Predictive Modeling and Parameter Optimization of Cutting Forces During Orbital Drilling

To optimize cutting control parameters and provide scientific evidence for controlling cutting forces,cutting force modeling and cutting control parameter optimization are researched with one tool adopted to orbital drill holes in aluminum alloy 6061.Firstly,four cutting control parameters(tool rotation speed,tool revolution speed,axial feeding pitch and tool revolution radius)and affecting cutting forces are identified after orbital drilling kinematics analysis.Secondly,hybrid level orthogonal experiment method is utilized in modeling experiment.By nonlinear regression analysis,two quadratic prediction models for axial and radial forces are established,where the above four control parameters are used as input variables.Then,model accuracy and cutting control parameters are analyzed.Upon axial and radial forces models,two optimal combinations of cutting control parameters are obtained for processing a13mm hole,corresponding to the minimum axial force and the radial force respectively.Finally,each optimal combination is applied in verification experiment.The verification experiment results of cutting force are in good agreement with prediction model,which confirms accracy of the research method in practical production.

Parameters optimization in deepwater dual-gradient drilling based on downhole separation

To ensure safe drilling with narrow pressure margins in deepwater, a new deepwater dual-gradient drilling method based on downhole separation was designed. A laboratory experiment was conducted to verify the effectiveness of downhole separation and the feasibility of realizing dual-gradient in wellbore. The calculation of dynamic wellbore pressure during drilling was conducted. Then, an optimization model for drilling parameters was established for this drilling method, including separator position, separation efficiency, injection volume fraction, density of drilling fluid, wellhead back pressure and displacement. The optimization of drilling parameters under different control parameters and different narrow safe pressure margins is analyzed by case study. The optimization results indicate that the wellbore pressure profile can be optimized to adapt to the narrow pressure margins and achieve greater drilling depth. By using the optimization model, a smaller bottom-hole pressure difference can be obtained, which can increase the rate of penetration(ROP) and protect reservoirs. The dynamic wellbore pressure has been kept within safe pressure margins during optimization process, effectively avoiding the complicated underground situations caused by improper wellbore pressure.

An optimization method of fidelity parameters of formation fluid sampling cylinder while drilling

A design idea of fidelity sampling cylinder while drilling based on surface nitrogen precharging and supplemented by downhole pressurization was proposed, and the working mode and optimization method of sampling parameters were discussed. The nitrogen chamber in the sampling cylinder functions as an energy storage air cushion, which can supplement the pressure loss caused by temperature change in the sampling process to some extent. The downhole pressurization is to press the sample into the sample chamber as soon as possible, and further increase the pressure of sample to make up for the pressure that the nitrogen chamber cannot provide. Through the analysis of working mode of the sampling fidelity cylinder, the non-ideal gas state equation was used to deduce and calculate the optimal values of fidelity parameters such as pre-charged nitrogen pressure, downhole pressurization amount and sampling volume according to whether the bubble point pressure of the sampling fluid was known and on-site emergency sampling situation. Besides, the influences of ground temperature on fidelity parameters were analyzed, and corresponding correction methods were put forward. The research shows that the fidelity sampling cylinder while drilling can effectively improve the fidelity of the sample. When the formation fluid sample reaches the surface, it can basically ensure that the sample does not change in physical phase state and keeps the same chemical components in the underground formation.

Jet Drilling and Optimizing Parameter Drilling Technology in Shengli Oil Fields

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Analysis of effects of operating parameters on rate of penetration in drilling process with air down-the-hole hammer

