超深小井眼高性能油管磨铣工具优化及应用研究

Optimization and Application of High-Performance Tubing Milling Tools for Ultra-Deep Slim Holes

  • 摘要: 为解决超深小井眼修井作业中因井眼尺寸小、油管强度高而导致的磨铣井段长、磨铣速度慢及单趟进尺短等难题,优化了八角齿复合布齿高性能磨铣工具。基于P110钢级油管磨铣动力学仿真模型,优化设计了高性能磨铣工具,优选切削元件为八角齿,并确定后倾角为18°。磨铣作业时,八角齿利用其高切削吃入应力实现对高强度油管的有效“攻击”,同时凭借低切削力波动变异系数和低破碎比功保持切削稳定性;布齿方式采用全八角齿多级复合切削方式,进一步协同了切削齿的攻击性与稳定性,能量利用效率最高。高性能磨铣工具现场试验结果表明,单趟磨铣进尺相比常规磨鞋提高了32.86%,磨铣速度提升了33.33%,提速提效显著。八角齿复合布齿高性能磨铣工具的优化与应用,实现了高强度油管磨铣过程中的高稳定性与高效率,为超深小井眼修井作业提供了一种新的高效磨铣工具。

     

    Abstract: A high-performance milling tool featuring an octagonal cutter composite arrangement was optimized to address the challenges of the long milling section, low milling speed and short single-trip footage caused by small wellbore size and high tubing strength in workover operations of ultra-deep slim holes. Based on a milling dynamics simulation model for P110 steel grade tubing, optimization design was conducted on the high-performance milling tool and the octagonal cutter was identified as the optimal cutting element, with 18° determined as the optimal back rake angle. During milling operations, the octagonal cutter leverages its high cutting engagement stress to effectively penetrate high strength tubing. Simultaneously, cutting stability is maintained by exhibiting the low coefficient of variation in cutting force fluctuation and low specific crushing energy. Additionally, the multistage composite layout utilizing exclusively octagonal cutters further synergizes the aggressiveness and stability of cutters, thereby maximizing energy utilization efficiency. Field tests demonstrated that compared to conventional mill shoes, the high-performance mill shoe increased single-trip milling footage by 32.86% and milling speed by 33.33%, yielding significant improvements in operational speed and efficiency. The optimization and application of the high-performance milling tool with octagonal cutter composite arrangement achieved both high stability and efficiency during the milling of high strength tubing, providing a novel and efficient milling tool for workover operations of ultra-deep slim holes.

     

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