Rotary steerable drilling system test matching system

Abstract

A rotary steerable drilling system test matching system, the test matching system mainly comprises a rotary drilling system, a wellbore system, a stratum simulation system and a coiled tubing; wherein the rotary drilling system applies drilling pressure and provides rotary torque to the test system during the test; the wellbore system and the coiled tubing are structures simulating a wellbore; the stratum simulation system simulates a stratum rock structure; the rotary drilling system is connected with the wellbore system through a positioner on the rotary drilling system and a flange plate of a wellhead wellbore to form an integrated body; a terminal port of the wellbore system is connected with a flange of the stratum simulation system; an outlet of a mud pump is communicated with the coiled tubing; and an outlet of the coiled tubing is communicated with a central pipe of the rotary drilling system through a high-pressure manifold. The application simulates oilfield drilling conditions through a rotary drilling stratum simulation system process, verifies the flow, pressure drop, applied drilling pressure and borne torque of the rotary steerable tool under different rotating speeds through a simulation test, and establishes the relationship among them, thereby providing technical support for developing the rotary steerable tool.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of oil and gas drilling, in particular to a laboratory ground simulation test device for rotary steering products in the oil and gas drilling industry. BACKGROUND

[0002] With the needs of special oil wells such as ultra-deep wells, high-difficulty directional wells, horizontal wells, large displacement wells and horizontal branch wells in the development of special reservoirs in domestic oilfields, the research on rotary steering drilling technology is becoming more and more intense. In order to research and develop rotary steering technology products, a reliable ground simulation test device is one of the necessary conditions. The ground simulation test before going down the well is used to verify and detect the function principle of the rotary steering tool, the steering force and the steering effect, and to examine the reliability of the tool product. Foreign rotary steering tool products are expensive. In order to realize the localization of rotary tools and reduce the drilling cost, oil and gas fields accelerate the research and development of rotary steering tool products. At present, the domestic rotary steering tool product ground simulation system test capability is insufficient, which seriously restricts the localization process of domestic rotary tools. SUMMARY

[0003] In view of this situation, the present application discloses a rotary steering drilling system test matching system, which is committed to solve the need for ground simulation test of rotary steering products and improve the test capability of the rotary steering drilling system test system as a whole. The industry problem of restricting the localization process of rotary tools due to insufficient test system capability is solved.

[0004] The technical scheme adopted by the present application is:

[0005] A rotary steering drilling system test matching system, which mainly comprises a rotary drilling system, a wellbore system, a formation simulation system and a coiled tubing. The rotary drilling system applies drilling pressure and provides rotary torque to the test system during the test. The wellbore system and the coiled tubing are structures simulating the wellbore. The formation simulation system simulates the structure of the formation rock. The rotary drilling system and the wellbore system are connected through the positioner on the rotary drilling system and the flange of the wellhead wellbore to form an integral whole. The end port of the wellbore system is connected with the flange of the formation simulation system, the outlet of the mud pump is communicated with the coiled tubing, and the outlet of the coiled tubing is communicated with the central pipe of the rotary drilling system through the high-pressure manifold.

[0006] The rotary drilling system mainly comprises a motor, a hydraulic cylinder, a guide rod, a moving seat, a central pipe, a fixed seat and a positioner; one end of the central pipe is connected with the motor, the other end is connected with a drill pipe, and the whole is installed on the moving seat; the guide rod is installed on both sides of the fixed seat and is in sliding fit with the moving seat, the upper and lower ends of the guide rod are respectively installed with an upper limit switch and a lower limit switch to limit the stroke of the moving seat; the hydraulic cylinder body is installed on the moving seat, and the piston end is installed on the fixed seat; a plurality of drill pipes are connected through drill pipe threaded fasteners to form a drill string, the front end of the drill pipe is connected with a rotary steering tool through a threaded fastener, and the front end of the rotary steering tool is connected with a drill bit through a threaded fastener.

[0007] The wellbore system mainly comprises a wellhead wellbore, an inclined straight section wellbore, a curved section wellbore and a horizontal section wellbore which are arranged from high to low and are tangentially and sealingly connected, and are supported by a wellbore support, and a discharge port is arranged at the end of the horizontal section wellbore, and a wellbore flange is arranged at the end port of the horizontal section wellbore.

