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1、APS Technology,Inc.技术交流-,May 20,2010,交流目录,Introduction介绍,3,APS成立于1993超过25年专业化MWD/LWD设计、开发、制造经验四大服务公司之外开发MWD/LWD经验最为丰富的公司超过 35%的工程技术人员来自原来Teleco Oilfield Services的设计团队，Teleco是世界上首台商用MWD的开发制造商独立的制造商,4,历史与现在,全球第二大独立的MWD/LWD制造、供应商四大服务公司重要的供应商和合作伙伴：Schlumberger,Baker Hughes INTEQ,Halliburton,Weatherford,
2、GE,CNPC,COSL工业界公认的最佳泥浆脉冲器井下振动分析、预测、利用的领导者全球超过 700支脉冲器、280套MWD系统在作业完全的产品工程、设计、支持、测试能力拥有25项专利，6项在申请专利,5项DOE大奖,5,历史与现在,6,重点产品和目标,核心生产线:MWD&LWD 测量工具钻井工具 旋转导向螺杆(RSM)振动工具 AVD,VMS&,Shock Isolators产品目标:#1：2013年成为独立的MWD/LWD 系统供应商#1：独立的旋转导向工具供应商#1：可靠性/高质量/客户支持#1：技术&创新,新的技术用来降低钻进成本提高可靠性更高的产品来服务市场WPR：电阻率工具 EM：与
3、泥浆脉冲集成的电磁波传送技术HDR：高速数据传输脉冲器RSM：旋转导向螺杆AVD：智能振动控制仪DDM：钻井监测短节,7,能力发展,8,全球产品布局图示,Infrastructure and Assets设备设施,9,资源与设施,工厂Connecticut总部拥有60,000平方尺的设计、测试和制造中心休斯敦拥有20,000平方尺的销售、维修服务中心 阿联酋迪拜拥有5,000平方尺的销售、维修服务中心2000平方尺的中国成都维修服务基地设备业界前10的名制造能力多相流循环模拟体系(650HP,700lpm,1000psi)高温高压全尺寸压力测试罐(27000psi,200,5m)振动测试台、环
4、境应力测试箱 全尺寸工具疲劳强度及可靠性试验架 HALT/HASS(-50-200,0-50g)综合的ERP管理系统,10,公司地点,Houston 中心,Jebel Ali中心,11,Wallingford,CT总部,成都中心,机械加工能力,拥有现代化一流的数控机床能够加工大至10-”x 20 的工具短节3-4&5轴各式数控机床4-5轴数铣、车综合性加工中心数控的深孔钻、侧孔钻激光对焊机数字化生产,12,机加工中心,13,加工中心,14,电子实验室,15,客户支持与服务,众多的维修中心 Houston;Dubai;Nizhnevartovsk;Wallingford,CT;Chengdu,C
5、hina丰富的库存为客户快速提供各种消耗配件负责任的客户支持工程师队伍脉冲器10天返修承诺探管10天返修承诺，APS提供替代探管客户支持网站维护培训提供完善的支持仪器和工具,16,MWDSureShot MT 随钻测量工具,MWD SureShot TM 系统,18,7年现场服务历史，近300套系统为超过90多家用户服务泥浆脉冲与电磁波传输方式集成 1.50bps-4.0bps传输速度 3.5”-9”BHA范围175，20000psi标配是WPR，RSM，PWD，AVD等工具的平台适用各种泥浆体系，过平衡、欠平衡体系开放式系统设计特点是高温和深井,MWD最新发展,无刷电机动作控制高可靠性 没有
6、电刷和整流器减少30%的工作电耗和70%静止电耗带2,400小时的诊断内存脉冲器的轴磁耦合改进 FlowStat的改进 改善了FlowStat在各种温度下的表现深度跟踪系统集成到SIU深度跟踪系统和解码集成到同一个箱子降低了成本和空间要求,19,MWD最新发展,新的井下CPU编码电路板32 MB内存更低的电耗更高的作业温度改善了电能管理系统新的电路板工作耗电更低改善的电能管理系统将把没有工作的元件关闭振动监控模块测量并记录轴向、横向和Stick-slip实时传输传输速度提高DSP,20,SureShot 简装地面系统,21,SureShot 简装地面系统,22,Printrex log plo
7、tter,Hookload sesor anddraw works encoder,SureShot 重装地面系统,23,司钻房显示器,24,现场测试箱,自动检测坚固耐用行/不行简单逻辑指示灯显示颜色区分,25,SSCC 截屏,26,MWD SureShot TM 系统,27,固定式与可打捞式,28,可打捞配置,固定、不可打捞式配置,可打捞式脉冲器,29,Pulser Shroud,Muleshoe,Stinger,Rotor,Stator,Spearpoint,旋转脉冲器,业界最强劲的脉冲器，往复式振荡运动专利的防堵“open flow/single flow path”设计专利设计，服务油
8、田超过7年超过 700脉冲器正在作业被许多不同的MWD系统采用Schlumberger，BHI采用，美国30%Tensor系统采用可打捞和固定式配置现场维护内存诊断能力1.5bps-4.0bps 数据传输速度,30,SureShot 电池组,标准Li DD-cells电池组每组电池可连续作业140 150小时组装和更换电池组十分简单提供合格的供应商名单测试、批准合格的供应商,31,涡轮发电机,175操作温度150W发电能力当TA工作时不会消耗电池大范围泥浆排量可代替电池组200可选,32,SureShot TM 带涡轮发电机,33,6-3/4 in.Flow Sub Configuration
