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1、上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Motor -1 1、前言上海奥森油田服务为渤海石油天津钻井部提供螺杆钻具设备服务，与此同时联同各油田、科研院所，在消化国内外先进技术，结合我国国情的基础上，开发和制造出多种型号的螺杆钻具，能为油田提供满意服务。本手册主要介绍螺杆钻具的性能和使用要求以及注意事项，便于用户更好地了解我公司的钻具，结合钻井的需要，选好、用好、维护好钻具，发挥其应有的技术性能，提高钻井经济效益。2螺杆钻具工作原理螺杆钻具是以泥浆为动力的一种井下动力钻具。泥浆泵泵出的泥浆液流经旁通阀进入马达，在马达进出口处形成一
2、定压差推动马达的转子旋转，并将扭矩和转速通过万向轴和传动轴传递给钻头。螺杆钻具的性能主要取决于螺杆马达的性能参数。3螺杆钻具的组成螺杆钻具由旁通阀、马达、万向轴和传动轴四大总成组成如图11、Introduction Shanghai Ocean Oilfield Service Co supplied Downhole Motor to Drilling Department of Bohai Offshore Oil Company LTD.(Tianjin), on base of mastering foreign and domestic advanced technology and
3、 linking China national situation, has developed and manufactured some types of screw drills in cooperation with oilfields and scientific research institutes. With them, we may provide satisfactory services to the oilfields. This manual mainly introduces screw drill property, application and caution
4、s, so as for the customers to know well our screw drills, and to do better selection, application, repair and maintenance of screw drill according to drilling demand. As a result, our screw drill may bring into play in its reliable technical function, to enhance drilling economic efficiency. 2、Princ
5、iple Screw drill is a kind of downhole dynamic drilling tool upon the power of drilling mud. Mud stream from the outlet of mud pump flows through a by-pass valve into the motor. This stream produces pressure loss at both inlet and outlet of the pump, to push the rotor into rotating, and to transmit
6、the torque and speed onto the bit. The screw drill property mainly depends upon its property parameters 3、Constitution Screw drill is composed of four assemblies of by-pass valve, motor, cardan 精选学习资料 - - - - - - - - - 名师归纳总结 - - - - - - -第 1 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downh
7、ole Motor -2 31 旁通阀总成它有旁通和关闭两个位置如图2 ，在起下钻作业过程中处于旁通位置，使钻柱中泥浆循环绕过不工作马达进入环空，这样起下钻时泥浆不溢于井台上。当泥浆流量和压力到达标准设定值时，阀芯下移，关闭旁通阀孔，此时泥浆流经马达，把压力能转变成机械能。当泥浆流量值过小或停泵时，所产生的压力不足以克服弹簧力和静摩擦力时，弹簧把阀芯顶起，旁通阀孔又处于开启位置。32 马达总成它由定子和转子组成。定子是在钢管内壁上压注橡胶衬套而成。橡胶内孔是具有一定几何参数的螺旋。转子是一根有镀铬硬层的螺杆。转子与定子相互啮合，是用两者的导程差而形成的螺旋密封线，同时形成密封腔。随着转子在定子
8、中的转动，密封腔沿着轴向移动，不断的生成与消失，完成其能量转换，这就是螺杆马达的基本工作原理。马达转子的螺旋线有单头和多头之分定子的螺旋线头数比转子多1 。转子的头数越少，转速越高，扭矩越小; 头数越多，转速越低，扭矩越大。图 3 是几种典型马达配合的截面轮廊：3.1 By-pass Valve Assembly It has two positions of by-pass and close (Fig.2). It is in by-pass position during trip operation, circulates mud fluid in the drill string i
9、nto the annular space by-passing the idle motor, so that no mud may spray out onto the platform during the trip operation. When mud flow rate and pressure reach the setting value, the valve stem moves down and closes the valve. Meanwhile, mud stream flows through the motor, and converts the pressure
10、 energy into mechanical energy. As mud flow rate is too low, or mud pump stops, and as the created pressure is not enough to overcome spring force and static friction force, the spring presses the stem upward ,and by-pass is in open position. 3.2 Motor Assembly It consists of stator and rotor. Stato
