PVC-U塑料管水井成井技术应用研究
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摘要
该课题全面系统对PVC-U塑料管成井工艺进行研究和其进行的PVC-U示范井建设在国内外尚属首次,涉及学科主要有钻探工程学、材料力学、腐蚀学、弹塑性力学等。
随着浅层地热能开发、地下应急(后备)水源地、农村饮水安全工程、厂矿供水、城镇供水等建设的迅速发展,地下供水管井的工程技术开始引起关注和重视。传统的成井管材主要是普通钢管和铸铁管,其最大的问题是腐蚀结垢严重,从而降低了其使用寿命；再者,资源的日趋枯竭、铁矿开采和钢铁工业的高能耗、高污染问题严重影响着生态环境和可持续发展。所以,在资源与环境形势问题矛盾突出的严峻形势下,采用新型井管材料代替金属,对低碳社会、节能减排、环境保护和可持续发展具有重大的现实意义。
20世纪50年代,美国首先在水井工程中采用塑料管替代钢管和铸铁管,我国在60年代也开始关注塑料管成井技术研究和试验,从而掀起了塑料管研发和试验应用的高潮。由于当时的管材配方质量和成井技术所限,其成井深度一般在十儿米到几十米。70-90年代,国外多数水井依然稳步采用塑料管成井,其口径和深度较小；国内则几乎处于“空白”时期,其成井管材主要以钢管和铸铁管为主。进入21世纪初期,人们逐步发现金属管井使用寿命低、腐蚀结垢严重、成本高、维修频繁等问题。为此,少数单位和生产厂家开始新一轮的研发和采用塑料管成井,其成井深度多数依然在几十米到百米左右,个别成井深度大于200m。但是,由于在成井过程中塑料井管下入困难和容易爆裂两大问题一直未能较好解决,从而影响着PVC-U塑料管在水文水井中的推广应用。
针对上述现状和存在的主要问题,提出了《PVC-U塑料管成井技术应用与研究》课题,通过大量文献查阅和实际调查,分析研究了目前金属管井腐蚀结垢和PVC-U塑料管成井深度浅、下入困难、易爆裂等问题,并就研究课题提出了具体的研究技术路线。
对于新型改性PVC-U塑料井管,主要从材料类型、性质、配方和加工工艺进行了分析研究。通过PVC-U形变—温度曲线,可以看出PVC-U材料随温度的不同会呈现出玻璃态、高弹态和粘流态三种状态,同时分析研究了加工各工序温度对其质量的影响；在PVC-U塑料管特点归纳基础上,分别对其物理力学性能指标、卫生安全指标和PVC-U塑料管材中砷、镉、铅、汞、酚类、锑、锡、铝、铬、氯仿、四氯化碳等有害物质进行了测试和溶解析出试验。通过有关性能指标的测试和溶解析出试验结果可以说明：PVC-U塑料管材具有较好的综合力学和卫生安全性能指标,并且在水中不会发生析出和溶解现象。
为了合理选择成井管材,并直观了解腐蚀结垢现象、速度等,选择了常用普通金属管材、球墨铸铁管、桥式镀锌过滤管、PVC-U管、梯形丝过滤管等,采用实验室挂片试验和实际井下彩色电视检测等手段进行了腐蚀试验和研究。通过腐蚀试验计算和实际工程检测可知：金属管材普遍存在着腐蚀结垢问题,并且金属管材腐蚀后其强度急剧下降；PVC-U塑料管则不存在腐蚀结垢现象。
针对PVC-U塑料管特性,参照石油套管受力分析,利用材料力学、弹塑性力学理论分别从轴向拉力、轴向压力、外挤压力、管内压力、横向剪切力、弯矩、温度等方面对塑料管在井内进行了受力分析研究,并以示范井为例从PVC-U管材下入、冲孔—投砾、PVC-U管完井三个主要工序进行了实际受力分析和计算。并得出以下结论：
(1)管外上覆岩层压力、管外液柱压力、管内液柱压力随着PVC-U管下入深度呈线性增加趋势,即：井越深管体受到的压力越大。并且,当水文地质条件一定时,其压力值无法人为改变。
(2)当井内泥浆密度等于PVC-U塑料管材密度时,则管体轴向重力和浮力相等,出现管材下入困难或下不去问题。
(3) PVC-U塑料管在完井后,抽水阶段或正常开采期间,由于井管内外受力类型和压力不同,故存在着管内外压力差问题。井管下入越深,压力差越大。
(4)当成井质量较差,洗井不彻底或地下水降深过大时,管体内外压力差更大。PVC-U管安全稳定性则差,当PVC-U塑料管质量存在问题时,易出现挤毁爆裂事故。
(5)利用石油钻井理论和拉梅(Lame)方程分别对示范井动载荷(冲击载荷)和抗挤压力进行了定量分析,计算结果表明：井内压力差≥4.53MPa时和地层坍塌、投砾“架桥”瞬间下沉速度≥0.73m/s时,其外挤压力和冲击载荷值超过PVC-U塑料管的强度,也是PVC-U塑料管挤毁爆裂的临界值。
(6)为保证PVC-U塑料管在井内的安全,尽可能减少压力差。
(7) PVC-U塑料井管在下管、投砾和洗井抽水(开采)三个过程中受力不同。在下管过程和完井后正常使用过程较为安全,在PVC-U塑料管下入后冲孔换浆和砾料投放过程最为危险,其安全系数最小。也就是说,井管下入后,井内压力差和动载荷(冲击载荷)是导致管体爆裂事故的两个主要原因。所以,在实际工程中必须采取必要的技术措施,尽可能减少井管内外的压力差和动载荷(冲击载荷)。避免下管过程中的泥浆密度过大和负压、动载(冲击)的产生是PVC-U管成井的关键技术。
在理论研究基础上,分别组织实施了400m、437m两口大口径PVC-U塑料管示范井试验和建设,其井深和成井直径在国内外尚属首次。据国土资源部查新可知：采用全塑成井工艺组织实施的两口示范井,其成井口径、成井深度和研究成果在国内外处于先进水平。为了与传统金属井管成井工艺对比,示范井分别按照两种钻井结构进行了设计,在其它工艺技术和水文地质条件不变的情况下,在同一个场地(两口示范井相距50m)按照不同的钻井结构组织了试验和成井。其结果如下：
(1)试验1(示范)井的钻井和成井结构设计主要特点是钻井口径小,塑料管体与钻井口径的环状间隙为67.5mm,塑料管丝扣连接部位与钻井口径间隙为50mm。尽管口径小钻井速度较快,但是,在成井过程中其风险较大。由于钻井口径和PVC-U塑料管环状间隙较小,所以,出现了砾料“架桥”和瞬间坍塌现象,从而导致了井内过大动载荷(冲击载荷)和井管爆裂事故。