9、,4-3/4 in.Flow Sub Configuration,3-1/2 in 小井眼脉冲器,34,3-1/2 in.Flow Sub Configuration,模块间的连接,可靠的旋转连接方式 军用Deutsch 22 conductor connectors，为MWD各个模块间提供可靠的连接方式最强的压力外筒连接避免失效的机理:没有拉伸、扭转和弯曲载荷没有接触失效没有断裂、磨损或湿连接没有冲蚀,35,APS 脉冲器服务例子,36,SureShot定向和伽玛探管,APS设计并制造探管定向探管可带32 MB内存175作业温度自然伽玛探管Rugged NaI scintillator/ph
10、otomultiplier tube(PMT)业界公认优秀的供应商,37,PWD 随钻测压,测量井底环空压力 测量井底钻具内压力集成到SureShot MWD测量ECD&ESD测量Surge&Swab实时,38,39,Electromagnetic Telemetry 电磁波传输方式,APS 电磁波MWD系统,集成成熟系统，第三代电池波厂商与固定式泥浆脉冲方式集成一起与泥浆脉冲方式可以现场互换与泥浆脉冲方式共享井下供电、测量模块共享Sureshot地面系统APS改进系统,40,41,电磁波信号传输系统,发射天线,绝缘短节,EM电子模块,MWD悬挂短节,流量控模块,欠平衡钻进空气或泡沫钻进极高L
11、MC,42,电磁波信号传输系统,43,EM 绝缘短节,EM 发射天线,EM 电子模块,MWD 悬挂短节,扶正器,电磁波信号传输系统,图示,44,45,电磁波信号传输系统,即插即用特性，与泥浆脉冲现场互换使用根据岩性自动调节信号强度，优化电耗新一代的地面接收系统，提高了弱信号的灵敏度特殊设计的绝缘短节，提高了绝缘特性TA-增强了发射信号强度、不受电池限制,46,电磁波信号传输系统,47,电磁波信号传输系统,WPR：电磁波电阻率工具,48,WPR：电磁波电阻率工具,49,APS生产的电阻率LWD名称是WPR，是Wave Propagation Resistivity Sub的简称。该工具是双频、双
12、间距、带真实实时补偿的随钻测井工具WPR可以应用于各种类型的井眼，可进行地质导向、井眼纠正、孔隙压力趋势分析、套管下深选择、代替测井、起钻测井作业等。WPR可以用于各种类型的泥浆，油基和水基，为作业者提供实时地层电阻率数据。高精度的测量数据也储存在工具的内存中，便于起钻后精确分析。APS提供完整的地质导向软件用来计算和分析。,SureShot 带电阻率 WPR,50,WPR 背景,在电阻率工具上有丰富的、被实践验证的经验和积累设计、制造GE Centerfire 电阻率工具 与BHI MPR类似采用油田普遍使用的材料和被证明了的技术采用被实践证实的原理技术上由ex-Teleco/BHI 电阻率
13、工具高级工程师带队产品水平与目前主要服务商的同类产品相当,51,WPR基础规范,外径:3.5 in.(89 mm),4.75 in.(121 mm),6.75 in.(171 mm),8.0 in.(203 mm)通过RS-485Interface 与 APS SureShot MWD 相连接两种操作频率：2 MHz and 400 kHz内存:32 MB由2x 3x 36v电池组或1x 涡轮发电机+0 x 2x电池供电可实现LWD 和“Measurement After Drilling”(MAD)作业模式测试/编程/下载数据等高安全性设计8.0 in.,6.75 in.and 4.75 i
14、n.尺寸的工具可集成随钻测压最高作业温度：175最大承压:20 kpsi(137.9 MPa),52,WPR工作原理,53,幅度差,相位差,从发射极发出的电磁波，通过地层到达中间的接收天线，由于地层的导电性不同，因此电磁波到达接收天线处出现相位差和幅差。由于不同的地层出现相位差和幅差不同，故可以判别地层。,电磁波的传导受井眼情况的影响较小,WPR工作原理示意图,WPR补偿原理,54,WPR工作原理示意图,对称天线结构设计可实现最佳井眼补偿,补偿可提高测量精度、消除接收天线和电路板测量漂移,接收天线置于仪器中间位置，可消除测量时间差造成的补偿误差,WPR 优势,真实直接的井眼补偿，而不是复杂的运
15、算补偿钻进时提供实时补偿的电阻率测量由设计消除了接收天线的漂移,55,WPR 优势,工业界标准的频率和天线间距业界最佳的脉冲发生器，正脉冲、顶置高速数据传输，泥浆与EM电磁波集成传输提供随钻测压PWD集成井下涡轮发电机供电，没有电池的限制 提供地质导向软件和培训现场操作简单容易、可靠性高天线现场容易维修更换不含湿连接,56,Catoosa,OK现场测试,57,2009年2月11-12日,Samoltor 油田现场测试,58,2010年4月27日,WPR 提供随钻测压PWD选择,59,Drilling OptimizationRSM旋转导向螺杆,60,RSM优点,大幅提高ROP提高轨迹控制精度提
16、高轨迹质量延长钻进井段提高井眼清洁状况降低钻井综合成本,61,旋转导向螺杆(RSM),旋转导向螺杆*“推钻头式”，全旋转定向、稳斜、垂直钻进导向部分被集成在泥浆螺杆的轴承壳体内，上面与标准螺杆动力相连,*US Patent#7,389,830,issued June 24,2008,62,独特设计,63,所有部件全部旋转独特设计与普通螺杆连用 充分发挥泥浆螺杆与顶驱的动力所有泥浆螺杆均可采用 不影响钻头水利参数的设计 带“近钻头”参数 密封轴承每周导向块伸出一次 导向块伸出力量、距离固定,RSM与螺杆动力部分,CV Joint(customer),64,关键点,交流发电机 利用螺杆转子转动发电
17、 叶轮泵 由螺杆转子驱动，为导向块提供液压动力 导向块“推钻头”式控制导向探管 测量井斜和提供动态工具面控制电路 根据工具面，控制导向块伸出时间,65,主要部分,下密封轴承,驱动头,液力泵和传动轴,6 个控制仓:交流发电机/整流器交流发电机控制电路3.控制电路4.导向探管 EM 短距传输 GM 预留,上密封轴承,滑套式扶正器,3个导向块,66,可调试导向块,67,旋转导向系统,68,目前规格,69,操作模式,垂直钻进模式VDM直井段钻进保持井斜尽可能地小，井眼近似垂直导向模式RSM工具面由MWD提供，工程师调到设计方位Downlink 具体的造斜率稳斜钻进模式TAH 稳斜段钻进自动保持当前井斜
