自动控向垂钻系统小型化设计的关键技术研究
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摘要
钻井过程中影响井斜的因素很多,且井斜给钻井、完井作业等带来一系列的危害,并造成巨大损失。国外近年来研制了VDS、SDD、Vertitrak、PowerV等具有主动防斜能力的自动化井斜闭环控制系统,成功解决了高陡构造、断层、盐层等情况下钻进时的井眼质量问题。自动控向垂直钻井技术是在工程钻井钻进时随钻测量钻孔的偏斜,确定孔斜后随即通过控制纠斜单元来纠正井斜,是当代钻探技术发展的热点。在实际的钻探工程中,各种高垂直度要求的钻孔越来越多,自动控向垂直钻进技术也就成为目前钻探工程界研究和工程实践的一个重要方向。
自动垂直钻井系统主要由测斜、信号传输、控制、钻具纠斜及动力源等几个基本的单元组成。测斜单元用于测量钻孔的井斜角与相对方位角等参数；信号传输单元将井下的参数信息传送到地面监控中心,并接收地面控制指令；井下控制单元对井斜角和相对方位角等信息进行处理和比较,检测实际倾角与垂直度的偏差,然后发出纠斜控制指令驱动纠斜单元；钻具纠斜单元按纠斜控制指令动作,给出一个适当的合力矢量指向高边,保持钻具向垂直方向钻进。动力源用于给纠斜单元的液压泵组、液压控制阀组以及其它电气元件提供动力。
近年来,国外已开始逐步重视小井眼钻井技术的研究和实际应用,在取芯钻进等地质钻探中,小口径井眼尺寸的钻探占了较大比重。在油气开采领域,由于小井眼钻井技术在降低油气勘探和开发成本、提高经济效益、减轻环境污染等方面比常规钻井具有十分突出的优越性。自动控向垂直钻井系统的小型化随着市场需求特别是随着技术的发展而不断进步。然而国外在这一研究领域一直对我国处于技术封锁状态。因此,打破国外大公司技术垄断,开发适合我国国情的自动化垂钻系统就显得很有意义。自动化垂钻系统的小型化将使得小井眼钻机的自动控向垂直钻井成为可能,其经济效益更为显著。开发出适合我国国情的小型化自动化垂钻系统,对我国的深部资源勘探和开采是很有意义的事情。
论文主要根据自动控向垂钻系统的功能原理,对自动控向垂钻系统的整体结构进行了分析,指出实现自动控向垂钻系统的小型化设计的重点是实现随钻测量仪(MWD)、动力源以及纠斜单元的小型化。然后分别对上述三种单元工作原理和结构形式进行了分析,提出了实现三者小型化的设计思路。
全文共分六章,每章内容如下：
第一章：
本章主要论述了国内外对自动控向垂钻系统的研究历史和研究现状；分析了钻采领域对小井眼钻探和小口径自动控向垂钻系统的需求,提出了本文的研究目标和研究内容。把研究重点定位于自动控向垂钻系统小型化设计所涉及到的与纠斜单元、通讯单元与动力单元有关的机械及液压方面的关键技术问题。同时对本文的研究背景和研究意义也进行了阐述。
第二章：
主要根据自动控向垂钻系统的功能原理,对自动控向垂钻系统的整体结构进行了分析,指出实现自动控向垂钻系统的小型化设计的重点是实现随钻测量仪(MWD)、动力源以及纠斜单元的小型化。然后分别对上述三种单元工作原理和结构形式进行了分析,提出了实现三者小型化的设计思路,其中重点分析了纠斜单元的几种纠斜策略和对应的结构布置形式,提出采用单缸独立动作与双缸异步动作结合的纠斜策略,确定以单泵组三液压缸横向布置形式作为纠斜单元小型化设计的方案。
第三章：
本章主要根据小孔径电磁波随钻测量仪工作的工作环境条件及小型化设计要求,解决其机械结构设计上遇到的抗压、密封、抗震、散热问题,以及解决狭小空间内实现电气可靠和快速联接的有关问题。在进行机械密封结构设计时,采用高级非线性有限元软件SC.Marc对管筒连接头处的O形橡胶圈径向密封以及端面处的O形橡胶圈轴向密封进了仿真运算,利用仿真运算结果,对初始设计中O形橡胶圈密封沟槽的结构尺寸以及O形橡胶圈的过盈量等参数进行了优化。最后介绍了小孔径电磁波随钻测量仪的实际装调和试验情况,以及对原设计方案的改进意见。
第四章：
本章根据适应于纠斜单元小型化设计的纠斜策略,分析了几种液压控制系统方案的特点,设计了采用二位二通螺纹插装阀换向和保压的液压控制系统方案,利用AMESim软件建立了液压控制系统仿真模型,在不同压力条件下,对液压缸单缸动作、双缸同步动作、双缸异步动作以及停泵保压工况进行了仿真运算和分析,利用仿真结果调整了卸荷阀等部分元件的参数。随后以压力传感器、数据采集卡、PLC控制器及微机等组成的测试平台,对所设计的液压系统进行了试验测试,验证了仿真结果的合理性,同时也肯定了自动控向垂钻系统纠斜单元小型化设计思路的正确性。
第五章：
本章主要介绍了井下涡轮发电机设计的基本理论,分析了影响井下涡轮发电机效率的因素,对井下涡轮发电机的几种结构形式进行三维建模,利用计算流体力学的方法,使用CFD软件FloWorks对井下涡轮发电机不同外部结构形式下的内部流场特性进行了仿真,提出了适于井下涡轮发电机小型化的结构方案,并就小口径井下涡轮发电机的结构设计与试验方案提出了参考建议。
第六章：
第六章为总结部分。主要介绍了经过有关的理论分析和试验研究,获得的一些研究成果和主要创新点,并指出了论文中的不足之处,提出了进一步研究的内容和思路,最后对我国自动控向垂钻系统的技术发展进行了乐观的展望。