[0008] The formation simulation system is composed of a plurality of identical modules made of cement and gravel in a certain proportion, and a pre-embedded flange and a plurality of wellheads are arranged on the head module.

[0009] The coiled tubing is provided in a plurality of groups, and each group is switched on or off by a stop valve.

[0010] The test matching system comprises a purification circulation system, which is connected to the end of the wellbore system through a perfusion pump and a mud pump, the outlet of the mud pump is communicated with the coiled tubing, and the outlet of the coiled tubing is communicated with the central pipe of the rotary drilling system through a high-pressure manifold.

[0011] The purification circulation system mainly comprises a settling tank, a vibrating screen and a circulating tank; the vibrating screen is installed above the settling tank, the settling tank and the circulating tank are arranged adjacently, and a baffle is arranged therebetween; the discharge port of the horizontal section wellbore of the wellbore system is communicated with the vibrating screen through a hose; the central pipe and the drill pipe adopt a hollow structure, and the drilling fluid can flow through the middle part; the outer surfaces of the drill string formed by the drill pipes connected with each other, the rotary steering tool and the drill bit are communicated with the inner surfaces of the formation simulation system and the wellbore system to form an annulus, and the high-pressure drilling fluid enters the drill pipe from the central pipe, passes through the rotary steering tool and the drill bit, and then flows out from the discharge port arranged on the wellbore system through the annulus and enters the vibrating screen.

[0012] This invention simulates oilfield drilling conditions using a rotary drilling formation simulation system. Through simulation experiments, it verifies the flow rate, pressure drop, applied drilling pressure, and torque under different rotational speeds of the rotary steerable tool (SWP), establishing the relationships between these parameters. This provides technical support for the development of SWPs and can also be used to evaluate their quality. The entire experimental process measures the pressure drop and flow rate range of the SWP, providing technical basis for product development and quality assessment. It aims to address the need for ground simulation testing of SWP products and comprehensively improve the testing capabilities of rotary steerable drilling system testing systems. This solves the industry problem of insufficient testing system capabilities hindering the localization of rotary tools. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the present invention;

[0014] Figure 2 This is a schematic diagram of the rotary drilling system of the present invention;

[0015] Figure 3 This is a schematic diagram of the annular structure of the present invention. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of the present invention clearer and more explicit, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0017] Reference Figure 1 A test system for a rotary steerable drilling system is disclosed. This test system mainly consists of a rotary drilling system 1, a wellbore system 2, a formation simulation system 6, and coiled tubing 12. The rotary drilling system 1 applies drilling pressure and provides rotational torque to the test system during testing. The wellbore system 2 and coiled tubing 12 simulate the structure of the wellbore, and the formation simulation system 6 simulates the rock structure of the formation. The rotary drilling system 1 is connected to the wellbore system 2 via a locator 1-7 connected to the flange of the wellhead wellbore 2-4, forming a single unit. The end port of the wellbore system 2 is connected to the flange of the formation simulation system 6. The outlet of the mud pump 11 is connected to the coiled tubing 12, and the outlet of the coiled tubing 12 is connected to the central pipe 1-5 of the rotary drilling system 1 via a high-pressure manifold 14.

[0018] The rotary drilling system 1 mainly consists of a motor 1-1, a hydraulic cylinder 1-2, a guide rod 1-3, a moving base 1-4, a central tube 1-5, a fixed base 1-6, and a positioner 1-7. One end of the central tube 1-5 is connected to the motor 1-1, and the other end is connected to the drill rod 3 via a drill rod thread, and the entire assembly is mounted on the moving base 1-4. The guide rod 1-3 is mounted on both sides of the fixed base 1-6 and slides in cooperation with the moving base 1-4. Upper limit switches 1-8 and lower limit switches 1-9 are respectively installed at the upper and lower ends of the guide rod 1-3 to limit the stroke of the moving base 1-4. The hydraulic cylinder 1-2 is mounted on the moving base 1-4, and its piston end is mounted on the fixed base 1-6. Several drill rods 3 are connected by drill rod threads to form a drill string. The foremost drill rod 3 is connected to a rotary guide tool 7 via a thread, and the front end of the rotary guide tool is connected to the drill bit via a thread. The fixed base 1-6 is fixed to the ground with bolts. Hydraulic cylinder 1-2 extends and retracts, causing movable seat 1-4, along with motor 1-1 and central tube 1-5, to move up and down along guide rod 1-3. When hydraulic cylinder 1-2 retracts, movable seat 1-4, along with motor 1-1 and central tube 1-5, moves downward along guide rod 1-3, allowing for drilling tests and applying drilling pressure to the test system. A drilling test is completed when movable seat 1-4 touches the lower limit switch 1-9. When hydraulic cylinder 1-2 extends, movable seat 1-4, along with motor 1-1 and central tube 1-5, moves upward along guide rod 1-3, stopping upon touching upper limit switch 1-8, allowing for the connection of a single drill rod. The rotation of motor 1-1 rotates central tube 1-5, thereby rotating drill rod 3 and providing rotational torque to the test system.

