固井泄压缓冲装置研制及应用

Development and application of well cementing pressure relief buffer device

  • 摘要: 针对页岩气水平井固井替浆碰压后套管内高压流体直接放喷存在射流冲击强、振动剧烈、作业安全风险高的工程难题,基于Navier-Stokes 方程与流体动能梯度耗散机理,采用两级旋流缓冲思路研制一套固井泄压缓冲装置。该装置通过切线引流使高压流体在初级缓冲腔内形成强制涡流,将轴向动能转化为旋转动能;配套对称双二级缓冲腔并联结构大幅扩大总出口过流面积,实现流速平方级衰减;对称腔体反向扭矩相互抵消,保障装置作业稳定。采用SolidWorks Flow Simulation软件开展标准κ-ε湍流仿真与Schnerr-Sauer空化耦合冲蚀数值模拟,结合室内排量试验与页岩气井现场应用完成性能验证。仿真结果表明:60 MPa 高压工况下,流体入口流速350 m/s,经两级缓冲后出口流速降至10 m/s,仅为入口流速的2.86%;冲蚀高风险区集中于初级缓冲腔射流正对壁面,选用 35CrMo 材质可满足长期服役要求,高磨损区域可通过表面强化涂层进一步提升抗冲蚀性能。室内试验显示,2 m3/min 排量条件下流体冲击可削弱80%以上;重庆涪陵页岩气井现场应用证实,58 MPa 井口压力下放喷持续30 s,流体冲击显著减弱,射流扩散范围控制在1 m2以内;累计应用50口井后壁厚磨损量仅0.1 mm左右,耐冲蚀性能达标。该装置依靠分级旋流耗散流体动能,可大幅降低固井泄压流体流速与现场安全风险,为页岩气水平井高压固井放喷作业提供可靠配套装备。

     

    Abstract: Aiming at the engineering problems of strong jet impact, severe vibration and high operation safety risk caused by direct blowdown of high-pressure fluid inside casing after cementing displacement bump pressure of shale gas horizontal wells, a two-stage cyclone pressure relief buffer device for cementing was developed based on Navier-Stokes equations and fluid kinetic energy gradient dissipation mechanism. The device guides high-pressure fluid tangentially to form forced vortex in the primary buffer chamber to convert axial kinetic energy into rotational kinetic energy. The parallel structure of symmetrical double secondary buffer chambers greatly expands the total outlet flow area to realize square-order attenuation of flow velocity, and the reverse torque of symmetrical chambers counteracts each other to ensure stable operation of the device. Standard κ-ε turbulence simulation coupled with Schnerr-Sauer cavitation erosion numerical simulation was carried out by SolidWorks Flow Simulation software, and performance verification was completed combining indoor displacement test and field application in shale gas wells. The simulation results show that under 60 MPa high-pressure working condition, the fluid inlet flow velocity is 350 m/s, and the outlet flow velocity drops to 10 m/s after two-stage buffering, accounting for only 2.86% of the inlet flow velocity. The high erosion risk area is concentrated on the wall facing the jet in the primary buffer chamber. 35CrMo steel can meet the long-term service requirements, and surface strengthening coating can further improve the erosion resistance of severely worn areas. Indoor tests demonstrate that fluid impact can be reduced by more than 80% under 2 m3/min displacement. Field application in Fuling shale gas wells of Chongqing verifies that the blowdown lasts for 30 s under 58 MPa wellhead pressure, the fluid impact is obviously weakened, and the jet diffusion range is controlled within 1 m2. The wall thickness wear is only 0.1 mm after cumulative application in 50 wells, and the erosion resistance meets the design requirements. Relying on staged cyclone to dissipate fluid kinetic energy, the device can greatly reduce the fluid flow velocity and field safety risks during cementing pressure relief, providing reliable supporting equipment for high-pressure cementing blowdown operation of shale gas horizontal wells.

     

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