Air down-the-hole(DTH)hammer drilling has long been recognized to have the potential of drilling faster than conventional rotary drill,especially in some hard rocks such as granite,sandstone,limestone,dolomite,etc.with the same weight on bit(WOB)and rotations per minute(RPM).So,it has been widely used in many drilling fields including mineral resource exploration drilling,oil and gas drilling and geothermal drilling.In order to reduce drilling cost by selecting optimal drilling parameters,rate of penetration(ROP)should be estimated accurately and the effects of different factors on ROP should be analyzed.In this research,ANN model with several multi-layer perception back propagation(BP)networks for predicting ROP of air DTH hammer drilling was developed using controllable parameters such as impact energy,impact frequency,WOB,RPM and bit operating time for the formations with a certain drillability index of rock.Several BP neural networks with the different neurons in hidden layers were developed and compared for selecting optimal architecture of ANN.The effects of the drilling parameters such as impact energy,impacting frequency,WOB,RPM and bit operating time on the ROP of air DTH hammer drilling were investigated by trained ANN.From the analyses,the optimum range of drilling parameters for providing high ROP were determined and analyzed for a formation with a certain drillability index of rock.The methodology proposed in this study can be used in many mathematical problems for optimization of drilling process with air DTH hammer.

Properties and testing of a hydraulic pulse jet and its application in offshore drilling

Offshore drilling has attracted more attention than ever before due to the increasing worldwide energy demand especially in China. High cost, long drilling cycles, and low rate of penetration （ROP） represent critical challenges for offshore drilling operations. The hydraulic pulse generator was specifically designed, based on China offshore drilling technologies and parameters, to overcome problems encountered during offshore drilling. Both laboratory and field tests were conducted to collect the characteristics of the hydraulic pulse generator. The relationships between flow rate and pressure amplitude, pressure loss and pulse frequency were obtained, which can be used to optimize operation parameters for hydraulic pulse jet drilling. Meanwhile a bottom hole assembly （BHA） for pulse jet drilling has been designed, combining the hydraulic pulse generator with the conventional BHA, positive displacement motor, and rotary steerable system （RSS） etc. Furthermore, the hydraulic pulse jet technique has been successfully applied in more than 10 offshore wells in China. The depth of the applied wells ranged from 2,000 m to 4,100 m with drilling bit diameters of 311 mm and 216 mm. The field application results showed that hydraulic pulse jet technique was feasible for various bit types and formations, and that ROP could be significantly increased, by more than 25%.

Influence of process parameters on drilling characteristics of Al 1050 sheet with thickness of 0.2 mm using pulsed Nd:YAG laser

The object of this work is to investigate the influence of process parameters on drilling characteristics of an Al 1050 sheet with a thickness of 0.2 mm using a pulsed Nd:YAG laser through numerical analyses and experiments. By comparing the numerical analyses with the experiments, a proper numerical model was obtained. From the results of the numerical analyses and the experiments, the effects of process parameters on entrance diameters of drilled holes, shapes of the holes, taper angles of the holes and temperature distributions in the vicinity of the holes were examined quantitatively. In addition, the optimal drilling condition was estimated to improve the quality of the drilled holes.

Optimization of operating parameters of seeding device in plot drill with seeding control system

Plot drill has a significant impact on field breeding by replacing manual seeding.However,the seeding performance of plot drill needs to be further improved as the mechanical transmission method cannot work under the optimal combination of operating parameters.In this study,a cone compartment tray of sowing device was evaluated under the laboratory conditions,using a self-designed seeding control system to adjust the operating parameters.Among them,a plot seeding control system was involved that could set operating parameters through an Android terminal,which effectively reduced the difficulty of parameters adjustment.The method of central composite experiment design was employed to conduct experiments and explore the effects of experiment factors such as lifting height of storage tube(LHST),rotation speed of cone compartment tray(RSCCT),and rotation speed seed distributor(RSSD)on the seeding uniformity coefficient of variation among rows(SUCVR)and the rate of damaged seeds(RDS).For SUCVR of wheat,the results showed that the importance order of main factors from high to low was RSSD,RSCCT and LHST.And for SUCVR of buckwheat,RSCCT had the largest influence,followed by RSSD,and LHST had the smallest influence.For RDS of wheat and buckwheat,only RSSD had a very significant effect among the main factors.The experiments data of wheat indicated that when operated at 27.2 mm for LHST,4.5 r/min for RSCCT and 1169 r/min for RSSD,the sowing performance of wheat was optimal,with SUCVR and RDS values of 5.02%and 0.117%,respectively.The buckwheat seeding performance was found to be optimal when the LHST,RSCCT and RSSD were 26.5 mm,3.9 r/min and 711 r/min,and SUCVR and RDS were 4.74%and 0.113%.The seeding control system realized the electromechanical control of the seeding equipment,was convenient for parameter setting and stepless adjustment,and could be operated under an optimized combination of operating parameters.The research results could provide a reference for the performance improvement and application of plot drill.

