Design and Implementation of a Downhole Safety Monitoring System
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摘要: 针对目前国内井下故障频发，而预警效率低、安全监测技术较为滞后的问题，设计研制了一种具有自主知识产权的井下安全监控系统。该系统可以直接测量近钻头力学参数和工程参数，利用钻井液脉冲将所测参数实时传输至钻井风险分析评估模块，该模块通过分析计算接收到的数据判断钻井风险类型，并评估风险等级。现场试验表明，井下安全监控系统功能完善、性能稳定，风险评估准确率大于95%，部分技术指标达到了国外同类监测系统的水平。研究表明，井下安全监控系统可以降低深部复杂地层钻井风险和钻井成本、解决深部复杂地层井下故障预警效率低等问题，可以产生较大的经济效益。Abstract: In order to solve the problems of frequent downhole safety accidents, low early-warning efficiency, lagging safety monitoring technology in China, a downhole safety monitoring system with independent intellectual property rights was designed and developed. This system directly measures near-bit mechanical parameters and engineering parameters, and transmits the measured parameters to the drilling risk analysis and assessment module in real time by using the drilling fluid pulse, by which the received data can be analyzed and calculated to determine the type of drilling risk and assess the risk level. Field tests confirmed that the downhole safety system is fully functional and has a stable performance. The accuracy rate of the risk assessment is higher than 95%, and some technical indexes have reached the level of similar monitoring system abroad. The research show that the downhole safety monitoring system could reduce the drilling risk and drilling cost in deep complex formations. It could create great economic benefits for it has solved the problem of low early warning efficiency of downhole safety accidents.
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Keywords:
- downhole failure /
- safety monitoring /
- risk assessment /
- data acquisition /
- data transmission /
- field test
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图 3 井下参数测量模块结构示意
Figure 3. Structure diagram of the downhole parameters measuring module
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图 4 钻井工具钻压、弯矩、扭矩标定试验台
Figure 4. Calibration test bench for weight on bit, bending moment and torque of drilling tools
表 1 井下安全监控系统现场试验情况
Table 1 Field test of the downhole safety monitoring system
阶段 油田 井名 试验井段/m 工作时间/h 机械钻速提高率，% 备注 原理样机功能试验 新疆油田 T83002井 2 026.00～2 070.00 42 无故障 新疆油田 阜北3井 3 682.00～3 739.00 49 无故障 新疆油田 沙130井 1 928.00～2 195.00 150 无故障 新疆油田 JL230井 4 250.00～4 395.00 23 无故障 定型 吐哈油田 恰10-5井 670.00～896.00 52 10 无故障 新疆油田 玛607井 3 446.00～3 453.00 53 10 无故障 3 676.00～3 821.00 158 新疆油田 BT1185井 1 800.00～2 380.00 177 40 无故障 效果验证 塔里木油田 英买49井 5 510.00～5 590.00 108 30 无故障 青海油田 圆探1井 4 603.00～4 840.00 236 10 无故障 4 847.00～4 950.00 新疆油田 玛湖15井 4 000.00～4 033.00 33 25 无故障 塔里木油田 牙哈304H井 4 936.00～5 122.00 55 20 无故障 
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表 2 井下安全监控系统与国外同类监控系统的技术指标对比
Table 2 Comparison between technical indexes of the downhole safety monitoring system and those of the similar monitoring systems abroad
名称 钻压 弯矩 扭矩 振动 压力 转速 CoPilot井下随钻诊断系统 量程 ±375 kN ±113 kN·m ±38 kN·m ±50g 0～138 MPa –500～1 000 r/min 分辨率 <60 N <3 N·m <2 N·m <0.002g <7 kPa 误差 ±0.2%① ±0.9%① ±1.9%① ±5.0%① 0.25%① <1 r/min② 井下安全监控系统 量程 ±400 kN ±113 kN·m ±40 kN·m ±62.5g 0～138 MPa ±360 r/min 分辨率 <78 N <34 N·m <23 N·m <0.008g <5 kPa 误差 ±0.6%① ±0.4%① ±2.0%① ±5.0%① 0.05%① <1 r/min② 注：①为相对误差；②为绝对误差。
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