(2)试验2井在前期试验和理论分析计算基础上,采用合理的钻井结构(最小环空间隙100mm),保证了砾料投放的顺畅,避免了“架桥”现象。按照2号示范井的钻井结构和施工技术又在河南、山西等地组织实施了15口(含2口示范井)松散地层大口径和80口小口径基岩地层全塑管的推广应用,总钻探和成井工作量达9377m。通过大量的工程实践和试验证明了2号示范井技术的合理性和安全性。
(3)两眼试验井的单井出水量和含砂量差别很大,2号试验井的单位涌水量是1号井的3.1倍,含砂量低于1号井的10倍。其主要原因是：试验1井处理事故时间过长,并且在处理事故过程中由重新使用大量的泥浆(膨润土12吨),而导致含水层堵塞,并且填砾厚度没有保证。
(4)在理论分析和计算的基础上解释了PVC-U管下入困难和爆裂问题的原因,提出了通过泥浆性能调整、“压力平衡法”成井管柱设计、钻孔结构设计和投砾控制(井内冲击载荷控制)等技术措施来解决下管困难和爆裂两个主要问题,并在其它工程实例中取得了显著成效。
(5)通过示范井的试验和建设提出了PVC-U井管质量、运输保管方式、投砾速度过快、投砾量较大、洗井抽水降深过大等是造成塑料管不安全的主要因素。
在大量工程实践中总结了PVC-U塑料管常见事故类型和处理技术。提出了在成井和正常开采地下水过程中塑料管常见的事故有破碎爆裂和蠕动变形两种,其中,破碎爆裂是主要问题,蠕动变形是特殊情况下的个例。就事故类型和成因,结合理论和实际进行了详细的分析研究,并结合工程实例提出了具体的解决措施和PVC-U管井事故处理技术及预防措施。
PVC材料来源充足和廉价,并且加工成型所需温度较低。所以,以两口示范井为例从“以塑代钢”效益、成井效率分析、社会效益、环境效益等方面进行了对比分析和具体计算。通过对比分析可知：采用PVC-U管代替钢管或铸铁管,仅成井管材每米成本降低59.65元；成井速度与钢管相比可提高13.86倍。通过对比分析证明PVC-U管不仅可以彻底解决传统金属管材的腐蚀结垢问题,而且是目前水文水井、浅层地热能开发、地下应急(后备)水源地、农村饮水安全等领域的最佳成井管材,并具有广泛的推广应用前景和巨大的市场空间,在环境保护、节能减排、节约钢铁资源等方面具有重要的意义和显著的经济效益、社会效益及环境效益。
在理论分析计算和大量的工程实践、试验基础上,根据PVC-U塑料管的材料性质、物理力学性能指标,分别对管材要求、钻孔结构和质量、钻井液、成井工艺和事故处理程序等做了详细的阐述,从而为PVC-U塑料管成井和大面积推广应用提供了科学依据和技术支撑。
主要结论是：
(1)金属管井普遍存在着腐蚀结垢速度快、维修频繁、使用寿命短(3-10年)、污染水质等问题,是影响供水管井质量和运行效果的根本原因。
(2) PVC-U塑料管成井过程中常见的主要问题是管材下入困难和破碎爆裂。其中在下管过程中泥浆密度的高低是影响下入的主要因素；井内动载荷(冲击载荷)和压力差过大是造成塑料管破碎爆裂的主要原因,同时与管材质量、运输保管方式有关。
(3)下管前井内泥浆密度大于1300Kg/m3或接近PVC-U管材密度时,下管困难或下不去。经理论计算和示范井试验表明：通过调整下管前泥浆密度,保持在1050～1200Kg/m3之间,并且在成井管柱底端管体上钻数个Φ10～20mm圆孔,即可解决PVC-U塑料管下入困难和在下管过程中产生压力差问题。
(4)对PVC-U塑料井管安全造成最大威胁的主要因素是井内的动载荷(冲击载荷)和过大的压力差,投砾、冲孔、洗井抽水过程中出现的砾料“架桥”瞬间下沉、地层坍塌和大降深洗井抽水易形成井内动载荷和压力差。PVC-U塑料管井出现坍塌、投砾下沉速度≥0.73m/s时和井内外压力差≥4.53MPa时,产生的井内动载荷(冲击载荷)和压力差将会出现井管挤毁爆裂事故。
(5)在一般松散地层中采用塑料管成井时,其钻孔结构设计是关键,环空间隙易大于100mm。
(6) PVC-U塑料管成井或正常使用中出现破碎爆裂和蠕动变形事故和问题时,与金属管材相比很容易处理解决。
(7) PVC-U塑料管不易在60℃以上环境中使用。
总之,PVC材料具有成本低、重量轻、综合物理力学性能好、管壁光滑阻力小、不腐蚀结垢、使用寿命长(50年)、成井速度快、不污染水质、无有害有毒物质溶解析出等特点。在水文水井、浅层地热能开发等领域可以达到“以塑代钢”之目的。所以,推广应用PVC-U塑料管不但可以降低成本和工人劳动强度,而且在环境保护、节能减排、节约钢铁资源等方面具有重要的意义和显著的经济效益、社会效益及环境效益。
通过查新,其研究成果主要有以下技术创新点：
(1)两眼400m和437m示范井全部采用PVC-U塑料管,其成井口径和深度在国内外尚属首次,填补了该领域空白,并起到了示范作用。成井工艺及事故处理等技术方实现了自主创新和突破,对完善和发展我国的水文水井钻探与成井技术起到了积极的推动作用。
(2)首次从PVC-U材料性能、腐蚀结垢试验、受力分析与计算、工程实例等方面进行了全面深入系统研究。在大量野外试验和实践基础上总结出了PVC-U塑料管成井技术和工艺,既有理论分析又有大量的工程实践,为塑料管材的产业发展和大面积推广应用提供了技术支撑;为今后我国成井材料的合理选择提供了科学依据。
(3)通过理论计算和示范井建设准确科学解释了PVC-U管下入困难和爆裂问题的原因,并且其理论计算与实际基本吻合,说明其计算公式选择合理。
This paper systematic research and demonstration well construction on PVC-U pipe well completion at home and abroad for the first time, the related main filed contains drilling engineering, mechanics of materials, corrosion, elastic and plastic mechanics.