[0019] The wellbore system 2 mainly consists of a wellhead wellbore 2-4, a straight inclined section wellbore 2-1, a curved section wellbore 2-2, and a horizontal section wellbore 2-3 arranged sequentially from high to low and connected tangentially and sealed. It is supported by a wellbore support 4. A discharge port 2-3-1 and a wellbore flange 2-3-2 are located at the end of the horizontal section wellbore 2-3. The wellbore system 2 uses a casing pipe to simulate the wellbore structure. The curved section wellbore 2-2 is prefabricated using casing pipe bent to a pre-designed bending radius. The wellbore support 4 is a welded steel truss structure. The wellhead wellbore 2-4, the straight inclined section wellbore 2-1, the curved section wellbore 2-2, and the horizontal section wellbore 2-3 are connected via convex flanges, concave flanges, O-rings, high-strength double-ended studs, and high-strength nuts. The wellbore support 4 is installed on the ground.

[0020] The formation simulation system 6 is composed of several identical modules prefabricated from cement and crushed stone in a specific ratio. The head module has a pre-embedded flange 6-1 and several wellheads. The formation simulation system 6 is bolted to the wellbore flange 2-3-2 located at the end port of the horizontal section of the wellbore 2-3, thus integrating the wellbore system 2 and the formation simulation system 6 into one unit.

[0021] The coiled tubing 12 is provided in several groups, and the groups are switched on or off via shut-off valves 13. The length of each coil of coiled tubing 12 is a fixed value; the specific number of coils used depends on the simulated drilling depth. Multiple coiled tubing 12s are connected in series by opening or closing the shut-off valves 13 to achieve the required simulated drilling depth. The coiled tubing 12 is connected to the central pipe 1-5 of the rotary drilling system 1 via a high-pressure manifold 14. The drilling fluid is pressurized by the mud pump 11 and then flows through the coiled tubing 12 and the high-pressure manifold 14 into the central pipe 1-5.

[0022] The experimental system includes a purification and circulation system, which is connected to the end of the wellbore system 2 via an injection pump 9 and a mud pump 11. The outlet of the mud pump 11 is connected to a coiled tubing 12, and the outlet of the coiled tubing 12 is connected to the central pipe 1-5 of the rotary drilling system 1 via a high-pressure manifold 14. An injection pump 9 is positioned between the mud pump 11 and the circulation tank 8-3, and is connected to the circulation tank 8-3 and the mud pump 11 via a low-pressure pipeline 10. Drilling fluid can be directly delivered to the suction port of the mud pump 11 via the injection pump 9 and the low-pressure pipeline 10 to form a circulation.

[0023] The purification and circulation system mainly consists of a settling tank 8-1, a vibrating screen 8-2, and a circulation tank 8-3. The vibrating screen 8-2 is installed above the settling tank 8-1, and the settling tank 8-1 and circulation tank 8-3 are arranged adjacent to each other with a baffle 8-4 in between. The discharge port 2-3-1 at the horizontal section of the wellbore 2 in the wellbore system 2 is connected to the vibrating screen 8-2 via a flexible hose 7. The central pipe 1-5 and the drill pipe 3 have a hollow structure, allowing drilling fluid to flow through. The drill string formed by the interconnected drill pipes 3, the rotary guide tool 7, and the drill bit form an annulus 15 with the formation simulation system 6 and the inner surface of the wellbore system 2. High-pressure drilling fluid enters the drill pipe 3 from the central pipe 1-5, passes through the rotary guide tool 7 and the drill bit, and then flows out through the annulus 15 from the discharge port 2-3-1 arranged on the wellbore system 2 into the vibrating screen 8-2.