11、r is made by squeezing rubber sleeve on the wall of steel tube. There forms spiral structure with a certain geometric parameter. Rotor is a crome-plated screw rod. Stator and rotor matches with each other, to form spiral line and seal cavity through their guide rail difference. With rotor running in
12、 the stator, the seal cavity is moving along its axial direction, continuously forms and disappears ,to complete its energy conversion. This is the basic principle of screw drill. motorSpiral seal line on rotor is divided into single end and multi-end ( stator with one more end than rotor). The less
13、 ends the motor has, the higher speed and the lower torque is. The more ends it has, the lower speed and the higher torque is. Fig.3 shows the sectional profile of several typical motors. 精选学习资料 - - - - - - - - - 名师归纳总结 - - - - - - -第 2 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Mo
14、tor -3 Mpa,最大压降为额定工作压力的 1.3 倍，如四级马达， 额定压降 应 为3.2Mpa, 最 大 压 降 为4.2Mpa。压降超过此值马达就会产生泄漏，转速很快下降，严重时会完全停止转动，甚至造成马达损坏，用户应特别注意。为了确保马达的密封效果，转子与定子之间的配合尺寸与不同井深的温度有关,因此在选择钻具时应尽可能准确地提供应厂家钻具应用场所的井温情况，以便推荐使用松紧配合状态适合的马达。现场使用的泥浆流量应在推荐的范围之内 ,否则将影响马达效率，甚至马达磨损加快。马达的输出扭矩与马达的压降成正比，输出转速与输入泥浆量成正比，随着负载的增加，钻具的转速有所降低，因此在地面只要根
15、据压力表控制压力，根据流量计控制泵的流量，就可以控制井下钻具的扭矩和转速。32 1 中空转子马达为了增加钻头的水马力和泥浆的上返速度，将转子加工成为带喷咀的中空转子。此马达的总流量应等于流经马达密封腔流量和流经转子喷咀流量的总和，每种规格的马达都有其推荐的最大和最小流量值。如果流量过大，转子会超速运转，定子和转子会出现提前损坏，如果流量过小，马达将停止转动。因此在选择转子喷咀尺寸时，应确保马达密封腔流量始终保持或高于最小推荐流量值，这样才能使马达正常运转。A guide rail forms a seal cavity in motor stator. This is called one s
16、tage. When the rated working pressure of each stage lows down to 0.8 Mpa, the maximum pressure loss will be 1.3 times of the rated pressure. For an example, for 4-stage motor, the rated pressure loss shall be 3.2 Mpa, maximum pressure loss shall be 4.2 Mpa. As the pressure loss is over such value, m
17、otor may bring about leakage and speed will quickly slow down. More seriously, it may cause operation into complete stop, even cause the motor to be damaged. This is the caution for the customers. In order to ensure rotor seal in good condition, the matching size between rotor and stator relates clo
18、sely to depth temperature. Therefore, correct downhole temperature shall be provided to the manufacturer for reliable selection of appropriate motor. The actual mud flow rate is required in the recommended range. Otherwise incorrect flow rate may affect the motor efficiency, even cause speeding up m
19、otor wear. Motor torque is proportional to its pressure loss, but its outlet speed is inversely proportional to mud flow rate. With load increasing, screw drill speed decreases. Thus, pressure shall be controlled by the pressure gauge and flow rate shall be controlled by the flow rate gauge on surfa
20、ce. This way may control both torque and speed of downhole screw drill. 3 21 Hollow Rotor Motor To increase hydraulic horsepower and upward speed of mud stream, rotor is manufactured into hollow rotor with nozzles. Thus, motor total flow rate is equal to the sum of the flow rate through seal cavity