As the rapid development of shallow geothermal develop, emergency (reserve) underground water source, project of rural safety drinking water, industrial water supply, town water supply, people begins to pay more attention on underground water well technology and engineering. The traditional well completion material is mainly contains ordinary steel pipe and cast iron pipe, and the corrosion and scale seriously which reduce the service life greatly is the biggest problem on traditional well completion; another aspect, the resource is dried up with each passing day, iron mine development and steel industrial have the high energy consume, high pollution problems which effect the ecological environment and sustainable development seriously. So under the conflicting situation between source and environment, use new material instead of metal has great significance on low carbon society, energy-saving emission reduction, environment protection and sustainable development.
In the1950s, the United States of America began to use plastic pipe instead of steel and iron pipe in water well project. In the1960s, China began to pay more attention on plastic pipe well completion research and test. This period is a climax on plastic pipe well completion research and test. Because of the limited of plastic pipe formula and the well completion technology, the depth of plastic pipe well is from more than ten meters to dozens of meters. From the1970s to the1990s, majority water well use plastic pipes in foreign countries, but the diameter and depth are smaller, and our country steel use the steel or iron pipes. In early twenty-first Century, people found the problems on low service life, corrosion and scale seriously, high cost, frequent repair gradually. A handful of institute and factory begins a new round of research on plastic pipe well completion, but the depth are steel from dozens of meters to hundreds of meters, only some individual well depth more than200meters. Because of the plastic pipe can not sinking easily and burst during the well completion, it very difficult to use plastic pipe well instead of steel pipe in ground water well. This paper aims to the situation and mainly problem, put forward the "The Application and Research on PVC-U Plastic Pipe Well Completion" research topic, according to the large number of literature review and practical investigation, analyzed the problems on steel pipes corrosion and scale, the low depth, pipe sinking difficult, burst easy of PVC-U pipe well, and give the Specific research technique route.
This paper aims to a new kind of PVC-U plastic pipe, from the material types, properties, formulation and processing technology aspect to analyzed and research. From the deformation-temperature curve of PVC-U pipe, the PVC-U materials with temperature difference will show a glassy, high elastic state and flow state, and analyzed the processing temperature effect on quality. Under the foundation of PVC-U plastic pipes characteristics summarized, it conduct the test on physical mechanical performance, safety and health, harmful substances(arsenic, cadmium, lead, mercury, antimony, tin, phenol, aluminum, chromium, chloroform, carbon tetrachloride) test. The test conclusion shows this kind of PVC-U plastic has the excellent mechanical and safety index, and does not dissolution in the water.
In order to choose the well completion pipe reasonable and observe the corrosion and it speed, ordinary steel, cast iron pipe, bridge galvanized screen pipe, PVC-U pipe, wire ladder screen pipe are use for corrosion and scale problem research and test, the test method conclude the laboratory corrosion test and the actual underground color television dection. According to the test result and the actual engineering test, the metal pipe has the corrosion and scale problems universal, and the pipe strength will be sharp decline because of the corrosion and scale, and the PVC-U pipe do not have the corrosion and scale situation.
This paper aim to the PVC-U pipe characters, and reference the stress analysis of oil casing, use the theory of material mechanics, elastic and plastic mechanics, from the point of axial tensile force, axial pressure, external pressure, the pressure in the tube, the transverse shearing force, bending moment, temperature aspects, researched the stress analysis of PVC-U pipe in water well, and use the demonstration well as an example, analyze and calculation the actual stress analysis form the PVC-U pipe sinking, well flushing and gravel throwing, well completion processing, got the following conclusions:
(1) The overburden pressure, outside fluid column pressure, inside fluid column pressure will should a linear increase tend with the PVC-U pipe sinking depth, it means the more depth, the more pressure. And under the certain hydrogeological condition, the pressure value can not changed by human.
(2) When the mud density in well equal to the density of PVC-U tube, the PVC-U pipe equal to the buoyancy, then appear the PVC-U pipe descending difficult.
(3) After the PVC-U pipe well completion, during the pumping test or normal pump water period, because of the pipe bear the different types of pressure, the PVC-U pipe has the different pressure value between inside and outside.
(4) Under low quality of well completion, well washing not enough, underground water had large deep down distance, the pressure different between inside and outside will be larger, it will effect the safety of PVC-U pipe. If the PVC-U pipe have quality problem, it is easily cause the burst accident.
(5) Use the theory of oil drilling and Lame equation analyzed the dynamic load and collapsing pressure, the calculation result shows:when the pressure difference value between pipe inside and outside is bigger than4.53MPa, and formation collapse, throwing gravel "bridge" sinking speed bigger than0.73m/s, the pressure form outside and the collapsing pressure will be over the PVC-U pipe strength, it means these value is the critical value of PVC-U pipe burst.
(6) In order to make sure the PVC-U pipe safe in well, it should be reduce the pressure difference between pipe inside and outside as possible.