18、钻进Downlinks调整方位漂移,70,如何工作的？-钻进,磁力计用来测定转速和磁工具面加速度计用来测定井斜和高边工具面控制电路决定每个导向块在指定的方向上推出来导向力的大小由导向块伸出时间长短决定（最大到1/3圈)每个导向块每圈伸出一次,71,测斜时，RSM探管测量磁工具面和井斜 控制电路根据工具面伸出导向块和决定时间导向力根据井斜值的大小自动调节 在接近垂直时将减小导向力自动操作,垂直钻进VDM,72,RSM 的工具面调整到设计的方位(一次性的操作)造斜率/降斜率是通过downlink 告诉工具的控制电路测量钻具旋转速度，并反向推出导向块定向井工程师根据实测对方位进行调整，Downlin
19、k造斜率/降斜率,旋转导向RSM,73,达到设定的井斜角时，RSM用最小的导向力来维持井斜角在测斜时，RSM测量MTF,GTF,INC:决定降斜或增斜趋势 决定维持井斜角度所需要的导向力决定导向矢量来维持井斜值现场工程师通过Downlink来控制方位的漂移：向左/右推出漂移被纠正后，重新设置,稳斜钻进TAH,74,通过开关泥浆泵来向下通讯，无需特殊设备简单、可靠、模式少“Dips”&“blips”：排量变化大于378 lpm,触发一个操作模式变化的信号排量升降变化 50 gpm,100 gpm，触发一个模式内作业变化信号，如漂移控制，改变TF，改变造斜率 向下通讯的时间范围是90-240秒所有
20、向下通讯可以在钻具旋转情况下完成,Downlink-向下通讯,75,76,向下通讯-VDM模式,77,向下通讯-RSM模式,78,向下通讯-TAH模式,79,最近的一次油田应用,Vibration Products Prediction,Measurement and Control,80,Drill String Vibration,Three typesAxialVertical“bounce”LateralHorizontalTorsionalTwisting,Vibration Products,Vibration ControlActive Vibration Damper(AVD)
21、Vibration Isolation Sub(VIS)MWD Isolators,Vibration PredictionWellDesigner Drillstring Modeling SuiteBHABendBHAVibBHAPredict,Vibration MeasurementVibration Memory Sub(VMS)Vibration Memory Module(VMM),WellDesigner,The WellDesigner suite models the downhole drilling environmentWellDesigner aids in opt
22、imizing drilling parameters,improving the drilling efficiency.Benefits include increased ROP,extended drillstring life and improved economics,83,WellDesigner,WellDrillTorque&DragStick-SlipHydraulicsVMS,84,WellDesigner includes:,WellDrill,85,WellDrill,WellDrill applications include:Optimizing drillin
23、g performanceDesigning drilling toolsAvoiding critical speeds,86,WellDrill,WellDrill includes:BHABend BHA bending analysis of deflections,side loads,bending moments and nominal stress BHAVib BHA critical speed analysisBHAPredict BHA drill-ahead tendency,87,WellDrill,WellDrill input includes well par
24、ameters and BHA components,88,WellDrill BHABend,89,Deflections,Side Forces,Bending Moment,Stress,WellDrill-BHAPredict,Predicts build rate,90,WellDrill-BHAPredict,Calculating sag correction,91,Bit,MWD Sensor,WellDrill-BHAPredict,Mud motor rotary and sliding build rates,92,WellDrill-BHAPredict,Effect
25、of WOB on build rates,93,WellDrill BHAVib,Predicting critical drilling speeds,94,WellDrill-BHAVib,95,Lateral deflections,Axial,Torsional,Bit critical speeds,Motor critical speeds,Rotary critical speeds,WellDrill,WellDrill includes many preprogrammed elements,96,WellDrill,ToolBuilder saves commonly u