In the well drilling process, there are many factors lead to slanting well. The slant for the well drilling and the well completion work bring a series of harms, and creates heavy loss. The foreign countrys recent years developed a automated well slanting closed-loop initiative control system such as VDS,SDD, Vertitrak, PowerV to against slant. The success has solved the hole quality problem when in high steep situations, complex structure and salt deposit area. Automatic Directional Vertical Drilling system (VDS)aims to restrain the drilling path to the desirable track by imposing force for well straightening through control system immediately when detecting the deviation of drilling hole through MWD (measurement while drilling). At present, the research on Automatic Directional Vertical Drilling technology is the hot pot of modern drilling technology development. Particularly there are more and more vertical drilling projects, so Automatic Vertical Drilling technology has become an important trend for research and project practice.
The system is composed of four basic units respectively for inclinometer, signal transmission, control, drilling oblique correction and the power source. The inclinometer unit measures the parameters of the apex angle and the relative azimuth angle of the hole; then the signal transmission unit sends the parameters to the aboveground monitoring and control unit and receives the control instructions; the down hole control unit compares and processes the message received, measures the deviation between the actual inclination angle and the verticality and sends control instructions to drive the well straightening device. Power source is used to powered for skew correction unit pump group, hydraulic control valves and other electrical components. which then imposes an appropriate resultant force vector directing upward and keep the drilling tool moving in the vertical direction.
In recent years, foreign countries have begun to gradually pay attention slimhole drilling technology and practical applications.In the core drilling and other geological drilling, the small diameter borehole drilling dimensions accounted for a larger share. In the oil and gas field,slimhole drilling technology has even more advantages than conventional drilling In reducing oil and gas exploration and development costs, improve economic efficiency, reducing environmental pollution, etc.