(7) During the well completion, gravel throwing, well washing and pumping processing, the PVC-U pipe will bear the different stress. The well completion and the use processing, PVC-U pipe are safer, and the well flush and gravel throwing processing are the danger period, the safe index is lowest. It means, after well completion, the difference between pipe inside and outside and the collasping pressure are the two main reasons which cause the pipe burst. So in the real project, the key point to make sure the PVC-U pipe safey is reduce the difference pressure between inside and outside, reduce the mud density as far as possible, and avoids the collapsing pressure. Using the theory research result, two PVC-U pipe large diameter demonstration wells were constructed, the depth are400m and437m, according to the science and technology novelty search (from Ministry of Land and Resources of the People's Republic of China), those two demonstration wells has the largest diameter and depth in the world at that time, the research level belongs to advanced at home and abroad, In order to compare with the traditional well completion technology, the demonstration wells designed two different well structure, in the same geology condition, the result as following:
(1) Test1well structure is the distance between PVC-U pipe and well wall is67.5mm, the PVC-U pipe joint part and drilling caliber distance is50mm, this kind of structure has the fast well drilling speed, but because of this less distance, the gravel found the "bridge" situation and increse the collapses pressure, cause the PVC-U pipe burst in well finally.
(2) From the accident of Testl well, Test2well use a more reasonable well structure(the distance between pipe and well wall is more than100mm), make sure the gravel throwing smooth. From the experience of Test2well, this well structure design and well completion technology are successful use in Henan, Shanxi area in China, the well amount are15, the total drilling amount is9377m. Those successful project shows the technology of Test2well are reasonable and safety.
(3) There are obvious different in water quantity and sand contains, the water amount in unit of Test2is3.1times than Testl, and the sand contains is one in tenth. The main reason is the Test1well has the pipe burst accident, the accident treatment cost long time, and use amount of mud, lead to the water plugging and the gravel thickness can not make sure.
(4) From the theory analyze and calculation, explain the reason of the PVC-U pipe sinking difficult and burst, put forward the mud characters adjustment,"pressure balance", well structure design, and gravel throwing speed control measure to solved those problems during the PVC-U pipe well completion, and successfully use in the real projects.
(5) According to the demonstration well construction and test, the low PVC-U pipe quality, wrong method of transport and keep the pipe, fast gravel throwing speed, large quantities gravel throw, water level drop too fast during the well washing and pumping are the main factors lead to the PVC-U pipe in the unsafe situation.
This paper summarize the common PVC-U pipe well type and treatment, put forward the well completion and water pumping, the PVC-U pipe burst or creep deformation. And the burst is the main problem; the creep deformation is only an special case. Combined with the real project, give the specific measure of PVC-U pipe accident treatment.
PVC material is very cheap, and the PVC-U pipe make do not need very high temperature. According to the calculation from the environment effect, well completion speed, social benefits, the PVC-U pipe well completion, the pipe cost reduced￥59.65yuan/m, the well completion speed increase13.86times. From the compare, the PVC-U pipe can solve the traditional metal pipe corrosion and scale problems, and PVC-U pipe is the best well pipe for water well, it has the board develop space, has great significance on low carbon society, energy-saving emission reduction, environment protection and sustainable development.
This paper has theory analyze and amount of projects and tests, from the PVC-U pipe material and analysis the mechanical properties, describe the pipe requirement, well structure and quanty, mud, well completion and accident treatment separately, and it can support the PVC-U pipe use in water well.
The main conclusions are as follows:
(1) The metal pipe are generally has the characteristics of fast scale and corrosion speed, maintenance frequent, short service lift time (3-10years), water quality polluted, those are the basic reasons which effect the water supply well quantity and running effect.
(2) The main problems which effect the processing of PVC-U pipe well completion are PVC-U pipe descending difficult and pipe burst. Among them, the mud density is the main factor; the dynamic load (impact load) in well and the pressure difference is the main reasons which lead to the PVC-U pipe burst, and also related with the PVC-U pipe quantity and the transport and keep method.
(3) Before the well completion, when the mud density larger than1300kg/m3, or similar to the density of PVC-U pipe, the PVC-U pipe may descending difficult or can not descending. According to the theory calculation and the demonstration well test:adjust the mud density before the well completion, and keep the mud density in1050-1200kg/m3, and make some holes on the bottom of the pipe, can resolve the PVC-U pipe descending difficult and pressure difference.
(4) The biggest threats for PVC-U pipe safe in the well are dynamic load (impact load) and the large pressure difference, during the gravel throwing, well washing, pumping processing, it is easy happened the "gravel bridge" descending suddenly, collapse, and the large water level drop pumping water may lead the dynamic load and the pressure difference. When the gravel throwing speed bigger than0.73m/s and the pressure difference larger than4.53MPa, the dynamic load and the pressure difference may cause the PVC-U pipe burst accident.
(5) In general loose formation, the key to PVC-U pipe well completion is the well structure, the distance between well and pipe should be larger than100mm.
(6) During the use period of PVC-U well or well completion processing, if there has the problems of burst or peristalsis deformation, the treat measure is easier than metal pipe well.
(7) PVC-U pipes are not allowed use in the environment which temperature above60℃.
In a word, PVC material has the characteristics of low cost, light weight, excellent comprehensive physical and mechanical performance, no corrosion and scale, long service life (50years), fast well completion speed, no polluted water quantity, no harmful material dissolve in water. It may realize the purpose of "use plastic instead of metal" in water well and shallow geothermal development field. So, to popularization and application the PVC-U pipe can not only reduce the cost and labor intensity, and have important significance in environment protect, energy saving and emission reduction, save the metal resource, it have significant economic, social and environment benefits. According to the novelty search, this paper technology innovation concludes:
(1) Two demonstration well (400m,437m) use PVC-U pipe, has the largest diameter and depth in the world at that time, the research level belongs to advanced at home and abroad, fill the gaps in the field, and has played an exemplary role. The PVC-U pipe wells completion and the accident treatment realize the innovation; it is helpful for the water well drilling and well completion development.
(2) It is the first time to analyze the PVC-U material character, conduct the corrosion and scale test, analysis the pressure and calculation, real project aspects to research. From the amount wild test and practice to conclude the technology of PVC-U pipes well completion, combined with the theory analyze and project, it formed the support for the plastic pipe industry development and application in larger field, it also provides the scientific basis for the future of China's well pipe choose.