超深井钻柱动态疲劳失效特征及参数优选

随着油气勘探深度不断增大,超深井钻柱井下振动更加复杂,应力状态随时间变化显著,为保障超深井钻柱的安全性,开展了受空间挠曲井筒约束超细长钻柱的动态疲劳失效特征研究,并进行钻柱结构及工作参数优选。基于实际井眼轨迹,考虑钻柱与井壁的碰撞特征,通过有限元仿真分析,得到全井钻柱动力学特性;根据疲劳损伤累积理论,研究了超深井全井钻柱在非对称循环变幅应力状态下的疲劳强度;结合现场实例,研究了超深井钻柱的危险截面,分析了钻柱疲劳强度随转速、钻压和稳定器安装位置的变化规律。研究表明:钻压和高转速对钻柱疲劳强度的影响较大,低转速对钻柱疲劳强度的影响较小;稳定器可以大幅降低底部钻具组合疲劳失效的概率,而且稳定器安装位置对钻柱疲劳强度的影响较为显著。研究结果为超深井钻柱组合结构参数和钻井参数优选提供了理论依据。

晒旗河磷矿掘进巷道工作面钻孔卸压参数优化

岩爆是困扰晒旗河磷矿安全开采的主要技术难题,该矿钻孔卸压参数与围岩应力分布不匹配,卸压效果有待提高。以该矿+80 m工作面为研究对象,采用数值模拟对掘进巷道工作面不同钻孔卸压参数下巷道围岩的应力和弹性能变化情况进行分析,探寻最优的卸压钻孔参数方案。引入谷-陶岩爆判据,计算最大主应力和单轴抗压强度的比值,评价卸压钻孔参数优化前后的岩爆等级,验证钻孔卸压效果。研究结果表明:随着钻孔深度的增加,巷道围岩应力先减小后增大,当钻孔深度为10 m时,围岩应力和弹性能最小;在保持钻孔数量不变的情况下,钻孔间距过小,钻孔周围形成的卸压区域重叠,整体卸压范围受限,钻孔间距过大,每个钻孔间形成的卸压区域无法起到协同卸压作用。卸压钻孔参数优化后最大主应力下降了14 MPa,岩爆风险等级由中等岩爆降为无岩爆。研究结果可为鄂西地区类似矿山卸压钻孔参数的选用提供参考。

塔东区块庆玉1井超深井优快钻井技术

随着油气勘探开发逐步从深层向超深层领域推进,塔东区块储层埋藏深,井下温度高、地质条件异常复杂,使得钻速慢、钻井周期长和钻井风险高。庆玉1井是大庆钻探工程公司在该区块钻的最深的井,为打好打成该井,开展施工难度因素分析,制定技术措施,应用高温仪器、工具、钻井液,施工参数优化等方法,研发超深井配套工艺技术,并结合现场施工要求,实现了塔东区块超深井庆玉1井的优快安全钻井。结果表明:该技术具有安全高效的优点,为深层、超深层油气的经济有效开发提供有效工程技术手段。

基于WOA-BP算法的氟金云母钻削工艺参数优化

通过氟金云母陶瓷钻削实验,测试了在不同加工参数下的材料去除量和刀具磨损量。利用WOA算法优化BP神经网络,并基于单因素实验值和WOA-BP网络预测值,利用最小二乘法拟合,建立了材料去除率和刀具磨损率关于工艺参数的一元模型,以相关系数检验了模型的精确度。在一元模型的基础上提出了多元模型,基于正交实验值和WOA算法对多元模型进行求解,模型误差在合理范围内。以材料去除率最大和刀具磨损率最小为优化目标,基于WOA算法进行了工艺参数双目标优化,得到了一组最优参数。基于最优工艺参数进行验证实验,实验结果表明得到的最优参数是合理的。

