矢量推靠式堵漏防卡PDC钻头研制及应用

Development and Application of a Vector Thrust-Type Plugging and Anti-Sticking PDC Bit

  • 摘要: 川渝地区裂缝性地层钻井中井漏频发,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验证了钻头的结构,并在川渝地区多个裂缝性漏失区块进行了现场应用。切削力学分析表明,该钻头横向不平衡力系数0.039,钻进稳定性良好,流场分布有效确保堵漏材料在井底的定向运移;室内试验证实,该钻头可借助刀翼刮压作用将堵漏材料持续压入裂缝性漏失通道;现场10口井的应用显示,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%。研究结果证明,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: Circulation loss occurs frequently during drilling in fractured formations in the Sichuan-Chongqing region where plugging operations and drilling processes constrain each other. Conventional polycrystalline diamond compact (PDC) bits lack the capability of active extrusion-based plugging, which results in long plugging treatment cycles and frequent tripping operations, severely restricting drilling speed and efficiency improvement. To address this technical challenge, with “adding blades, weakening gauge protection, and enlarging nozzles” as the core design concept, a blade load vector regulation method was proposed, and a vector thrust-type plugging and anti-sticking PDC bit was developed. The bit achieved vector synthesis of lateral loads through an asymmetric blade configuration, so that the lateral thrust force acted directionally on the dedicated plugging blade. The bit structure was verified through cutter layout optimization, cutting mechanics analysis, computational fluid dynamics (CFD) numerical simulation of the bottom hole flow field, and laboratory plugging tests, and the bit was field-applied in several fractured lost-circulation blocks in the Sichuan-Chongqing area. The results showed that the lateral unbalanced force coefficient of the bit was 0.039, indicating good drilling stability, and the flow field distribution effectively ensures the directional migration of the plugging material at the well bottom. Laboratory tests confirmed that the bit could continuously press plugging materials into fractured lost-circulation channels through the scraping and pressing action of the blades. Field application in 10 wells showed that the bit achieved active plugging while drilling, reduced tripping operations by more than 2 trips per well, exhibited no sticking during tripping in gypsum and high-pressure brine layers, and maintained bit newness of more than 95% upon exit from the wells. The research demonstrates that the vector thrust-type plugging and anti-sticking PDC bit can simultaneously achieve rock-breaking drilling and plugging while drilling, effectively shortening the treatment cycle for complicated downhole conditions, and providing a new technical means for controlling severe circulation loss in fractured formations in the Sichuan-Chongqing area.

     

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