(3) The theory calculation and demonstration well explained the PVC-U pipe sinking difficult and burst problem, the theory calculate and the real situation almost equal, it shows the calculation formula choose is reasonable.
随着浅层地热能开发、地下应急(后备)水源地、农村饮水安全工程、厂矿供水、城镇供水等建设的迅速发展,地下供水管井的工程技术开始引起关注和重视。传统的成井管材主要是普通钢管和铸铁管,其最大的问题是腐蚀结垢严重,从而降低了其使用寿命；再者,资源的日趋枯竭、铁矿开采和钢铁工业的高能耗、高污染问题严重影响着生态环境和可持续发展。所以,在资源与环境形势问题矛盾突出的严峻形势下,采用新型井管材料代替金属,对低碳社会、节能减排、环境保护和可持续发展具有重大的现实意义。
20世纪50年代,美国首先在水井工程中采用塑料管替代钢管和铸铁管,我国在60年代也开始关注塑料管成井技术研究和试验,从而掀起了塑料管研发和试验应用的高潮。由于当时的管材配方质量和成井技术所限,其成井深度一般在十儿米到几十米。70-90年代,国外多数水井依然稳步采用塑料管成井,其口径和深度较小；国内则几乎处于“空白”时期,其成井管材主要以钢管和铸铁管为主。进入21世纪初期,人们逐步发现金属管井使用寿命低、腐蚀结垢严重、成本高、维修频繁等问题。为此,少数单位和生产厂家开始新一轮的研发和采用塑料管成井,其成井深度多数依然在几十米到百米左右,个别成井深度大于200m。但是,由于在成井过程中塑料井管下入困难和容易爆裂两大问题一直未能较好解决,从而影响着PVC-U塑料管在水文水井中的推广应用。
针对上述现状和存在的主要问题,提出了《PVC-U塑料管成井技术应用与研究》课题,通过大量文献查阅和实际调查,分析研究了目前金属管井腐蚀结垢和PVC-U塑料管成井深度浅、下入困难、易爆裂等问题,并就研究课题提出了具体的研究技术路线。
对于新型改性PVC-U塑料井管,主要从材料类型、性质、配方和加工工艺进行了分析研究。通过PVC-U形变—温度曲线,可以看出PVC-U材料随温度的不同会呈现出玻璃态、高弹态和粘流态三种状态,同时分析研究了加工各工序温度对其质量的影响；在PVC-U塑料管特点归纳基础上,分别对其物理力学性能指标、卫生安全指标和PVC-U塑料管材中砷、镉、铅、汞、酚类、锑、锡、铝、铬、氯仿、四氯化碳等有害物质进行了测试和溶解析出试验。通过有关性能指标的测试和溶解析出试验结果可以说明：PVC-U塑料管材具有较好的综合力学和卫生安全性能指标,并且在水中不会发生析出和溶解现象。
为了合理选择成井管材,并直观了解腐蚀结垢现象、速度等,选择了常用普通金属管材、球墨铸铁管、桥式镀锌过滤管、PVC-U管、梯形丝过滤管等,采用实验室挂片试验和实际井下彩色电视检测等手段进行了腐蚀试验和研究。通过腐蚀试验计算和实际工程检测可知：金属管材普遍存在着腐蚀结垢问题,并且金属管材腐蚀后其强度急剧下降；PVC-U塑料管则不存在腐蚀结垢现象。
针对PVC-U塑料管特性,参照石油套管受力分析,利用材料力学、弹塑性力学理论分别从轴向拉力、轴向压力、外挤压力、管内压力、横向剪切力、弯矩、温度等方面对塑料管在井内进行了受力分析研究,并以示范井为例从PVC-U管材下入、冲孔—投砾、PVC-U管完井三个主要工序进行了实际受力分析和计算。并得出以下结论：
(1)管外上覆岩层压力、管外液柱压力、管内液柱压力随着PVC-U管下入深度呈线性增加趋势,即：井越深管体受到的压力越大。并且,当水文地质条件一定时,其压力值无法人为改变。
(2)当井内泥浆密度等于PVC-U塑料管材密度时,则管体轴向重力和浮力相等,出现管材下入困难或下不去问题。
(3) PVC-U塑料管在完井后,抽水阶段或正常开采期间,由于井管内外受力类型和压力不同,故存在着管内外压力差问题。井管下入越深,压力差越大。
(4)当成井质量较差,洗井不彻底或地下水降深过大时,管体内外压力差更大。PVC-U管安全稳定性则差,当PVC-U塑料管质量存在问题时,易出现挤毁爆裂事故。
(5)利用石油钻井理论和拉梅(Lame)方程分别对示范井动载荷(冲击载荷)和抗挤压力进行了定量分析,计算结果表明：井内压力差≥4.53MPa时和地层坍塌、投砾“架桥”瞬间下沉速度≥0.73m/s时,其外挤压力和冲击载荷值超过PVC-U塑料管的强度,也是PVC-U塑料管挤毁爆裂的临界值。
(6)为保证PVC-U塑料管在井内的安全,尽可能减少压力差。
(7) PVC-U塑料井管在下管、投砾和洗井抽水(开采)三个过程中受力不同。在下管过程和完井后正常使用过程较为安全,在PVC-U塑料管下入后冲孔换浆和砾料投放过程最为危险,其安全系数最小。也就是说,井管下入后,井内压力差和动载荷(冲击载荷)是导致管体爆裂事故的两个主要原因。所以,在实际工程中必须采取必要的技术措施,尽可能减少井管内外的压力差和动载荷(冲击载荷)。避免下管过程中的泥浆密度过大和负压、动载(冲击)的产生是PVC-U管成井的关键技术。
在理论研究基础上,分别组织实施了400m、437m两口大口径PVC-U塑料管示范井试验和建设,其井深和成井直径在国内外尚属首次。据国土资源部查新可知：采用全塑成井工艺组织实施的两口示范井,其成井口径、成井深度和研究成果在国内外处于先进水平。为了与传统金属井管成井工艺对比,示范井分别按照两种钻井结构进行了设计,在其它工艺技术和水文地质条件不变的情况下,在同一个场地(两口示范井相距50m)按照不同的钻井结构组织了试验和成井。其结果如下：
(1)试验1(示范)井的钻井和成井结构设计主要特点是钻井口径小,塑料管体与钻井口径的环状间隙为67.5mm,塑料管丝扣连接部位与钻井口径间隙为50mm。尽管口径小钻井速度较快,但是,在成井过程中其风险较大。由于钻井口径和PVC-U塑料管环状间隙较小,所以,出现了砾料“架桥”和瞬间坍塌现象,从而导致了井内过大动载荷(冲击载荷)和井管爆裂事故。