26、sed tools and BHAs,97,Torque&Drag,98,Torque&Drag,99,Torque&Drag,100,Torque&Drag,101,Friction and tortousity,Torque&Drag,102,Torque&Drag,103,Stick-Slip,104,Stick-Slip,Stick-Slip uses the results from the Torque&Drag programBit drag is calculated based Bit type Bit condition Formation hardness,105,Sti
27、ck-Slip,For this case the rotary speed at the rig is 170 rpm.The bit speed is nearly constant,106,Stick-Slip,This case,the speed is decreased to 60 rpm,107,The bit speed varies between 0 and 335 rpm,VMS Vibration Memory Sub,The VMS tool measures and records downhole vibrations:Whirling(lateral vibra
28、tions)Bit bounce(axial vibrations)Stick-slip(rotary vibrations),108,VMS Vibration Memory Sub,Recorded and stored data:Lateral vibration RMS&Max Axial vibration RMS&MaxStick-Slip Min and Max RPM7 40 sec burst,raw data sets,109,VMS Vibration Memory Sub,Measures and records Axial,Lateral vibrations and
29、 RPMMemory module records maximum vibration and average RPM values every 4 secondsRecords seven 40 sec continuous“snapshot”time-based spectrum when level first passes pre-set limitsViewer software graphs recorded data for meaningful conclusions.,110,VMS Vibration Memory Sub,Memory:8 MB(250 hours of
30、data 4 sec)Data dump:via port in collar or end cap of sondeThe tool provides data in the form of ASCII text files which can analysed by APSs Vibration Data Viewer software or your own analysis software,111,VMS Vibration Memory Sub,112,VMS Vibration Memory Sub,Stick-Slip Example,113,VMS Vibration Mem
31、ory Sub,114,Running in hole,On bottom,drilling,Severe drilling vibrations,VMS Vibration Memory Sub,115,Burst data set#2,Stuck,Rotating(Slip)Vibration increases with rpm,VMS Vibration Memory Sub,VMS data combined with rig data provides insight to the downhole drilling conditions.In this example,drill
32、ing between 20 24k lbs reduces vibrations.,116,Hydraulics,117,Hydraulics,118,Vibration Measurement Applications,Post-well analysis of failuresWarranty violationsFuture BHA planningWith real-time transmission:Optimization of drilling parametersAvoidance of failures,Vibration Memory Sub,Vibration Memo
33、ry Sub(VMS)is a collar-based tool used for standalone vibration recording,Vibration Memory Sub Features,Measures and records axial and lateral vibrations and RPMMemory module records maximum vibration and average RPM values every 4 secondsRecords a 1 minute continuous“snapshot”time-based spectrum wh