煤矿井下钻进速度影响因素及其智能预测方法研究

在煤矿井下钻探领域,钻进速度(DR)是评估钻探作业最有效的指标之一,钻速预测是实现煤矿钻进智能化的前提条件,对于优化钻机钻进参数、降低作业成本、实现安全高效钻探具有重要意义。为此,提出煤矿井下钻进速度影响因素及其智能预测方法研究,探索基于钻压、转速、扭矩以及钻进深度等少量钻机参数采用机器学习算法实现钻进速度精准预测。首先通过实验室微钻试验,深入分析煤岩力学性能、钻压、转速和钻进深度对扭矩、钻进速度影响规律。研究结果显示,在煤矿井下钻进过程中,随着钻进压力增大,钻进速度呈逐渐升高趋势,在较高的转速条件下钻进压力对钻进速度影响更加明显,转速增加有利于提高钻进速度,但转速对硬度较低的煤层钻进速度影响更为显著;然后,根据煤矿井下防冲钻孔现场数据,采用K–近邻(KNN)、支持向量回归(SVR)和随机森林回归(RFR)3种不同的机器学习算法建立钻进速度预测模型,并结合粒子群算法(PSO)对3种模型超参数进行优化,最后对比分析PSO–KNN,PSO–SVR和PSO–RFR三种钻进速度预测模型预测结果。研究结果表明,PSO–RFR模型准确性最好,决定系数R2高达0.963,均方误差MSE仅有29.742,而PSO–SVR模型鲁棒性最好,在对抗攻击后评价指标变化率最小。本文研究有助于实现煤矿井下钻进速度的精准预测,为煤矿井下智能钻进参数优化提供理论支撑。

大位移井岩屑床厚度预测模型与现场应用:以CH1-1-XX井钻井为例

大位移井钻井过程中,岩屑极易在斜井段及水平段环空底部积聚成床,导致憋泵、卡钻等事故,严重影响钻井施工安全和钻井时效。现有的岩屑运移及岩屑床清除模型均针对标准圆球状岩屑,与实钻中返出的岩屑形状差异较大,导致模型应用范围受限,无法提供更准确的现场指导。为探究大位移井非标准圆球状岩屑运移规律,通过可视化岩屑运移实验与计算流体动力学(computational fluid dynamics,CFD)数值模拟结合的方法,建立了一套大位移井岩屑床厚度预测经验模型,并在CH1-1-XX井开展了现场应用,对不同开次下的钻进参数进行了优化,取得了良好效果。结果表明:利用模型预测岩屑床厚度并进行钻进工艺参数优化后,一开与二开钻井时最高岩屑床厚度分别为40.6 mm和33.9 mm,均低于同井深处的岩屑床厚度安全线,表明井眼清洁程度高,无憋卡风险。建立的岩屑床厚度预测经验模型对提高大位移井井眼净化效率,保障大位移井安全高效钻进具有重要意义。

李村煤矿顶板定向长钻孔瓦斯抽采参数优化研究

针对高抽巷工程量大、成本高、影响采掘接替等问题,分析了顶板定向长钻孔的合理布置范围、抽采机理及关键影响因素,并根据正交实验和方差分析确定了抽采效果敏感性指标。在李村煤矿1305工作面进行了顶板定向长钻孔代替高抽巷的试验,试验结果表明:顶板定向长钻孔达到了高抽巷瓦斯抽采的效果,将上隅角瓦斯浓度控制在安全范围内,且其施工进度快,成本低,有效解决了李村矿采掘接替紧张的局面。

