FKM/NBR螺杆泵定子共混胶摩擦磨损行为研究
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摘要
螺杆泵采油是一种新型的人工举升方式，具有结构简单、适用性强、安装方便、占地小、投资少、泵效高等特点，已经在国内外的油田生产中普遍使用。特别是目前较多油田已进入三次采油阶段，开采原油的难度不断加大，该技术的应用正呈明显上升趋势。螺杆泵的主要工作部件是由螺杆（金属转子）和衬套（橡胶定子）组成，定子橡胶衬套的性能直接影响整个采油螺杆泵系统的工作性能，其中螺杆泵的定子橡胶衬套的磨损是导致螺杆泵失效的主要原因之一。定子橡胶在工作过程中受多种因素的影响，引起橡胶的物理、化学性质发生变化，加速其老化和磨损进程，导致其使用寿命缩短，严重限制了螺杆泵的应用。螺杆泵定子橡胶材料的选择及进一步改进，对于提高采油螺杆泵性能，发挥螺杆泵在稠油井、携砂井、斜井中的作用，以及延长螺杆泵的工作寿命至关重要。目前，国内外已经有研究人员采用工程塑料或各种高性能填料与丁腈橡胶共混，以提高定子橡胶材料的性能，但是至今为止，研究人员没有考虑到针对采油需求引入性能更加优良的橡胶对螺杆泵常用定子橡胶进行共混改性，使定子橡胶进一步满足对强度、耐磨性、抗老化性等各种性能的要求，也没有对如何选择不同橡胶共混配比的问题进行深入研究。本文以不同性能的定子橡胶的共混为手段，为了能够根据实际工况选择最佳共混橡胶的配比，进一步实现在不同工况下提高定子橡胶衬套寿命及定子橡胶性价比的目标，将氟橡胶和丁腈橡胶进行了共混，开展其配方设计的试验研究和摩擦磨损机理分析。
考虑到采油螺杆泵定子橡胶的磨损受制于高温、高压、溶胀、转速等因素交互耦合作用，且各因素与磨损量之间的关系无法用精确的数学表达式进行描述。因此，本文对多种不同配比的丁腈基和氟基螺杆泵定子橡胶的耐磨性在MPV-600及MLS-225摩擦磨损试验机上进行了试验研究，分析了各种因素对磨损量的影响，确定了其间的影响关系；设计了能够模拟实际工况中高温、液体溶胀、气体溶胀等因素的专门试验装置，研究温度、溶胀对橡胶性能的影响，使实验数据及结果更加准确；整理了不同配比共混胶的实验数据并进行了对比分析，找到了与某种实际采油工况相匹配的性能优异的螺杆泵定子共混胶；采用扫描电镜和红外光谱分析等方式对不同配比的共混胶在不同工况下磨损试验前后的本构关系进行分析，确定了其在不同工况下的磨损机理。
在螺杆泵采油系统的实际工作过程中，定子橡胶的配方、共混胶的配比需要根据实际工况的变化而变化。为保证螺杆泵定子橡胶适应实际工况，自行开发了不同工况（温度、气体及液体溶胀等因素的影响）下的实验装置并结合磨损试验机，分析不同配方及配比的定子橡胶在不同工况下（干摩擦、水润滑、原油润滑条件下）的耐磨性。形成了考虑螺杆泵实际工况的载荷、温度、溶胀、转速等因素对定子橡胶耐磨性影响的一整套实验研究方法。通过磨损前后共混胶的实验数据、红外光谱和扫描照片的对比分析，验证了该实验方法的有效性和实用性。
通过上述实验方法的研究和试验设备的研制，本文构建了一个融合多因素于一体并针对螺杆泵定子橡胶性能进行分析的综合实验平台，该平台可以结合实际工况对不同配方及配比的定子橡胶进行相关试验分析，最终确定适应不同工况的最优定子橡胶配方及配比。
Progressing cavity pump (PCP) is a new type of artificial lift equipments with thecharacteristics of simple structure, great applicability, easy installation, less floor area, lessinvestment, high efficiency, etc. It has been widely used in oil production at home andabroad. At present, more oil fields have entered into the tertiary oil recovery stage and oilexploration is becoming difficult. Therefore, the application of progressing cavity pumpshows the clear upward trend. The progressing cavity pump composes of the stator ofelasticity and the metal rotor. The performance of stator rubber bushing directly affects theperformance of entire oil pumping system, and the wear of stator rubber is one of the mainreasons which lead to the failure of progressing cavity pump. The life of stator rubber isaffected by many factors in the course of working, which results in physical and chemicalproperty change of rubber, and accelerates aging and wear of the stator rubber. Theaffecting factors decrease the mechanical and volumetric efficiency of pump, shorten thelife of pump, and limit the scope of application. The selection of stator rubber material andits further improvement are crucial for improving the performance of progressing cavitypump, which plays an important role for extending the working life of progressing cavitypump in heavy oil wells, sand wells and inclined wells.