Automatic Directional Vertical Drilling system miniaturization is constantly developing with the market demand, especially as technology advances. However, overseas means us to take the technological blockade in this field of study. Therefore, to break the technological monopoly of foreign companies to develop China's national conditions suitable for automated vertical drilling system becomes very significant. VDS miniaturization has made Automatic Vertical Drilling slim hole drilling rig possible.It is even more significant economic benefits Development of China's national conditions suitable for the miniaturization of automatic vertical drilling system has great significance.i n our deep resource exploration and exploitation.
Paper analyzes the overall structure of the VDS according to its principle of functional. It pointed out that the realization of its focus on the miniaturization of the design is to achieve the miniaturization of drilling measuring instrument (MWD), the power source as well as the correcting oblique unit.Then each of these three kinds of units working principle and structure were analyzed, it put forward proposals to achieve he design of the three units Full-text is divided into six chapters, each chapter is as follows:
Chapter 1:
this part is introduction. This chapter deals primarily on the VDS at home and abroad to research history and research status. Paper analyzes the business needs of the VDS system in the field of drilling and mining,and presents the research objectives and research content. We focus on the study design targeted at miniaturization VDS involved with correcting oblique unit, communication unit and power unit of the machinery and hydraulic aspects of the key technical issues.at the same time, this research background and research interests have also been described.
Chapter 2:
Paper analyzes the overall structure of the VDS according to its principle of functional. It pointed out that the realization of its focus on the miniaturization of the design is to achieve the miniaturization of drilling measuring instrument (MWD), the power source as well as the correcting oblique unit.Then each of these three kinds of units working principle and structure were analyzed, it put forward proposals to achieve he design of the three units We focus on the study design targeted at miniaturization VDS involved with correcting oblique unit, communication unit and power unit of the machinery and hydraulic aspects of the key technical issues.at the same time, this research background and research interests have also been described.Paper focused on the analysis of several correction oblique strategy and the form of the corresponding structural arrangement. It analyzes the overall structure of VDS according to the function principle of it.Paper presents a combination of both methods which controling a single hydraulic cylinder operates independently and controling two hydraulic cylinders asynchronous action.
Chapter 3:
This chapter mainly based on the working environment conditions and the miniaturization design requirements of small small-aperture electromagnetic measurement while drilling instrument(EM-MWD)to solve their mechanical structure encountered in the design of compression, sealing, seismic, heat problem,and to achieve a reliable and fast connection of electrical related issues in tight spaces.We use an advanced non-linear finite element software SC.Marc analysis of the structure of rubber O-ring radial seal in tube connector and O-ring rubber seal into the axial ininstrument end. Utilizing the simulation calculation results,the initial design parameters of the rubber O-ring seal groove size and the pre-compression of O-shaped rubber ring t are optimized. Finally the situation of the actual assembly and test for small aperture EM-MWD is to be introduced, As well as the the improvements.
Chapter 4:
This chapter analyzes several features of the program of hydraulic control system, according to correction Oblique Strategies of adapting to the miniaturization tilt correcting unit.We designed the hydraulic control system program of change direction and keeping up the pressure with 2 Two-way Cartridge Valves.This chapter has established the simulation model of hydraulic control system using of AMESim software, many cases of hydraulic cylinder operation under different pressure conditions were Simulated.Use of simulation results to adjust the unloading valve and some other components of the parameters. Followed by the use of pressure sensors, data acquisition card, PLC controllers and computers set up a test platform,conducted a pilot test of the hydraulic System. The simulation results are verified as legitimate. At the same time, it affirmed the VDS correcting oblique miniaturization design ideas are correct.