34、en level first passes pre-set limitsViewer software graphs recorded data for meaningful conclusions.,Memory:8 Mb(250 hours of data 4 sec)Data dump:via port in collar or end cap of sonde,Vibration Memory Module(VMM),Interfaces with SureShot MWDNormal transmissionMaximum levels in each modeInclude in
35、standard diagnostic FIDsAlert transmissionsWhen maximum exceeds pre-set limitsInterrupts after current data wordSends alarm FID and levels,Vibration Memory Module(VMM),123,Interfaces with SureShot MWDNormal transmissionMaximum levels in each modeInclude in standard diagnostic FIDsAlert transmissions
36、When maximum exceeds pre-set limitsInterrupts after current data wordSends alarm FID and levels,VMS/VMM Data,124,VMS/VMM Data,VMS data combined with rig data provides insight to the downhole drilling conditions.In this example,drilling between 20 24k lbs reduces vibrations.,125,Stick-Slip Detection,
37、126,Running in hole,On bottom,drilling,Severe drilling vibrations,Stick-Slip Detection,127,Burst data set#2,Stuck,Rotating(Slip)Vibration increases with rpm,128,DDM-钻井监测短节,DDM-Drilling Dynamics Monitor,129,DDM-钻井监测短节,130,DDM-钻井监测短节,131,DDM-钻井监测短节,132,DDM-钻井监测短节,133,DDM-钻井监测短节,DDM-钻井监测短节,DDM-钻井监测短节,1
38、36,A V D,智能减振装置,井下振动的控制与应用,降低BHA承受的冲击与振动增加井下工具如MWD的使用寿命增加机械钻速(ROP)减少起下钻作业节约成本和时间,智能减振装置(AVD),工具监控钻柱，钻头的运动，实时调节，控制振动减少振动和跳钻保持钻头接触井底，传递钻压钻进增加机械钻速10%-30%阻隔振动的传递，保护MWD/LWD等井下工具,138,智能减振装置(AVD),AVD的特征包括:特殊设计的弹簧支撑、传递钻压轴向和横向承压轴承主动监测控制、实时程序控制振动,Active Vibration Damper(AVD),Active Vibration Damper(AVD),利用磁场瞬
39、间改变MR流动特性,Loving County,TX 现场试验,三口井的作业6 趟PDC钻头+AVD作业；对比10趟PDC作业不带AVD1 趟牙轮+AVD作业;4 趟不带 AVD：显著增加了ROP 和钻头寿命,AVD JobLoving Co.,TX March,2009,AVD ROP Improvement vs.Rock Strength,改善了PDC钻头的使用寿命,Bit#6 920 ft/87 hrs w/o AVD8 8 RO S X O HC PR,Bit#8 1091 ft/91 hrs w/AVD2 4 CT S X O WT PR,Loving County,TX,Impr
40、oved Bit Life Rock Bits,Bit#5 589 ft/38.5 hrs w/AVD2 2 WT A EEE In WT TQ,Bit#6 424 ft/26.5 hrs w/o AVD5 5 WT A EEE 1 WT TQ,Travis Peak-Central Texas F90,AVD现场试验总结,显著提高钻井效率减少钻头振动 减少切削齿的损坏提高了机械钻速显著增加单只钻头进尺 减低了下部钻具组合的损害显著降低了钻井成本,Vibration Isolation Sub(VIS),Protect drill string components from damaging
41、 shocksTwo loosely threaded cylindrical membersRubber is molded into the threaded cavityProvides vibration absorption and dampening in all three planesCan be customized by changing rubber type or helix design,MWD Vibration Isolators,Protect sensitive MWD components from damaging shocksTwo loosely th
42、readed cylindrical membersRubber is molded into the threaded cavityProvide vibration absorption and dampening in all three planesCan be customized by changing rubber type or helix design,Pulser Design,APS Rotary Pulser,APS pulser is the foundation of MWD systemsOperational for over 7 years 600 pulse