21、and rotor. Each type of motor has its own recommended maximum and minimum flow rate value. If flow rate is too high, rotor may be running at over speed, earlier damage would occur onto stator and rotor. If it is too low, motor will stop operating. Therefore, the flow rate through seal cavity shall b
22、e ensured or even higher than the recommended maintenance value ,while selecting nozzle size. Only in this way, can motor be kept in normal operation. 精选学习资料 - - - - - - - - - 名师归纳总结 - - - - - - -第 3 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Motor -4 在泥浆密度、喷咀尺寸和马达流量为定量时，流经转子喷咀的流量和
23、流经马达密封腔的流量总是随负载变化而变化的。钻头离开井底，马达负载近似为零，此时流经转子喷咀流量最小，而流经马达密封腔的流量最大。钻头钻进，使马达压差不断增加，使流经转子喷咀流量增加，而此时流经马达密封腔流量减少。流经马达密封腔的流量为Qm， 通过马达喷咀的流量Qz。即：总流量Q=Qm+Qz 设定马达转速n 值计算 Qm 值)/(60sLnqQM容积效率v 取Qz = Q Qm (L/s) 喷咀直径)(898422mmPpdQQm- 马达密封腔流量(L/s) Qz-转子喷咀的流量(L/s) Q-中空转子马达的总流量(L/s) v -容积效率马达压降P = Pst + Pop ? Pst马达启动
24、压降(Mpa) ? Pop马达工作压降(Mpa) 泥浆比重(kg/L) 计算公式中q 为中空转子马达的每转排量(L/r) 其数值参见表1。When mud density, nozzle size and total flow rate is a constant value, the flow rate through nozzle and seal cavity always changes with the load. On bit leaving hole bottom ,the load is approximately zero . Whereas, the flow rate b
25、ecomes minimum through nozzle on the rotor, but the flow rate becomes maximum through the seal cavity. While the bit dropping down, motor pressure loss will continuously increase, and the flow rate through rotor nozzle will become higher, but the flow rate through the seal cavity will become lower.
26、Flow rate through seal cavity is Qm, Flow rate through nozzle is Qz. Then ,total flow rate Q = Qm + Qz Suppose motor speed n, calculate Qm Volumetric efficiency )/(60sLnqQMSo Qz = Q Qm (L/s) Nozzle diameter )(898422mmPpdQQm-Flow rate of motor seal cavity (L/s) Qz-Flow rate of rotor nozzle(L/s) Q-Tot
27、al flow rate of motor with hollow rotor (L/s) v -V olumetric efficiency Motor pressure loss P = Pst + Pop ?PstMotor start pressure loss (Mpa) ?PopMotor operating pressure loss (Mpa) Mud density (kg/L) In the equation, q is flow rate of hollow rotor motor (L/r) For the parameters, see table-1 精选学习资料
28、- - - - - - - - - 名师归纳总结 - - - - - - -第 4 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Motor -5 表 1 Table 1 5LZ165X7.0Y BH 5LZ165X14.0 BH 5LZ197X7.0Y BH 5LZ197X14.0 BH 5LZ120X7.0Y BH 5LZ95X7.0Y BH 按以上推荐计算公式，用户可以根据使用需要随时更换不同直径的喷咀，从而到达理想的效果。Based on the above recommended equation, the
29、customers can timely change different diameter nozzles according to the actual demand, so as to reach ideal effect. 精选学习资料 - - - - - - - - - 名师归纳总结 - - - - - - -第 5 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Motor -6 33 万向轴总成万向轴的作用是将马达的行星运动转变为传动轴的定轴转动，将马达产生的扭矩及转速传递给传动轴至钻头。万向轴大多采用瓣形
30、，也有采用挠轴形式的。渤海启明钻具的瓣型万向轴采用线切割技术制成，切口平行度高，粗糙度可达且不破坏金属化学成分，因此使用寿命高、机械损失小如图4 。钻具使用后，应立即拆卸，检查万向轴，如磨损量超过维修标准，应及时更换有关易损件，否则会因万向轴的使用过度致使钻具无法正常工作。34 传动轴总成传动轴的作用是将马达的旋转动力传递给钻头，同时承受钻压所产生的轴向和径向负荷。我公司制造的钻具传动轴总成有两种结构：（1）钻头水眼压降为7.0Mpa，采用硬质合金径向轴承和中间有一组推力轴承的传动轴总成如图 5 ；（2）钻头水眼压降为14.0Mpa，采用硬质合金径向轴承和金刚石复合片 PDC的平面止推轴承，
