超长井眼PDC钻头破岩效率与提速策略

Study on rock-breaking efficiency of PDC bits and the corresponding ROP improvement strategies for ultra-long wellbores

  • 摘要: 针对万米深井、长水平段等超长井眼钻井中机械能量传递受限、钻压不足导致PDC钻头破岩效率低、机械钻速慢的问题,通过理论分析、室内单齿与全尺寸钻头破岩实验与现场试验相结合的方法,分析了机械钻速与钻压之间的对应关系,并系统探讨了地层岩性、钻井参数及切削齿/钻头选型对钻井提速的影响机制,并提出了超长井眼低钻压高效破岩提速策略。研究表明:PDC单齿切削与钻头破岩均遵循相同的机械比能-吃入深度变化规律;结合机械比能与机械钻速-钻压曲线斜率的内在联系,将机械钻速-钻压曲线划分为低效破岩、有效破岩、高效破岩和异常干扰4个特征阶段,其中有效破岩阶段为钻头与切削齿发挥提速优势的关键区间;地层岩性决定机械钻速基础水平,地层岩性与钻井参数共同决定实际钻速高低,钻头及切削齿的提速优势主要体现在有效破岩阶段。针对超长井眼钻压受限工况,可通过异形齿、小直径切削齿、降低布齿密度、优化钻头冠部与布齿方式等措施实现低钻压高效破岩,建议加强新一代超硬材料研发,以满足强攻击性切削齿耐用性的需求,助力实现高效破岩钻井技术变革。研究结果可为超长井眼PDC钻头高效破岩与钻井提速提供理论依据和技术参考。

     

    Abstract: To clarify the key factors affecting ROP improvement under different working scenarios, theoretical analysis, laboratory tests and field trials were conducted to reinterpret the corresponding relationship between ROP and WOB, and the influence mechanisms of rock lithology, drilling parameters, and cutters/bits on ROP improvement were also discussed. The study shows that both single-cutter cutting and full-scale bit rock-breaking follow the same variation law of mechanical specific energy (MSE) with depth of cut (DOC). Combined with the definition of mechanical specific energy, it is found that the ROP-WOB relationship exhibits four characteristic stages: inefficient rock-breaking, effective rock-breaking, high-efficiency rock-breaking, and abnormal interference. Notably, the effective rock-breaking stage has rarely been reported in previous publications. Then, it can be deduced that rock lithology determines the baseline of ROP, while rock lithology and drilling parameters jointly govern the ROP values. The advantages of cutters and bits in affecting the ROP improvement are mainly manifested in the effective rock-breaking stage, i.e., before the linear correlation between ROP and WOB is established. On this basis, to address limitations on energy transmission for rock breaking in ultra-long wellbores such as ten-thousand-meter deep wells and long horizontal sections, several promising solutions for high-efficiency rock-breaking under low WOB were explored from the perspectives of cutters and bits: (1) Under the same WOB, larger DOC and higher ROP can be achieved by optimizing cutter shape and reducing cutter density; (2) By breaking the conventional tip profile design and cutter arrangement strategies of bits, the WOB required for rock-breaking can be reduced.

     

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