Chapter 5:
This chapter introduced the design basic theory of downhole turbine generator, and analyzed the impact of the efficiency of the reasons for downhole turbine generator.Several downhole turbine generator structure is built of three-dimensional modeling. Using computational fluid dynamics method and CFD software FloWorks, We simulated downhole turbine generator external structure of different forms of internal flow field characteristics.Appropriate structure solution for underground small turbine generator was proposed. Finally, we made reference to the proposed For small diameter downhole turbine generator structure design and test program
Chapter 6:
This part is conclusion. This part mainly introduced the achievements obtained and main creative work after theory and practice research. Then the limitation of this research work and the further research that should be done are also pointed out. Finally, the prospect of our national VDS is put forward in the end of the paper.
自动垂直钻井系统主要由测斜、信号传输、控制、钻具纠斜及动力源等几个基本的单元组成。测斜单元用于测量钻孔的井斜角与相对方位角等参数；信号传输单元将井下的参数信息传送到地面监控中心,并接收地面控制指令；井下控制单元对井斜角和相对方位角等信息进行处理和比较,检测实际倾角与垂直度的偏差,然后发出纠斜控制指令驱动纠斜单元；钻具纠斜单元按纠斜控制指令动作,给出一个适当的合力矢量指向高边,保持钻具向垂直方向钻进。动力源用于给纠斜单元的液压泵组、液压控制阀组以及其它电气元件提供动力。
近年来,国外已开始逐步重视小井眼钻井技术的研究和实际应用,在取芯钻进等地质钻探中,小口径井眼尺寸的钻探占了较大比重。在油气开采领域,由于小井眼钻井技术在降低油气勘探和开发成本、提高经济效益、减轻环境污染等方面比常规钻井具有十分突出的优越性。自动控向垂直钻井系统的小型化随着市场需求特别是随着技术的发展而不断进步。然而国外在这一研究领域一直对我国处于技术封锁状态。因此,打破国外大公司技术垄断,开发适合我国国情的自动化垂钻系统就显得很有意义。自动化垂钻系统的小型化将使得小井眼钻机的自动控向垂直钻井成为可能,其经济效益更为显著。开发出适合我国国情的小型化自动化垂钻系统,对我国的深部资源勘探和开采是很有意义的事情。
论文主要根据自动控向垂钻系统的功能原理,对自动控向垂钻系统的整体结构进行了分析,指出实现自动控向垂钻系统的小型化设计的重点是实现随钻测量仪(MWD)、动力源以及纠斜单元的小型化。然后分别对上述三种单元工作原理和结构形式进行了分析,提出了实现三者小型化的设计思路。
全文共分六章,每章内容如下：
第一章：
本章主要论述了国内外对自动控向垂钻系统的研究历史和研究现状；分析了钻采领域对小井眼钻探和小口径自动控向垂钻系统的需求,提出了本文的研究目标和研究内容。把研究重点定位于自动控向垂钻系统小型化设计所涉及到的与纠斜单元、通讯单元与动力单元有关的机械及液压方面的关键技术问题。同时对本文的研究背景和研究意义也进行了阐述。
第二章：
主要根据自动控向垂钻系统的功能原理,对自动控向垂钻系统的整体结构进行了分析,指出实现自动控向垂钻系统的小型化设计的重点是实现随钻测量仪(MWD)、动力源以及纠斜单元的小型化。然后分别对上述三种单元工作原理和结构形式进行了分析,提出了实现三者小型化的设计思路,其中重点分析了纠斜单元的几种纠斜策略和对应的结构布置形式,提出采用单缸独立动作与双缸异步动作结合的纠斜策略,确定以单泵组三液压缸横向布置形式作为纠斜单元小型化设计的方案。
第三章：
本章主要根据小孔径电磁波随钻测量仪工作的工作环境条件及小型化设计要求,解决其机械结构设计上遇到的抗压、密封、抗震、散热问题,以及解决狭小空间内实现电气可靠和快速联接的有关问题。在进行机械密封结构设计时,采用高级非线性有限元软件SC.Marc对管筒连接头处的O形橡胶圈径向密封以及端面处的O形橡胶圈轴向密封进了仿真运算,利用仿真运算结果,对初始设计中O形橡胶圈密封沟槽的结构尺寸以及O形橡胶圈的过盈量等参数进行了优化。最后介绍了小孔径电磁波随钻测量仪的实际装调和试验情况,以及对原设计方案的改进意见。
第四章：
本章根据适应于纠斜单元小型化设计的纠斜策略,分析了几种液压控制系统方案的特点,设计了采用二位二通螺纹插装阀换向和保压的液压控制系统方案,利用AMESim软件建立了液压控制系统仿真模型,在不同压力条件下,对液压缸单缸动作、双缸同步动作、双缸异步动作以及停泵保压工况进行了仿真运算和分析,利用仿真结果调整了卸荷阀等部分元件的参数。随后以压力传感器、数据采集卡、PLC控制器及微机等组成的测试平台,对所设计的液压系统进行了试验测试,验证了仿真结果的合理性,同时也肯定了自动控向垂钻系统纠斜单元小型化设计思路的正确性。
第五章：
本章主要介绍了井下涡轮发电机设计的基本理论,分析了影响井下涡轮发电机效率的因素,对井下涡轮发电机的几种结构形式进行三维建模,利用计算流体力学的方法,使用CFD软件FloWorks对井下涡轮发电机不同外部结构形式下的内部流场特性进行了仿真,提出了适于井下涡轮发电机小型化的结构方案,并就小口径井下涡轮发电机的结构设计与试验方案提出了参考建议。
第六章：
第六章为总结部分。主要介绍了经过有关的理论分析和试验研究,获得的一些研究成果和主要创新点,并指出了论文中的不足之处,提出了进一步研究的内容和思路,最后对我国自动控向垂钻系统的技术发展进行了乐观的展望。