(2)试验2井在前期试验和理论分析计算基础上,采用合理的钻井结构(最小环空间隙100mm),保证了砾料投放的顺畅,避免了“架桥”现象。按照2号示范井的钻井结构和施工技术又在河南、山西等地组织实施了15口(含2口示范井)松散地层大口径和80口小口径基岩地层全塑管的推广应用,总钻探和成井工作量达9377m。通过大量的工程实践和试验证明了2号示范井技术的合理性和安全性。
(3)两眼试验井的单井出水量和含砂量差别很大,2号试验井的单位涌水量是1号井的3.1倍,含砂量低于1号井的10倍。其主要原因是：试验1井处理事故时间过长,并且在处理事故过程中由重新使用大量的泥浆(膨润土12吨),而导致含水层堵塞,并且填砾厚度没有保证。
(4)在理论分析和计算的基础上解释了PVC-U管下入困难和爆裂问题的原因,提出了通过泥浆性能调整、“压力平衡法”成井管柱设计、钻孔结构设计和投砾控制(井内冲击载荷控制)等技术措施来解决下管困难和爆裂两个主要问题,并在其它工程实例中取得了显著成效。
(5)通过示范井的试验和建设提出了PVC-U井管质量、运输保管方式、投砾速度过快、投砾量较大、洗井抽水降深过大等是造成塑料管不安全的主要因素。
在大量工程实践中总结了PVC-U塑料管常见事故类型和处理技术。提出了在成井和正常开采地下水过程中塑料管常见的事故有破碎爆裂和蠕动变形两种,其中,破碎爆裂是主要问题,蠕动变形是特殊情况下的个例。就事故类型和成因,结合理论和实际进行了详细的分析研究,并结合工程实例提出了具体的解决措施和PVC-U管井事故处理技术及预防措施。
PVC材料来源充足和廉价,并且加工成型所需温度较低。所以,以两口示范井为例从“以塑代钢”效益、成井效率分析、社会效益、环境效益等方面进行了对比分析和具体计算。通过对比分析可知：采用PVC-U管代替钢管或铸铁管,仅成井管材每米成本降低59.65元；成井速度与钢管相比可提高13.86倍。通过对比分析证明PVC-U管不仅可以彻底解决传统金属管材的腐蚀结垢问题,而且是目前水文水井、浅层地热能开发、地下应急(后备)水源地、农村饮水安全等领域的最佳成井管材,并具有广泛的推广应用前景和巨大的市场空间,在环境保护、节能减排、节约钢铁资源等方面具有重要的意义和显著的经济效益、社会效益及环境效益。
在理论分析计算和大量的工程实践、试验基础上,根据PVC-U塑料管的材料性质、物理力学性能指标,分别对管材要求、钻孔结构和质量、钻井液、成井工艺和事故处理程序等做了详细的阐述,从而为PVC-U塑料管成井和大面积推广应用提供了科学依据和技术支撑。
主要结论是：
(1)金属管井普遍存在着腐蚀结垢速度快、维修频繁、使用寿命短(3-10年)、污染水质等问题,是影响供水管井质量和运行效果的根本原因。
(2) PVC-U塑料管成井过程中常见的主要问题是管材下入困难和破碎爆裂。其中在下管过程中泥浆密度的高低是影响下入的主要因素；井内动载荷(冲击载荷)和压力差过大是造成塑料管破碎爆裂的主要原因,同时与管材质量、运输保管方式有关。
(3)下管前井内泥浆密度大于1300Kg/m3或接近PVC-U管材密度时,下管困难或下不去。经理论计算和示范井试验表明：通过调整下管前泥浆密度,保持在1050～1200Kg/m3之间,并且在成井管柱底端管体上钻数个Φ10～20mm圆孔,即可解决PVC-U塑料管下入困难和在下管过程中产生压力差问题。
(4)对PVC-U塑料井管安全造成最大威胁的主要因素是井内的动载荷(冲击载荷)和过大的压力差,投砾、冲孔、洗井抽水过程中出现的砾料“架桥”瞬间下沉、地层坍塌和大降深洗井抽水易形成井内动载荷和压力差。PVC-U塑料管井出现坍塌、投砾下沉速度≥0.73m/s时和井内外压力差≥4.53MPa时,产生的井内动载荷(冲击载荷)和压力差将会出现井管挤毁爆裂事故。
(5)在一般松散地层中采用塑料管成井时,其钻孔结构设计是关键,环空间隙易大于100mm。
(6) PVC-U塑料管成井或正常使用中出现破碎爆裂和蠕动变形事故和问题时,与金属管材相比很容易处理解决。
(7) PVC-U塑料管不易在60℃以上环境中使用。
总之,PVC材料具有成本低、重量轻、综合物理力学性能好、管壁光滑阻力小、不腐蚀结垢、使用寿命长(50年)、成井速度快、不污染水质、无有害有毒物质溶解析出等特点。在水文水井、浅层地热能开发等领域可以达到“以塑代钢”之目的。所以,推广应用PVC-U塑料管不但可以降低成本和工人劳动强度,而且在环境保护、节能减排、节约钢铁资源等方面具有重要的意义和显著的经济效益、社会效益及环境效益。
通过查新,其研究成果主要有以下技术创新点：
(1)两眼400m和437m示范井全部采用PVC-U塑料管,其成井口径和深度在国内外尚属首次,填补了该领域空白,并起到了示范作用。成井工艺及事故处理等技术方实现了自主创新和突破,对完善和发展我国的水文水井钻探与成井技术起到了积极的推动作用。
(2)首次从PVC-U材料性能、腐蚀结垢试验、受力分析与计算、工程实例等方面进行了全面深入系统研究。在大量野外试验和实践基础上总结出了PVC-U塑料管成井技术和工艺,既有理论分析又有大量的工程实践,为塑料管材的产业发展和大面积推广应用提供了技术支撑;为今后我国成井材料的合理选择提供了科学依据。
(3)通过理论计算和示范井建设准确科学解释了PVC-U管下入困难和爆裂问题的原因,并且其理论计算与实际基本吻合,说明其计算公式选择合理。
This paper systematic research and demonstration well construction on PVC-U pipe well completion at home and abroad for the first time, the related main filed contains drilling engineering, mechanics of materials, corrosion, elastic and plastic mechanics.