[0024] Drilling fluid discharged from the discharge port 2-3-1 on the horizontal section of the wellbore 2-3 can pass through the hose 7 and the vibrating screen 8-2 to remove cuttings before entering the settling tank 8-1 for sedimentation. After the drilling fluid reaches the height of the baffle 8-4 arranged between the settling tank 8-1 and the circulation tank 8-3, the clean drilling fluid after sedimentation enters the circulation tank 8-3.

[0025] This invention discloses a testing system for rotary steerable drilling systems, aiming to address the needs of ground simulation testing of rotary steerable products and comprehensively improve the testing capabilities of rotary steerable drilling system testing systems. The working process can be simplified as follows:

[0026] Preparations before the test: Before the drill string is lowered, the drill bit, rotary steering tool 7, and drill pipe 3 are connected together and placed in the wellbore system 2, with the joint exposed. The hydraulic cylinder 1-2 of the rotary drilling system 1 is extended, driving the moving seat 1-4, along with the motor 1-1 and the central tube 1-5, to move upward along the guide rod 1-3. It stops after touching the upper limit switch 1-8, and a single drill pipe can be connected. The drill pipe exposed in the wellbore system 2 is connected to the central tube 1-5 of the rotary drilling system 1 using the drill pipe 3. At this time, a drilling fluid circulation channel is established from the mud pump 11 outlet → coiled tubing 12 → high-pressure manifold 14 → into the central tube 1-5 → drill pipe 3 → rotary steering tool 7 → drill bit → annulus 8 → hose 7 → vibrating screen 8-2 → settling tank 8-1 → circulation tank 8-3 → low-pressure line 10 → injection pump 9 → mud pump 11 inlet.

[0027] Drill pipe 3 is lowered: Force is applied to the head of drill pipe 3 (referred to as drill pressure), and drill pipe 3 can be lowered from the wellhead wellbore 2-4. The lowered drill pipes are connected to form a drill string. According to process requirements, drill pipes of standard length or specified length can be lowered each time. When the hydraulic cylinder 1-2 of the rotary drilling system 1 retracts, the moving seat 1-4, together with the motor 1-1 and the central tube 1-5, can move downward along the guide rod 1-3, pushing drill pipe 3 downward in the wellbore system 2, and pushing the drill bit and rotary guide tool 7 through the inclined straight section of the wellbore 2-1, the curved section of the wellbore 2-2, and the horizontal section of the wellbore 2-3 to reach the wellhead position of the formation simulation system 6.

[0028] Rotary drilling process: After the preparation work is completed, the test begins. The control system sends a command to the motor 1-1 of the rotary drilling system 1. The rotation of the motor 1-1 drives the central tube 1-5 to rotate, which in turn drives the drill pipe 3 to rotate. This, in turn, drives the rotary guide tool 7 and the drill bit to rotate. At the same time, the control system sends a command. When the hydraulic cylinder 1-2 of the rotary drilling system 1 retracts, it drives the moving seat 1-4, together with the motor 1-1 and the central tube 1-5, to move downward along the guide rod 1-3, pushing the drill pipe 3 downward. At this time, the drill pipe 3 rotates and moves downward at the same time, driving the drill bit to rotate and drill in the formation simulation system 6.

[0029] During the test, the control system issued a command to start the mud pump 11. The drilling fluid flows from the outlet of the mud pump 11 → coiled tubing 12 → high-pressure manifold 14 → into the central pipe 1-5 → drill pipe 3 → rotary directional tool 7 → drill bit → annulus 8 → hose 7 → vibrating screen 8-2 → settling tank 8-1 → circulation tank 8-3 → low-pressure line 10 → injection pump 9 → mud pump 11 inlet, forming a drilling fluid system circulation. On the one hand, it cools the drill bit and tools, and on the other hand, it carries away the rock cuttings in the drilling process. The drilling fluid containing rock cuttings passes through the annulus 8, through the hose 7, and enters the purification circulation system. After settling in the settling tank 8-1, it enters the circulation tank 8-1 and then flows from the low-pressure line 10 through the injection pump 9 into the inlet of the mud pump 11 for circulation.