In the well drilling process, there are many factors lead to slanting well. The slant for the well drilling and the well completion work bring a series of harms, and creates heavy loss. The foreign countrys recent years developed a automated well slanting closed-loop initiative control system such as VDS,SDD, Vertitrak, PowerV to against slant. The success has solved the hole quality problem when in high steep situations, complex structure and salt deposit area. Automatic Directional Vertical Drilling system (VDS)aims to restrain the drilling path to the desirable track by imposing force for well straightening through control system immediately when detecting the deviation of drilling hole through MWD (measurement while drilling). At present, the research on Automatic Directional Vertical Drilling technology is the hot pot of modern drilling technology development. Particularly there are more and more vertical drilling projects, so Automatic Vertical Drilling technology has become an important trend for research and project practice.
The system is composed of four basic units respectively for inclinometer, signal transmission, control, drilling oblique correction and the power source. The inclinometer unit measures the parameters of the apex angle and the relative azimuth angle of the hole; then the signal transmission unit sends the parameters to the aboveground monitoring and control unit and receives the control instructions; the down hole control unit compares and processes the message received, measures the deviation between the actual inclination angle and the verticality and sends control instructions to drive the well straightening device. Power source is used to powered for skew correction unit pump group, hydraulic control valves and other electrical components. which then imposes an appropriate resultant force vector directing upward and keep the drilling tool moving in the vertical direction.
In recent years, foreign countries have begun to gradually pay attention slimhole drilling technology and practical applications.In the core drilling and other geological drilling, the small diameter borehole drilling dimensions accounted for a larger share. In the oil and gas field,slimhole drilling technology has even more advantages than conventional drilling In reducing oil and gas exploration and development costs, improve economic efficiency, reducing environmental pollution, etc.
Automatic Directional Vertical Drilling system miniaturization is constantly developing with the market demand, especially as technology advances. However, overseas means us to take the technological blockade in this field of study. Therefore, to break the technological monopoly of foreign companies to develop China's national conditions suitable for automated vertical drilling system becomes very significant. VDS miniaturization has made Automatic Vertical Drilling slim hole drilling rig possible.It is even more significant economic benefits Development of China's national conditions suitable for the miniaturization of automatic vertical drilling system has great significance.i n our deep resource exploration and exploitation.
