Optimization Design and Numerical Analysis of Flow Passage Converters in LWD Tools
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摘要: 随钻测井仪流道转换器流道截面设计不合理，不仅会造成随钻测井仪器内流道局部流场紊乱，致使仪器局部冲刷严重，造成仪器使用寿命缩短；还会导致仪器压力损失偏高，影响仪器的适用性。为此，采用CFD方法，对某型随钻测井仪流道转换器进行优化设计，并对4种设计方案进行了全三维数值模拟和对比，认为影响流道转换器流场性能的主要因素是扩张角和内流道截面积的连续性。最优设计方案的扩张角较小，内流道截面积连续，轴向速度下降更平缓，总压损失最小，流场流速分布更均匀。试验结果表明，流道转换器扩张角、内流道截面积不连续性与流道转换器流场分布均匀性呈负相关，与压力损失呈正相关；总压损失系数理论值与试验值对应的差值不大于0.076%，且变化趋势均与理论分析结果相同。研究结果为流道转换器的优化设计提供了理论依据。Abstract: Improper design of flow passage converter section in LWD ( logging while drilling) tools can cause local flow-field turbulence and result in serious local erosion of the tool, thus reducing its service life. It can also lead to large pressure loss of the tool and affect its applicability. For this reason, CFD (computational fluid dynamics) method was applied for the optimization design of a certain type of flow passage converter in an LWD tool. According to the full 3D numerical simulation and comparison of four design schemes, the main factors affecting the flow-field performance of the flow passage converter were thought to be the expansion angle and the continuity of the cross-sectional area of the internal flow passage. The optimal design has a smaller expansion angle, a more continuous cross-sectional area of the internal flow passage, a gentler decline in axial velocity, a minimum total pressure loss, and a more uniform flow velocity distribution in the flow field. The research results showed that the expansion angle and the discontinuity of the cross-sectional area of the internal flow passage were negatively associated with the uniformity of the flow field distribution in the flow passage converter and positively with the pressure loss. The difference between theoretical and experimental total pressure loss coefficients was not more than 0.076%, and the change trend was the same as the result of theoretical analysis. The research results can effectively serve as a theoretical basis for the optimization design of flow passage converters.
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Keywords:
- LWD tool /
- flow passage converter /
- optimization design /
- numerical simulation
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图 3 流道转换器流体计算域网格划分
Figure 3. Grid division for fluid computational domain of the flow passage converter
表 1 流道转换器设计方案
Table 1 Design schemes for the flow passage converter
设计方案 α/（°） d/mm 结构类型 加工工艺 原始设计 45 16 分体式，流道突变 简单 优化方案1 45 6 分体式，流道突变 较简单 优化方案2 30 6 分体式，流道突变 较简单 优化方案3 20 0 整体式，流道连续 复杂 
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表 2 流道转换器4种设计方案流动压力损失计算结果
Table 2 Calculated flow pressure loss in four design schemes of the flow passage converter
设计方案 进口压力/kPa 出口压力/kPa 总压损失系数，% 原始设计 10 000 9 853.8 1.462 优化方案1 10 000 9 880.8 1.192 优化方案2 10 000 9 886.0 1.140 优化方案3 10 000 9 959.3 0.407
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表 3 流道转换器4种设计方案的流动压力损失试验结果
Table 3 Experimental flow pressure loss in four design schemes for the flow passage converter
设计方案 进口压力/kPa 出口压力/kPa 总压损失系数，% 原始设计 520.0 512.0 1.538 优化方案1 585.0 577.7 1.248 优化方案2 514.0 508.0 1.167 优化方案3 477.0 475.0 0.419
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