Currently, in order to improve the performance of the stator rubber, researchers haveused plastic or various kinds of high performance fillers for blending with nitrile rubber.But so far, no researchers has taken the comprehensive performance requirements of statorrubber into account, such as strength, abrasive resistance and aging resistance, and also hasnot researched the optimization problem of rubber blend ratio. Therefore, the research onthe blend technology will be carried out in this thesis to optimize the stator rubber ofprogressing cavity pump by mixing fluorine rubber and nitrile rubber, and on wearmechanism to provide the theoretical basis for choosing stator rubber. The main works andcontributions of this thesis are listed as follows:
Considering that the wear of stator rubber is subjected to the interactive coupling ofhigh temperature, high pressure, swelling, rotate speed and other factors, and the relationship between the various factor and wear loss cannot be precisely described bymathematical expression, the wear resistance of rubber blend with the different ratio ofNBR (Nitrile butadiene rubber) and FKM (Fluorine rubber) was investigated by theMPV-600and MLS-225testers. In this thesis, the effect of various factors on the wear losswas analyzed and the relation model was constructed. Specialized experimental apparatusfor simulating the high temperature, high pressure, gas swelling, which was similar to thatin the actual working conditions, was designed to analyze the effect of these factors on theproperties of rubber, and it would make the experiment data and results more accurate. Theexperimental data was disposed and contrasted to find out the excellent performance blendadapt to the practical oil extraction condition. The constitutive relation of blend rubbers isanalyzed by using scanning electron microscopy and infrared spectroscopy before and afterthe wear experiment in different conditions to determine the wear mechanism.
During the actual working process of screw pump, the formulation of stator rubberand the blends ratio must be adjusted in accordance with the working conditions. Tocooperate the stator rubber formulation with the actual working conditions, theexperimental apparatus for the different conditions (temperature, swelling and other factors)is self-designed, and the relations between different formulations of stator rubber and thewear resistance in different condition (dry sliding, water lubrication, base oil lubrication)was analyzed using this wear tester. The full set of experimental method is proposed aboutthe effect of speed, load, temperature, swelling and other factors in the actual conditions onthe wear resistance of the stator rubber. The effectiveness and practicality of experimentalmethods are verified by the experimental data, infrared analysis and scanning photographsof wear experiment.
Through the above research about the experimental method the design of testequipment, this paper construct the comprehensive experiment platform, which could fusemultiple factors into one and aim at the analysis of the stator rubber of screw pump. Theexperiment and analysis of stator rubber with different formulation and ratio could berealized in this platform according to the actual condition. Finally, the optimal formulationand ratio of rubber blend could be found adapt to the related operation condition.
