矢量推靠式堵漏防卡PDC钻头研制及应用

Research and Application of a Vector Push-Type PDC Drill Bit for Plugging and Leakage Prevention in Complex Formations

  • 摘要: 川渝地区裂缝性地层钻井作业井漏频发,堵漏作业与钻进过程相互制约,常规PDC钻头缺少主动挤压堵漏能力,堵漏处置周期长、起下钻作业多,严重制约了钻井提速增效。针对该技术难题,以“增刀翼、弱保径、扩水眼”为核心设计思想,提出了刀翼载荷矢量调控方法,研制了矢量推靠式堵漏防卡PDC钻头。该钻头通过非对称刀翼构型实现钻头横向载荷矢量合成,使侧向推靠力定向作用于专用堵漏刀翼;结合布齿优化、切削力学分析、井底流场CFD数值模拟与室内堵漏试验完成钻头结构验证,并在川渝多个裂缝漏失区块进行现场应用。结果表明:该钻头横向不平衡力系数0.039,钻进稳定性良好,流场分布可保障堵漏固相颗粒顺利通过;室内试验证实钻头可借助刀翼刮压作用将堵漏材料持续压入裂缝漏失通道;现场10余井次应用显示,该钻头可实现随钻主动堵漏,单井可减少起下钻作业2趟以上,石膏及高压盐水层起下钻无挂卡,钻头出井新度高于95%。研究证明,矢量推靠式堵漏防卡PDC钻头可同步实现破岩钻进与随钻堵漏,有效缩短井下复杂处置周期,为川渝裂缝性地层恶性井漏治理提供新的技术手段。

     

    Abstract: Drilling operations in fractured formations in the Sichuan–Chongqing region are frequently accompanied by severe lost circulation, resulting in prolonged non-productive time and increased drilling costs. Efficient control of lost circulation has therefore become one of the major challenges restricting drilling efficiency in these formations.To address this issue, a vector push-type PDC drill bit was developed based on the design concept of increased blade number, weakened gauge protection, and enlarged hydraulic nozzles. The proposed bit utilizes the scraping, pressing, and vector push actions generated by the plugging blade during drilling to continuously force the plugging material into leakage channels, thereby improving plugging efficiency. Taking each blade as the basic load-bearing unit, the lateral cutting forces acting on individual blades were vectorially optimized so that the resultant lateral force was directed toward the plugging blade. Meanwhile, the inclination angle between the plugging blade and the borehole wall was optimized to enhance the directional extrusion and embedding capability of the plugging material. Based on this design concept, a complete personalized design methodology was established, including cutter layout optimization, cutting mechanics analysis, and numerical simulation of the flow field.The simulation results demonstrate that the proposed drill bit maintains favorable drilling performance while providing stable lateral supporting force and excellent operational stability. Laboratory drilling tests and field applications further verified its engineering feasibility and plugging performance. Field results indicate that the vector push-type PDC drill bit effectively enhances the squeeze-plugging capability, reduces lost-circulation treatment time, saves more than two drilling trips per well, shortens the overall complex-operation cycle, and significantly lowers drilling costs.

     

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