As the rapid development of shallow geothermal develop, emergency (reserve) underground water source, project of rural safety drinking water, industrial water supply, town water supply, people begins to pay more attention on underground water well technology and engineering. The traditional well completion material is mainly contains ordinary steel pipe and cast iron pipe, and the corrosion and scale seriously which reduce the service life greatly is the biggest problem on traditional well completion; another aspect, the resource is dried up with each passing day, iron mine development and steel industrial have the high energy consume, high pollution problems which effect the ecological environment and sustainable development seriously. So under the conflicting situation between source and environment, use new material instead of metal has great significance on low carbon society, energy-saving emission reduction, environment protection and sustainable development.
In the1950s, the United States of America began to use plastic pipe instead of steel and iron pipe in water well project. In the1960s, China began to pay more attention on plastic pipe well completion research and test. This period is a climax on plastic pipe well completion research and test. Because of the limited of plastic pipe formula and the well completion technology, the depth of plastic pipe well is from more than ten meters to dozens of meters. From the1970s to the1990s, majority water well use plastic pipes in foreign countries, but the diameter and depth are smaller, and our country steel use the steel or iron pipes. In early twenty-first Century, people found the problems on low service life, corrosion and scale seriously, high cost, frequent repair gradually. A handful of institute and factory begins a new round of research on plastic pipe well completion, but the depth are steel from dozens of meters to hundreds of meters, only some individual well depth more than200meters. Because of the plastic pipe can not sinking easily and burst during the well completion, it very difficult to use plastic pipe well instead of steel pipe in ground water well. This paper aims to the situation and mainly problem, put forward the "The Application and Research on PVC-U Plastic Pipe Well Completion" research topic, according to the large number of literature review and practical investigation, analyzed the problems on steel pipes corrosion and scale, the low depth, pipe sinking difficult, burst easy of PVC-U pipe well, and give the Specific research technique route.
This paper aims to a new kind of PVC-U plastic pipe, from the material types, properties, formulation and processing technology aspect to analyzed and research. From the deformation-temperature curve of PVC-U pipe, the PVC-U materials with temperature difference will show a glassy, high elastic state and flow state, and analyzed the processing temperature effect on quality. Under the foundation of PVC-U plastic pipes characteristics summarized, it conduct the test on physical mechanical performance, safety and health, harmful substances(arsenic, cadmium, lead, mercury, antimony, tin, phenol, aluminum, chromium, chloroform, carbon tetrachloride) test. The test conclusion shows this kind of PVC-U plastic has the excellent mechanical and safety index, and does not dissolution in the water.
In order to choose the well completion pipe reasonable and observe the corrosion and it speed, ordinary steel, cast iron pipe, bridge galvanized screen pipe, PVC-U pipe, wire ladder screen pipe are use for corrosion and scale problem research and test, the test method conclude the laboratory corrosion test and the actual underground color television dection. According to the test result and the actual engineering test, the metal pipe has the corrosion and scale problems universal, and the pipe strength will be sharp decline because of the corrosion and scale, and the PVC-U pipe do not have the corrosion and scale situation.
This paper aim to the PVC-U pipe characters, and reference the stress analysis of oil casing, use the theory of material mechanics, elastic and plastic mechanics, from the point of axial tensile force, axial pressure, external pressure, the pressure in the tube, the transverse shearing force, bending moment, temperature aspects, researched the stress analysis of PVC-U pipe in water well, and use the demonstration well as an example, analyze and calculation the actual stress analysis form the PVC-U pipe sinking, well flushing and gravel throwing, well completion processing, got the following conclusions:
(1) The overburden pressure, outside fluid column pressure, inside fluid column pressure will should a linear increase tend with the PVC-U pipe sinking depth, it means the more depth, the more pressure. And under the certain hydrogeological condition, the pressure value can not changed by human.
(2) When the mud density in well equal to the density of PVC-U tube, the PVC-U pipe equal to the buoyancy, then appear the PVC-U pipe descending difficult.
(3) After the PVC-U pipe well completion, during the pumping test or normal pump water period, because of the pipe bear the different types of pressure, the PVC-U pipe has the different pressure value between inside and outside.
(4) Under low quality of well completion, well washing not enough, underground water had large deep down distance, the pressure different between inside and outside will be larger, it will effect the safety of PVC-U pipe. If the PVC-U pipe have quality problem, it is easily cause the burst accident.
(5) Use the theory of oil drilling and Lame equation analyzed the dynamic load and collapsing pressure, the calculation result shows:when the pressure difference value between pipe inside and outside is bigger than4.53MPa, and formation collapse, throwing gravel "bridge" sinking speed bigger than0.73m/s, the pressure form outside and the collapsing pressure will be over the PVC-U pipe strength, it means these value is the critical value of PVC-U pipe burst.
(6) In order to make sure the PVC-U pipe safe in well, it should be reduce the pressure difference between pipe inside and outside as possible.