考虑到采油螺杆泵定子橡胶的磨损受制于高温、高压、溶胀、转速等因素交互耦合作用，且各因素与磨损量之间的关系无法用精确的数学表达式进行描述。因此，本文对多种不同配比的丁腈基和氟基螺杆泵定子橡胶的耐磨性在MPV-600及MLS-225摩擦磨损试验机上进行了试验研究，分析了各种因素对磨损量的影响，确定了其间的影响关系；设计了能够模拟实际工况中高温、液体溶胀、气体溶胀等因素的专门试验装置，研究温度、溶胀对橡胶性能的影响，使实验数据及结果更加准确；整理了不同配比共混胶的实验数据并进行了对比分析，找到了与某种实际采油工况相匹配的性能优异的螺杆泵定子共混胶；采用扫描电镜和红外光谱分析等方式对不同配比的共混胶在不同工况下磨损试验前后的本构关系进行分析，确定了其在不同工况下的磨损机理。
在螺杆泵采油系统的实际工作过程中，定子橡胶的配方、共混胶的配比需要根据实际工况的变化而变化。为保证螺杆泵定子橡胶适应实际工况，自行开发了不同工况（温度、气体及液体溶胀等因素的影响）下的实验装置并结合磨损试验机，分析不同配方及配比的定子橡胶在不同工况下（干摩擦、水润滑、原油润滑条件下）的耐磨性。形成了考虑螺杆泵实际工况的载荷、温度、溶胀、转速等因素对定子橡胶耐磨性影响的一整套实验研究方法。通过磨损前后共混胶的实验数据、红外光谱和扫描照片的对比分析，验证了该实验方法的有效性和实用性。
通过上述实验方法的研究和试验设备的研制，本文构建了一个融合多因素于一体并针对螺杆泵定子橡胶性能进行分析的综合实验平台，该平台可以结合实际工况对不同配方及配比的定子橡胶进行相关试验分析，最终确定适应不同工况的最优定子橡胶配方及配比。
Progressing cavity pump (PCP) is a new type of artificial lift equipments with thecharacteristics of simple structure, great applicability, easy installation, less floor area, lessinvestment, high efficiency, etc. It has been widely used in oil production at home andabroad. At present, more oil fields have entered into the tertiary oil recovery stage and oilexploration is becoming difficult. Therefore, the application of progressing cavity pumpshows the clear upward trend. The progressing cavity pump composes of the stator ofelasticity and the metal rotor. The performance of stator rubber bushing directly affects theperformance of entire oil pumping system, and the wear of stator rubber is one of the mainreasons which lead to the failure of progressing cavity pump. The life of stator rubber isaffected by many factors in the course of working, which results in physical and chemicalproperty change of rubber, and accelerates aging and wear of the stator rubber. Theaffecting factors decrease the mechanical and volumetric efficiency of pump, shorten thelife of pump, and limit the scope of application. The selection of stator rubber material andits further improvement are crucial for improving the performance of progressing cavitypump, which plays an important role for extending the working life of progressing cavitypump in heavy oil wells, sand wells and inclined wells.
Currently, in order to improve the performance of the stator rubber, researchers haveused plastic or various kinds of high performance fillers for blending with nitrile rubber.But so far, no researchers has taken the comprehensive performance requirements of statorrubber into account, such as strength, abrasive resistance and aging resistance, and also hasnot researched the optimization problem of rubber blend ratio. Therefore, the research onthe blend technology will be carried out in this thesis to optimize the stator rubber ofprogressing cavity pump by mixing fluorine rubber and nitrile rubber, and on wearmechanism to provide the theoretical basis for choosing stator rubber. The main works andcontributions of this thesis are listed as follows:
Considering that the wear of stator rubber is subjected to the interactive coupling ofhigh temperature, high pressure, swelling, rotate speed and other factors, and the relationship between the various factor and wear loss cannot be precisely described bymathematical expression, the wear resistance of rubber blend with the different ratio ofNBR (Nitrile butadiene rubber) and FKM (Fluorine rubber) was investigated by theMPV-600and MLS-225testers. In this thesis, the effect of various factors on the wear losswas analyzed and the relation model was constructed. Specialized experimental apparatusfor simulating the high temperature, high pressure, gas swelling, which was similar to thatin the actual working conditions, was designed to analyze the effect of these factors on theproperties of rubber, and it would make the experiment data and results more accurate. Theexperimental data was disposed and contrasted to find out the excellent performance blendadapt to the practical oil extraction condition. The constitutive relation of blend rubbers isanalyzed by using scanning electron microscopy and infrared spectroscopy before and afterthe wear experiment in different conditions to determine the wear mechanism.
During the actual working process of screw pump, the formulation of stator rubberand the blends ratio must be adjusted in accordance with the working conditions. Tocooperate the stator rubber formulation with the actual working conditions, theexperimental apparatus for the different conditions (temperature, swelling and other factors)is self-designed, and the relations between different formulations of stator rubber and thewear resistance in different condition (dry sliding, water lubrication, base oil lubrication)was analyzed using this wear tester. The full set of experimental method is proposed aboutthe effect of speed, load, temperature, swelling and other factors in the actual conditions onthe wear resistance of the stator rubber. The effectiveness and practicality of experimentalmethods are verified by the experimental data, infrared analysis and scanning photographsof wear experiment.
Through the above research about the experimental method the design of testequipment, this paper construct the comprehensive experiment platform, which could fusemultiple factors into one and aim at the analysis of the stator rubber of screw pump. Theexperiment and analysis of stator rubber with different formulation and ratio could berealized in this platform according to the actual condition. Finally, the optimal formulationand ratio of rubber blend could be found adapt to the related operation condition.
引文
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