43、r units Used by many MWD companies in multiple architecturesFixed mount&retrievable,151,Mud Pulser Types,Negative PulseSondex-GeolinkHalliburton-Sperry Sun(BGD tool)BHI,AccutrakPositive PulsePilot-assisted valveTensorBlueStarNewsco-Camber BHI-Navitrak,UPUPathfinder,MOPHalliburton-Sperry Sun,HDS1Clos
44、ed-loop poppet valve(BHI-Teleco design)Siren(Schlumberger)Rotary oscillating valve(APS),152,Mud Pulser Types,Negative Pulse Largely obsolete except for GeoLink GeolinkHalliburton BGD(Obsolete but still being run in selective areas)Sperry Sun Negative pulse tools have been obsoleted in favor of“Mark
45、Series”of pulsersBaker Hughes,Accutrak Obsolete by Teleco,NaviTrak,and UPUPilot-assisted valvesTensorBaker Hughes-Navitrak,UPUBlueStar(now G.E.)Was a G.E.copy cat designPathfinder,MOPHalliburton-Sperry Sun,HDS1Closed-loop poppet valves Baker Hughes-Teleco design Sperry Sun Mark designShear valvesSch
46、lumberger-Siren(continuous rotation)APS-Oscillating Rotary Pulser Baker Hughes-Oscillating Rotary Pulser(BHI licensed APS design),153,Mud Pulser Types,154,Negative Pulse Valves,PrinciplePressure pulse is generated by porting drilling fluid from inside of tool to the annulus via a sliding valveAdvant
47、agesValve design is fairly simpleDisadvantagesOld Technology All major service companies have abandoned this design in favor of positive pulseDecoding is not as reliable as positive pulsePulse height is a function of P through the tool;requires a restrictor which is generally disfavored by operators
48、Prone to washout,valve leaks can cause catastrophic tool washout Many operators will not run negative pulse toolsNot retrievableNot very tolerant to debris&LCMSlow,155,Pilot-assisted Valves,AdvantagesLow power requirementLow purchase costAdaptable to retrievableDisadvantagesPoor LCM toleranceValve w
49、ears quickly because seals are mud lubricatedUnpredictable valve performance because pulse generation is dependent on mud properties and hydraulicsLow data ratePoor reliability:400 hrs.MTBF,156,Pilot Operated Valve,Orifice(2)creates pressure differential(P1 P2)With pilot valve(30)open,pressure in ca
50、vity(42),P2=P2With pilot closed,P2=P1Area difference across front of cavity causes piston(34)to move forward,partially closing orifice,and generating pulseRalph F.Spinnler,U.S.Pat.#3,958,217,“Pilot Operated Mud-Pulse Valve,”May 18,1976.,157,Closed-loop Poppet Valves,AdvantagesVery debris tolerantVal