[0030] Throughout the test, at each drilling depth, when the hydraulic cylinder 1-2 of the rotary drilling system 1 retracts, it drives the moving base 1-4, along with the motor 1-1 and the central tube 1-5, to move downwards along the guide rod 1-3. Upon contacting the lower limit switch 1-9, the control system issues a stop signal, causing the hydraulic cylinder 1-2 to stop moving and the motor 1-1 to stop rotating, thus completing one drilling test. The control system then sends a start signal to the hydraulic cylinder 1-2, causing it to extend and drive the moving base 1-4, along with the motor 1-1 and the central tube 1-5, to move upwards along the guide rod 1-3. Upon contacting the upper limit switch 1-8, the control system issues a stop signal, causing the hydraulic cylinder 1-2 to stop moving, allowing the connection of a single drill pipe 3. This process of rotary drilling and single drill pipe replacement continues until the entire test is completed.

[0031] The entire test process involves a closed annulus, in which drilling fluid flows. The fluid is purified and recycled after passing through a purification and circulation system to remove cuttings. This process is energy-saving, environmentally friendly, and produces no pollution.

[0032] The rotary drilling formation simulation system 6 simulates oilfield drilling conditions. Through simulation tests, the flow rate, pressure drop, applied drilling pressure, and torque of the rotary steering tool 7 are measured at different rotation speeds, and the relationships between them are established. This provides technical support for the development of rotary steering tools and can also be used to evaluate the quality of rotary steering tools as needed.

[0033] The entire test process measured the pressure drop and flow range of the rotary guide tool, providing technical basis for the research and development of rotary guide tool products, as well as for product quality assessment.

[0034] The above control system works as follows: when the upper limit switch 1-8 and the lower limit switch 1-9 are touched, the upper limit switch 1-8 and the lower limit switch 1-9 send open and close signals to the PLC controller to control the start and stop of the motor 1-1 and the extension and retraction of the hydraulic cylinder.

Claims

1. A test support system for a rotary steerable drilling system, characterized in that: The experimental system mainly consists of a rotary drilling system, a wellbore system, a formation simulation system, and coiled tubing. The rotary drilling system applies drilling pressure and provides rotational torque during the experiment. The wellbore system and coiled tubing simulate the wellbore structure, while the formation simulation system simulates the formation rock structure. The rotary drilling system is connected to the wellbore system via a locator that connects to the wellhead flange, forming a single unit. The end port of the wellbore system is connected to the formation simulation system flange, and the mud pump outlet is connected to the coiled tubing. The coiled tubing outlet is connected to the central pipe of the rotary drilling system via a high-pressure manifold. The test system includes a purification and circulation system, which is connected to the end of the wellbore system via an injection pump and a mud pump. The outlet of the mud pump is connected to the coiled tubing, and the outlet of the coiled tubing is connected to the central pipe of the rotary drilling system via a high-pressure manifold. The purification and circulation system mainly consists of a settling tank, a vibrating screen, and a circulation tank. The vibrating screen is installed above the settling tank, and the settling tank and circulation tank are arranged adjacent to each other with a baffle in between. The discharge port at the horizontal section of the wellbore in the wellbore system is connected to the vibrating screen through a flexible hose. The central pipe and drill pipe adopt a hollow structure, allowing drilling fluid to flow through. The drill string, rotary guide tool, and drill bit formed by the interconnected drill pipes create an annulus with the formation simulation system and the inner surface of the wellbore system. High-pressure drilling fluid enters the drill pipe from the central pipe, passes through the rotary guide tool and drill bit, and then flows out through the annulus from the discharge port arranged on the wellbore system into the vibrating screen. The rotary drilling system mainly consists of an electric motor, a hydraulic cylinder, a guide rod, a movable seat, a central tube, a fixed seat, and a positioner. One end of the central tube is connected to the electric motor, and the other end is connected to the drill pipe. The entire central tube is then mounted on the movable seat. The guide rod is installed on both sides of the fixed seat and slides with the movable seat. An upper limit switch and a lower limit switch are respectively installed at the upper and lower ends of the guide rod to limit the stroke of the movable seat. The hydraulic cylinder body is mounted on the movable seat, and its piston end is mounted on the fixed seat. Several drill pipes are connected to each other through drill pipe threaded connections to form a drill string. The foremost drill pipe is connected to a rotary guide tool through a threaded connection, and the front end of the rotary guide tool is connected to the drill bit through a threaded connection. The well system mainly consists of a wellhead well, an inclined straight section well, a curved section well, and a horizontal section well, arranged sequentially from high to low and connected tangentially and sealed. It is supported by well support. A discharge port is arranged at the end of the horizontal section well, and a well flange is installed at the end port of the horizontal section well. The formation simulation system is composed of several identical modules prefabricated from cement and crushed stone in a certain proportion. The head module is equipped with a pre-embedded flange and several wellheads. The continuous tubing is provided in several groups, and each group is switched on or off by a shut-off valve. Establish a drilling fluid circulation channel from mud pump outlet → coiled tubing → high-pressure manifold → into center pipe → drill pipe → rotary guide tool → drill bit → annulus → hose → vibrating screen → settling tank → circulation tank → low-pressure pipeline → injection pump → mud pump inlet; Simulation tests were conducted to verify the flow rate, pressure drop, applied drilling pressure, and torque of the rotary guide tool at different rotation speeds, and the relationships between them were established.