(7) During the well completion, gravel throwing, well washing and pumping processing, the PVC-U pipe will bear the different stress. The well completion and the use processing, PVC-U pipe are safer, and the well flush and gravel throwing processing are the danger period, the safe index is lowest. It means, after well completion, the difference between pipe inside and outside and the collasping pressure are the two main reasons which cause the pipe burst. So in the real project, the key point to make sure the PVC-U pipe safey is reduce the difference pressure between inside and outside, reduce the mud density as far as possible, and avoids the collapsing pressure. Using the theory research result, two PVC-U pipe large diameter demonstration wells were constructed, the depth are400m and437m, according to the science and technology novelty search (from Ministry of Land and Resources of the People's Republic of China), those two demonstration wells has the largest diameter and depth in the world at that time, the research level belongs to advanced at home and abroad, In order to compare with the traditional well completion technology, the demonstration wells designed two different well structure, in the same geology condition, the result as following:
(1) Test1well structure is the distance between PVC-U pipe and well wall is67.5mm, the PVC-U pipe joint part and drilling caliber distance is50mm, this kind of structure has the fast well drilling speed, but because of this less distance, the gravel found the "bridge" situation and increse the collapses pressure, cause the PVC-U pipe burst in well finally.
(2) From the accident of Testl well, Test2well use a more reasonable well structure(the distance between pipe and well wall is more than100mm), make sure the gravel throwing smooth. From the experience of Test2well, this well structure design and well completion technology are successful use in Henan, Shanxi area in China, the well amount are15, the total drilling amount is9377m. Those successful project shows the technology of Test2well are reasonable and safety.
(3) There are obvious different in water quantity and sand contains, the water amount in unit of Test2is3.1times than Testl, and the sand contains is one in tenth. The main reason is the Test1well has the pipe burst accident, the accident treatment cost long time, and use amount of mud, lead to the water plugging and the gravel thickness can not make sure.
(4) From the theory analyze and calculation, explain the reason of the PVC-U pipe sinking difficult and burst, put forward the mud characters adjustment,"pressure balance", well structure design, and gravel throwing speed control measure to solved those problems during the PVC-U pipe well completion, and successfully use in the real projects.
(5) According to the demonstration well construction and test, the low PVC-U pipe quality, wrong method of transport and keep the pipe, fast gravel throwing speed, large quantities gravel throw, water level drop too fast during the well washing and pumping are the main factors lead to the PVC-U pipe in the unsafe situation.
This paper summarize the common PVC-U pipe well type and treatment, put forward the well completion and water pumping, the PVC-U pipe burst or creep deformation. And the burst is the main problem; the creep deformation is only an special case. Combined with the real project, give the specific measure of PVC-U pipe accident treatment.
PVC material is very cheap, and the PVC-U pipe make do not need very high temperature. According to the calculation from the environment effect, well completion speed, social benefits, the PVC-U pipe well completion, the pipe cost reduced￥59.65yuan/m, the well completion speed increase13.86times. From the compare, the PVC-U pipe can solve the traditional metal pipe corrosion and scale problems, and PVC-U pipe is the best well pipe for water well, it has the board develop space, has great significance on low carbon society, energy-saving emission reduction, environment protection and sustainable development.
This paper has theory analyze and amount of projects and tests, from the PVC-U pipe material and analysis the mechanical properties, describe the pipe requirement, well structure and quanty, mud, well completion and accident treatment separately, and it can support the PVC-U pipe use in water well.
The main conclusions are as follows:
(1) The metal pipe are generally has the characteristics of fast scale and corrosion speed, maintenance frequent, short service lift time (3-10years), water quality polluted, those are the basic reasons which effect the water supply well quantity and running effect.
(2) The main problems which effect the processing of PVC-U pipe well completion are PVC-U pipe descending difficult and pipe burst. Among them, the mud density is the main factor; the dynamic load (impact load) in well and the pressure difference is the main reasons which lead to the PVC-U pipe burst, and also related with the PVC-U pipe quantity and the transport and keep method.
(3) Before the well completion, when the mud density larger than1300kg/m3, or similar to the density of PVC-U pipe, the PVC-U pipe may descending difficult or can not descending. According to the theory calculation and the demonstration well test:adjust the mud density before the well completion, and keep the mud density in1050-1200kg/m3, and make some holes on the bottom of the pipe, can resolve the PVC-U pipe descending difficult and pressure difference.
(4) The biggest threats for PVC-U pipe safe in the well are dynamic load (impact load) and the large pressure difference, during the gravel throwing, well washing, pumping processing, it is easy happened the "gravel bridge" descending suddenly, collapse, and the large water level drop pumping water may lead the dynamic load and the pressure difference. When the gravel throwing speed bigger than0.73m/s and the pressure difference larger than4.53MPa, the dynamic load and the pressure difference may cause the PVC-U pipe burst accident.
(5) In general loose formation, the key to PVC-U pipe well completion is the well structure, the distance between well and pipe should be larger than100mm.
(6) During the use period of PVC-U well or well completion processing, if there has the problems of burst or peristalsis deformation, the treat measure is easier than metal pipe well.
(7) PVC-U pipes are not allowed use in the environment which temperature above60℃.
In a word, PVC material has the characteristics of low cost, light weight, excellent comprehensive physical and mechanical performance, no corrosion and scale, long service life (50years), fast well completion speed, no polluted water quantity, no harmful material dissolve in water. It may realize the purpose of "use plastic instead of metal" in water well and shallow geothermal development field. So, to popularization and application the PVC-U pipe can not only reduce the cost and labor intensity, and have important significance in environment protect, energy saving and emission reduction, save the metal resource, it have significant economic, social and environment benefits. According to the novelty search, this paper technology innovation concludes:
(1) Two demonstration well (400m,437m) use PVC-U pipe, has the largest diameter and depth in the world at that time, the research level belongs to advanced at home and abroad, fill the gaps in the field, and has played an exemplary role. The PVC-U pipe wells completion and the accident treatment realize the innovation; it is helpful for the water well drilling and well completion development.
(2) It is the first time to analyze the PVC-U material character, conduct the corrosion and scale test, analysis the pressure and calculation, real project aspects to research. From the amount wild test and practice to conclude the technology of PVC-U pipes well completion, combined with the theory analyze and project, it formed the support for the plastic pipe industry development and application in larger field, it also provides the scientific basis for the future of China's well pipe choose.
(3) The theory calculation and demonstration well explained the PVC-U pipe sinking difficult and burst problem, the theory calculate and the real situation almost equal, it shows the calculation formula choose is reasonable.
引文
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