非爆破机械钻进联合静力膨胀裂切技术应用研究

采用钻爆法进行非煤矿山巷道掘进的过程中,往往会产生诸多安全隐患。随着机械装备的快速发展,非爆破机械采矿逐渐成为非煤矿山开采的主流研究方向。为解决某矿山下向进路充填采矿时,首采层采场回采难度大、回采周期长、支护难度高和作业安全性差等问题,提出非爆破机械钻进联合静力膨胀裂切的技术思路。首先,通过数值模拟的方式进行机械钻进静态裂切孔网参数优化,确定裂切孔网方案,然后进行现场试验检验技术效果。结果表明,非爆破机械钻进联合静力膨胀裂切技术应用良好,能够切实解决矿山面临的生产难题。

苏75区块小井眼钻完井技术

随着新环保法的实施,苏里格地区钻井全面实施“泥浆不落地”技术,而小井眼钻井技术是减少钻井液的用量、减少废弃物、降低入井钢材费用和减少固井成本的有效途径。针对苏里格气田小井眼水平井钻进过程中的岩石可钻性差、造斜点选择难度大、水平段轨迹复杂、地质复杂造成的井下安全等问题,开展了井身结构优化、小井眼轨迹优化与控制、钻头优选及水力参数优化、钻井液体系优选及性能参数优化研究。结论认为:①在加强安全钻井配套措施的基础上,优化后的井身结构更具经济性及合理性;②低固相钻井液体系抗温稳定性强,具有良好的抑制岩心分散的能力,能够有效防止黏附卡钻的发生,且成本低、封堵效果较好;③针对各个地层岩性特征优选的高效PDC钻头,优化水力参数性能,能够有效提高机械钻速,确保砂体钻遇率达到95%以上。

甩干机分离水基钻井岩屑的数值模拟研究及参数优化

为分析水基钻井岩屑固相颗粒在甩干机中的运移机理,并研究甩干机关键参数对处理量和分离效率的影响,采用FLUENT对水基钻井岩屑的分离进行数值模拟研究。研究结果表明,固体颗粒粒径越大,甩干机分离效率越高,在处理200 μm固相颗粒时有较好的处理效果。优选筛网尺寸为0.50 mm、甩干机转速差为7~10 rpm、泥浆密度范围为1840~1920 kg/m^(3)。

探管式智能钻头参数测量装置研制与现场试验

现有螺杆上游的测量装置无法获得钻头位置处的真实数据,智能钻井在决策控制层面存在严重的数据偏见与不可预测的实施风险。为此,研制了一种探管式智能钻头参数测量装置,可以安装在钻头内部,在不改变现有钻具组合与施工工艺的前提下直接采集钻头处的真实数据;硬件结构仿真优化结果表明,30 L/s排量与80 MPa环空压力下,理论水力压耗小于0.1 MPa、安全系数为3.06。同时,基于六面法与ARMA+移动Kalman滤波,实现了该装置的误差标定与降噪。该装置在胜利工区现场试验9井次,配套井下工程参数测量短节进行了装置功能验证与井下数据对比,融合综合录井数据进行了试验井提速分析与参数优化决策。试验结果表明,探管式智能钻头参数测量装置能够获取钻头位置处的真实数据,能够为针对性提速提效分析与钻井参数优化提供可靠依据。

五虎山煤矿水力造穴增透物理模拟及钻孔优化设计

针对五虎山煤矿煤层透气性差、瓦斯吸附性强导致钻孔抽采效果差、抽采率低的问题,采用物理模拟和现场试验的方法,数值模拟水力造穴前后钻孔参数的变化特征,进而优化出适合该矿的瓦斯抽采钻孔布置方式。结果表明:五虎山煤矿011006工作面在符合矿上生产接续的情况下,水力造穴的最优钻孔造穴直径为0.5 m,合理布设间距为4 m;采用水力造穴工艺时瓦斯抽采体积分数平均为70.4%,达普通钻孔平均体积分数的3.8倍,抽采纯量是普通钻孔的3.5倍;采用水力造穴优化参数与普通钻孔间隔布置方式,可有效激活间隔的普通钻孔;通过对比钻孔施工卸压增透效果、瓦斯抽采效率、煤体扰动面积、体积及钻孔成孔率等评价指标,在相同面积模块下,采用间隔布设钻孔的模块2瓦斯抽采纯量达到模块1的1.8倍。