2. The test system for a rotary steerable drilling system as described in claim 1, characterized in that, Drill pipe running: Force is applied to the drill pipe head, and the drill pipe can be run from the wellhead. After the drill pipes are connected to each other, they form a drill string. According to the process requirements, drill pipes of standard length or specified length are run each time. When the drill pipe is retracted by the hydraulic cylinder of the rotary drilling system, it drives the moving seat, together with the motor and the central tube, to move downward along the guide rod, pushing the drill pipe downward in the wellbore system, and pushing the drill bit and rotary guide tool through the inclined straight section of the wellbore, the curved section of the wellbore, and the horizontal section of the wellbore to reach the wellhead position of the formation simulation system. Rotary drilling process: After the preparation work is completed, the test begins. The control system sends a command to the motor of the rotary drilling system. The motor rotates, which drives the central tube to rotate, which in turn drives the drill pipe to rotate. This, in turn, drives the rotary guide tool and drill bit to rotate. At the same time, the control system sends a command. When the hydraulic cylinder of the rotary drilling system retracts, it drives the moving seat, along with the motor and the central tube, to move downward along the guide rod, pushing the drill pipe downward. At this time, the drill pipe rotates and moves downward at the same time, driving the drill bit to rotate and drill in the formation simulation system. During the test, the control system issued a command to start the mud pump. The drilling fluid flowed from the mud pump outlet → coiled tubing → high-pressure manifold → into the center pipe → drill pipe → rotary guide tool → drill bit → annulus → hose → vibrating screen → settling tank → circulation tank → low-pressure pipeline → injection pump → mud pump inlet, forming a drilling fluid system circulation. On the one hand, it cooled the drill bit and tools, and on the other hand, it carried away the rock cuttings in the drilling process. The drilling fluid containing rock cuttings passed through the annulus, entered the purification circulation system through the hose, settled in the settling tank, and then entered the circulation tank. From the low-pressure pipeline, it entered the mud pump inlet through the injection pump and circulated. Throughout the test, each time a certain depth of drilling is achieved, i.e., when the hydraulic cylinder of the rotary drilling system retracts, the moving base, along with the motor and central tube, moves downward along the guide rod. Upon touching the lower limit switch, the control system issues a stop signal, the hydraulic cylinder stops moving, and the motor stops rotating, completing one drilling test. The control system then issues a start signal to the hydraulic cylinder, causing it to extend and move upward along the guide rod, along with the moving base, motor, and central tube. Upon touching the upper limit switch, the control system issues a stop signal, the hydraulic cylinder stops moving, and a single drill pipe is connected. This process of rotary drilling and connecting single drill pipes continues until the entire test is completed.

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