31、其寿命更长、 承载能力更高。3.3 Cardan Shaft The function of cardan shaft is to convert planetary motion into fixed constant rotation of drive shaft, to transmit torque and speed from motor on the drive shaft ,and to the bit. Cardan shaft mostly use flat shaft ,but some are flexible shafts .Our flat type shaft us
32、ed on our screw drill is made by linear cutting technology. So the cut has high parallelism ,roughness can reachAnd it doesn t damage metal chemical composition. Thus, it has longer running life and less mechanical loss (Fig.4). Screw drill shall be disassemblied as quickly as possible after use to
33、examine cardan shaft. If it is found out that wear degree is over maintenance standard, relevant consumable components shall be changed promptly. If it is not, screw drill can not be running normally due to over run time of cardan shaft. 3.4 Drive Shaft Assembly Drive shaft is to transmit motor rota
34、ry dynamic force onto the bit, meanwhile to withstand axial and radial load from drilling weight. We have two types of drive shafts, as follows: 1)Bit nozzle pressure loss is 7.0 Mpa, using hard alloy radial bearing and drive shaft assembly with thrust bearings (Fig.5); 2)Bit nozzle pressure loss is
35、 14.0 Mpa, using hard alloy radial bearing and PDC cutter flat thrust bearing. It has longer lasting life and higher bearing capacity. 精选学习资料 - - - - - - - - - 名师归纳总结 - - - - - - -第 6 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Motor -7 4螺杆钻具型号说明4. Model Number例： 5 表示为转子头数与定子头数比为 56
36、 的、外径为165mm 螺杆钻具，钻头水眼压降为7.0Mpa。BH( 渤海 )。5使用须知51 井场钻井技术人员和司钻必须了解钻具的结构原理和使用参数。按使用手册的要求合理使用钻具。52 根据整个井眼的钻井作业计划，由钻井工程师根据任务结合地层结构、井眼孔径、深度、机械转速选定所用钻头与钻具型号，决定水眼直径和钻具组合。现场施工必须严格按制定的钻井作业计划执行。53 对钻井液的要求：螺杆钻具的马达为容积式，决定钻具性能的因素是马达的输入流量和作用于两端的压力降，而不是钻井液的类型。钻井液的物理化学性能除个别有损钻具寿命外，一般不影响钻具性能，应注意考虑钻井It expresses: Ratio
37、 of the number of rotor ends and the number of stator ends is 5:6;O.D of Screw drill is 165mm; Bit nozzle pressure loss is 7.0 Mpa; BH is Bo Hai 5. Application Notices 5.1 Site drilling technical persons and drillers shall know well screw drill structure principle and technical parameters, correctly
38、 apply screw drill in accordance with requirements specified in this manual. 5.2 Drilling engineer shall make operation program upon the whole hole, and select the model of screw drill and bit to be used , determine nozzle size and screw drill combination according to formation edge structure, hole
39、size, depth and mechanical speed . The determined drilling program shall be strictly carried out accordingly on the location. 5.3 Drilling Fluid Requirement: Screw drill motor shall be volumetric. The key factor to screw drill property is motor inlet flow rate, and the pressure loss functioning onto
40、 both ends. But it is not the kind of drilling fluid. Physical and chemical property of drilling fluid, except the individual damage to screw drill running life, normally does not affect its 精选学习资料 - - - - - - - - - 名师归纳总结 - - - - - - -第 7 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole
