、验封后管柱正转完成丢手，采用ϕ88.9 mm油管连接回接插头进行回接作业，管柱到位后丢手，调节井口油管长度安装采油树，进行压裂施工，入井砂量406.9 m3，入井液量3 695.0 m3，施工最高泵压61 MPa，管柱锚定及环空封压可靠，顺利完成压裂施工作业。该井压裂后无阻流量8.70×104m3/d，与该区块平均无阻流量6.85×104m3/d相比，提高了27.0%。
5. 结论与建议
1）研制了可解挂双向锚定悬挂封隔器，现场应用表明，该封隔器可实现管串的送入、双向锚定、环空封隔及解挂，解决常规双向锚定封隔器存在的问题，确保现场施工的安全性。
2）可解挂双向锚定悬挂封隔器具有更好的锚定性能、封压性能和下入安全性能。其中：整体式合金卡瓦的锚定能力可达1 200 kN以上；V形交叠式胶筒的密封压力达到80 MPa以上；防提前坐封装置可有效防止回接筒及胶筒提前动作，实现封隔器的安全下入。
3）建议研发不同规格的可解挂双向锚定悬挂封隔器，进一步增强其在不同井况下的适应能力。
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图 1 智能钻完井技术应用场景及架构设计
Figure 1. Application scenario and architecture design of intelligent drilling and completion technology
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图 2 智能钻完井技术的发展层次
Figure 2. Development level of intelligent drilling and completion technology system
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表 1 国内外典型的智能完井系统
Table 1 Typical intelligent well completion system at home and abroad
智能完井系统 年份 公司 驱动方式 技术特点 SCRAMS 1997 哈里伯顿 液压 只需1根液压管线和1根电缆管线即可完成流量控制 MultiNodeTM 2014 贝克休斯 电力 单根特制电缆将井下所有节点连接到地面控制系统 Simply Intelligent 2014 威德福 液压 可以实现分辨率为0.5 m的全井温度以及井下剖面监测 Manara 2015 斯伦贝谢 电力 能够实现井下永久监控，并对分支井眼的不同目的层进行流量控制 EIC-Riped 2017 中国石油 电力 信号传输距离4 km，可做到100级流量调节 SureCONNECT 2020 贝克休斯 电力 无需干预的井筒产液监测控制，实现数据驱动的生产智能决策 
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