增材制造技术在超高膨胀封隔器中的应用

石油和天然气行业不断关注增材制造技术在航空航天和汽车行业的应用发展。研发了利用增材制造技术的超高膨胀封隔器,该封隔器的支承环系统由增材制造。增材制造设计大幅减少了支承系统的构件数量,同时显著提高了膨胀能力和额定压力。密封元件系统与增材制造支承环安装在一起,提供了极端膨胀比、零挤压间隙和对不规则孔的良好适应性。分析和测试结果表明:直径膨胀比高达111%,与常规封隔器相比,提高50%以上;至少涵盖5种线重的套管(外径相同);在148.89℃的温度下,密封元件能够保持压力68.95 MPa。介绍了增材制造技术、增材制造支承环概念、增材制造材料力学性能、密封元件系统优化和测试情况,以期给我国的完井作业提供借鉴。

The Ultra-expansion Completion Packer Integrated with Additive Manufacturing Technology

The development of the application of additive manufacturing technology in the aerospace and automotive industries has been longly connected with the oil and gas industry. An ultra-high expansion packer was developed with AM technology and the backup ring system of this ultra-high expansion packer was manufactured by additive material. The additive manufacturing design greatly reduces the number of components of the support system, while significantly increases the expansion capacity and pressure rating. The packer element system installed with these AM backup rings offers extreme expansion ratio, truly zero extrusion gap, and superior conformability to as-rolled casing. The analysis and test results show that the diameter expansion ratio is up to 111%, which is more than 50% higher than that of the conventional packer, at least 5 kinds of line weight casings(at the same outer diameter)are covered and at a temperature of 148.89 ℃, the pressure of 68.95 MPa can be maintained by sealing elements. The AM technology, additive manufactured backup design conception, mechanical properties of additive manufactured material, element system validation and optimization were introduced in the paper, which can provide reference for Chinese completion operation.