41、 Motor -8 工艺的需要。但钻井液所含的各种硬颗粒必须予以限制，因为它会加速轴承、马达的磨损而降低钻具的使用寿命，建议固相含砂量不超过1%事实证明：假设含砂量到达5% ，钻具寿命会降低50% 。同时注意钻井液中不要混有各种气体，因为混有气体的钻井液在钻具中压力的变化下容易产生“气蚀作用”，加速钻具的损坏，尤其是定子橡胶更容易被气蚀坏，必须予以足够的重视。54 使用钻头的选择：与螺杆钻具一起使用的钻头在选择上是十分重要的问题。因此螺杆钻具是否能成功的发挥作用的几个因素中，钻头与钻具的匹配是最重要的，希望能引起现场使用人员的重视。选择钻头与螺杆钻具配套使用的因素应是：（1） 钻井方案及计划；
42、（2） 针对地层需要的刃部结构；（3） 钻井液流通通道的结构；（4） 预先计划的机械钻速；（5） 使用该钻头，钻具运转的时间估算：（6）钻头水眼压降的设计。什么样的地层结构、地层软硬、使用哪类钻头、用什么样的刃部设计，请参考有关钻头的专业资料，这里仅就使用螺杆钻具完成各种钻井作业，对钻头的选择作些简要说明。A：除了钻头水眼造成的压降外，要使钻井液流经钻头底部时别再形成其他较大的压力损失，尤其是钻头水眼压降已到达该型号钻具规定的压降值时更应注意。这对牙轮钻头不必担忧，但是PDC钻头冠部液体通道的设计，就必须考虑通道过流面积是否可能造成额外过多的压力损失问题，同时并能保证岩屑及时排出及钻头冷却需要
43、。B：牙轮钻头： 这类钻头在螺杆钻具配合使用时，更实用于钻井周期不长的作业，如定向造斜、侧钻等。This shall be considered for the need of drilling process. However, the content of hard grains in mud stream must be limited since they can speed up wear of bearing and motor, may cause shortening screw drill running life. It is suggested that solid sa
44、nd content should not be over 1%( actually when sand content is 5%, running life will be reduced by 50%). Also, take care, not let drilling fluid mixed with any gas , because the fluid with gas may easily cause “ Gas Erosion” . It may speed up tool damage with change of pressure. In particular, the
45、rubber on stator is more easily damaged by gas erosion. Enough attention shall be paid to this problem. 5.4 Bit Selection: For bit selection, it is important to combine and match screw drill to be used. It relates to success of screw drill application. It is advised site operators shall take care of
46、 this matter. Application factors to combine bit with screw drill are as follows: (1) Drilling Plan and Program; (2) Formation Edge Structure; (3) Structure of Mud Flowing Channels; (4) Determined Mechanical Drilling Speed; (5) Estimation of Bit and Screw Drill Running Life; (6) Design of Bit Nozzle
47、 Pressure Loss Please refer relevant professional information for detail bit selection on formation structure. Hereby it briefly describes bit selection for performance of drilling operation with screw drill. A: Except bit nozzle pressure loss, in order to avoid producing higher pressure loss while
48、drilling fluid flowing through bit bottom, attention shall be specially paid to this matter when the nozzle pressure loss has reached the specified loss value of this kind drilling tool. This does not affect rock bit, but for the crown passage design of PDC bit. The problem shall be considered that
49、passing fluid area may cause much extra loss, meanwhile to ensure prompt discharge of cuttings and bit cooling. B: Rock Bit : When this kind of bit is used with screw drill it is more appropriate to shorter drilling period, such as directional deflection and re-entry etc. 精选学习资料 - - - - - - - - - 名师
50、归纳总结 - - - - - - -第 8 页，共 21 页上海奥森油田服务Shanghai Ocean Oilfield Service Co. Downhole Motor -9 C：PDC 钻头： PDC 钻头不仅适用于定向造斜，更适用于钻井周期较长的作业，如打直井等。在较长周期的钻井作业中，最重要的因素就是钻头与钻具作为一个整体，不要由于其中的哪一部分出了问题，而造成不必要的起下钻。大家已熟知：复合片钻头较牙轮钻头寿命长，而且结构是整体的，具有很多优点。D：提高钻具和钻头的使用寿命，也是一个重要因素。改善传动轴的稳定性，例如加稳定器，对提高钻具寿命发挥钻头性能是有帮助的。考虑钻头金刚石