Paper analyzes the overall structure of the VDS according to its principle of functional. It pointed out that the realization of its focus on the miniaturization of the design is to achieve the miniaturization of drilling measuring instrument (MWD), the power source as well as the correcting oblique unit.Then each of these three kinds of units working principle and structure were analyzed, it put forward proposals to achieve he design of the three units Full-text is divided into six chapters, each chapter is as follows:
Chapter 1:
this part is introduction. This chapter deals primarily on the VDS at home and abroad to research history and research status. Paper analyzes the business needs of the VDS system in the field of drilling and mining,and presents the research objectives and research content. We focus on the study design targeted at miniaturization VDS involved with correcting oblique unit, communication unit and power unit of the machinery and hydraulic aspects of the key technical issues.at the same time, this research background and research interests have also been described.
Chapter 2:
Paper analyzes the overall structure of the VDS according to its principle of functional. It pointed out that the realization of its focus on the miniaturization of the design is to achieve the miniaturization of drilling measuring instrument (MWD), the power source as well as the correcting oblique unit.Then each of these three kinds of units working principle and structure were analyzed, it put forward proposals to achieve he design of the three units We focus on the study design targeted at miniaturization VDS involved with correcting oblique unit, communication unit and power unit of the machinery and hydraulic aspects of the key technical issues.at the same time, this research background and research interests have also been described.Paper focused on the analysis of several correction oblique strategy and the form of the corresponding structural arrangement. It analyzes the overall structure of VDS according to the function principle of it.Paper presents a combination of both methods which controling a single hydraulic cylinder operates independently and controling two hydraulic cylinders asynchronous action.
Chapter 3:
This chapter mainly based on the working environment conditions and the miniaturization design requirements of small small-aperture electromagnetic measurement while drilling instrument(EM-MWD)to solve their mechanical structure encountered in the design of compression, sealing, seismic, heat problem,and to achieve a reliable and fast connection of electrical related issues in tight spaces.We use an advanced non-linear finite element software SC.Marc analysis of the structure of rubber O-ring radial seal in tube connector and O-ring rubber seal into the axial ininstrument end. Utilizing the simulation calculation results,the initial design parameters of the rubber O-ring seal groove size and the pre-compression of O-shaped rubber ring t are optimized. Finally the situation of the actual assembly and test for small aperture EM-MWD is to be introduced, As well as the the improvements.
Chapter 4:
This chapter analyzes several features of the program of hydraulic control system, according to correction Oblique Strategies of adapting to the miniaturization tilt correcting unit.We designed the hydraulic control system program of change direction and keeping up the pressure with 2 Two-way Cartridge Valves.This chapter has established the simulation model of hydraulic control system using of AMESim software, many cases of hydraulic cylinder operation under different pressure conditions were Simulated.Use of simulation results to adjust the unloading valve and some other components of the parameters. Followed by the use of pressure sensors, data acquisition card, PLC controllers and computers set up a test platform,conducted a pilot test of the hydraulic System. The simulation results are verified as legitimate. At the same time, it affirmed the VDS correcting oblique miniaturization design ideas are correct.
Chapter 5:
This chapter introduced the design basic theory of downhole turbine generator, and analyzed the impact of the efficiency of the reasons for downhole turbine generator.Several downhole turbine generator structure is built of three-dimensional modeling. Using computational fluid dynamics method and CFD software FloWorks, We simulated downhole turbine generator external structure of different forms of internal flow field characteristics.Appropriate structure solution for underground small turbine generator was proposed. Finally, we made reference to the proposed For small diameter downhole turbine generator structure design and test program
Chapter 6:
This part is conclusion. This part mainly introduced the achievements obtained and main creative work after theory and practice research. Then the limitation of this research work and the further research that should be done are also pointed out. Finally, the prospect of our national VDS is put forward in the end of the paper.
引文
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