基于压力波自动识别的智能尾管悬挂器设计与评价

Design and Evaluation of an Intelligent Liner Hanger Based on Automatic Pressure Wave Recognition

  • 摘要: 针对传统液压尾管悬挂器液缸水眼常开、易受循环压力波动误触发而提前坐挂的工程难题,研制了一种基于压力波自动识别的智能尾管悬挂器电控机构。该机构采用井口压力波编码指令触发模式,通过井下压力传感器采集压力信号、单片机识别编码,驱动电机控制液缸水眼通断,实现“常态关闭、按需开启”,从原理上杜绝异常坐挂风险。结构上采用环空短节形成绝压密封仓,内置耐高温低功耗国产电控系统,阀体选用2A12 铝合金加工并校核了强度;基于Mooney–Rivlin 本构模型与有限元方法,系统分析了不同硬度橡胶O形密封圈在不同压力下的密封性能,并验证了密封摩擦力与电机拉力的匹配性。性能分析表明:阀体在50 MPa 极限压力下的安全系数为 1.16,满足强度与钻磨要求;90 HA丁腈橡胶O形密封圈在 0~50 MPa工况下的接触应力始终高于介质压力,密封可靠;电机有效拉力显著大于密封摩擦力,动作稳定。地面承压试验验证机构承压性能良好,可有效适应深井高温高压复杂工况,为尾管固井安全高效施工提供新型智能解决方案。

     

    Abstract: To address the engineering problem that the inlet of the hydraulic cylinder in a traditional hydraulic liner hanger is normally open and is prone to premature setting caused by the false triggering of circulating pressure fluctuations, an electronic control mechanism for an intelligent liner hanger based on automatic pressure wave recognition was developed. This mechanism introduced the trigger mode of wellhead pressure wave coding instructions. By pressure signals acquisition with a downhole pressure sensor and recognizing the codes with a single-chip microcomputer, it drove the motor to control the opening and closing of the inlet on the hydraulic cylinder, realizing “normally close and open on demand” and fundamentally eliminating the risk of miss-setting. Structurally, an hollow mandrel was adopted to form an absolute pressure sealing cabin, internally equipped with a China made high-temperature-resistant and low-power-consumption electronic control system. The valve body was made of 2A12 aluminum alloy, and its strength was verified. Based on the Mooney-Rivlin constitutive model and finite element method, the sealing performance of rubber O-rings with different hardness under different pressures was systematically analyzed, and the matching between the sealing friction force and the motor pulling force was verified. The results indicate that the safety factor of the valve body is 1.16 under an ultimate pressure of 50 MPa, which meets the requirements for strength and drilling/ milling. The contact stress of a 90 HA nitrile rubber O-ring is always higher than the medium pressure under the conditions of 0 to 50 MPa, ensuring reliable sealing. The effective pulling force of the motor is significantly greater than the sealing friction force, ensuring stable operation. The surface pressure-bearing test verifies that the mechanism has good pressure-bearing performance, can effectively adapt to the complex conditions of high temperature and high pressure in deep wells, and provides a novel intelligent solution for the safe and efficient operation of liner cementing.

     

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