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Sand Erosion Mitigation for Offshore Pipeline and Riser – Erosion Prediction by Computational Fluid Dynamic CFD Analysis and Experimental Testing 海洋管道和隔水管的减沙——基于计算流体动力学CFD分析和实验测试的减沙预测
Pub Date : 2022-03-18 DOI: 10.4043/31451-ms
I. Putra, Tan Chin Chien, M. Badaruddin, M. Isa, Cheong Xiang Hou, Liu Dongjie, Sun Dalin
Late life production of oil & gas facilities are faced with significant challenge especially when sand is produced along with the production fluid. It can cause premature failure of the equipment, for example piping and pipeline. Mitigation by adding sand removal facility is limited by space, available load, and handling at satellite wellhead platform. It also introduced additional pressure drop which limit the production that already in low pressure. One of the measures to mitigate sand erosion issue for the offshore pipeline and riser is by flow assurance, to reduce the flow velocity so that the sand velocity will be less than the erosional velocity. This mitigation comes with drawback where reducing velocity will require bigger size pipeline, higher cost, and introduce higher liquid dropout along the pipeline which will create severe slugging issue in the pipeline. Next mitigation can be done by increasing bend radius along the pipeline, to reduce impact angle of the sand to the internal surface of the pipeline. Last mitigation will be increasing resistance of the material to the sand erosion. Combination of those methodology is required to achieve the most optimum solution to mitigate sand erosion. This paper present sand erosion mitigation on one of the existing pipeline replacement projects in PETRONAS by application of unbonded flexible pipe. Modeling of the of the erosion due to sand particle solution in the pipeline was done using computational fluid dynamic finite element analysis simulation. Experimental test with samples positioned at various orientation of the riser bend location were also investigated. Concerning the exceptional balance between results efficiency and simulation time, a grid sensitivity test has also been included. Various parameters were used to verify the sensitivity of the simulation including materials properties for various fluid composition data obtained from production forecast and fluid velocity as modeled in the pipeline steady state hydraulic analysis and transient flow assurance analysis. As result, the thickness of internal carcass is found sufficient to withstand the erosion threat generated by sand particles for the entire design life of the pipeline. The results obtained from finite element analysis and erosion experimental test were then correlated, and the comparison were illustrated in graph of velocity against erosion rate for each of sand concentration. The result of the modeling and experimental testing may improve prediction model of the sand erosion in the offshore pipeline especially for flexible pipeline and riser application.
油气设施的后期生产面临着巨大的挑战,特别是当出砂随生产液一起排出时。它可能导致设备的过早失效,例如管道和管道。增加除砂设施的缓解措施受到空间、可用载荷和卫星井口平台处理能力的限制。它还引入了额外的压降,限制了已经处于低压状态的产量。缓解海上管道和隔水管砂蚀问题的措施之一是通过流动保证,降低流速,使出砂速度小于侵蚀速度。这种缓解措施也有缺点,降低速度需要更大的管道尺寸,更高的成本,并且沿着管道会产生更高的液差,从而在管道中产生严重的段塞问题。下一步可以通过增加管道弯曲半径来减小砂体对管道内表面的冲击角度。最后的缓解措施是增加材料对沙蚀的抵抗力。需要将这些方法结合起来,以获得减轻砂石侵蚀的最佳解决方案。本文介绍了在马来西亚国家石油公司(PETRONAS)现有的一个管道更换项目中,应用无粘结柔性管来缓解砂蚀。采用计算流体力学有限元分析方法,对管道内砂粒溶液的侵蚀过程进行了模拟。在立管弯曲位置的不同方向进行了实验试验。考虑到结果效率和模拟时间之间的特殊平衡,还包括网格灵敏度测试。在管道稳态水力分析和瞬态流动保证分析中,利用各种参数验证了模拟的敏感性,包括从生产预测中获得的各种流体成分数据的材料特性和流体速度。结果表明,在管道的整个设计寿命期内,内胎体厚度足以承受砂粒的侵蚀威胁。将有限元分析结果与冲蚀试验结果进行对比,并绘制出不同砂浓度下流速与冲蚀速率的对比图。模拟和试验结果对海上管道特别是柔性管道和隔水管的砂蚀预测模型有一定的改进作用。
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引用次数: 0
Assessment on Deformed Pipeline Using Integrated Metal Magnetic Memory i-MMM Technology 基于集成金属磁记忆i-MMM技术的变形管道评估
Pub Date : 2022-03-18 DOI: 10.4043/31424-ms
Raja Zahirudin Raja Ismail, Zahrin Zain, Mohd Noor Baharin Che Kamaruddin, Mohd Faridz Mod Yunoh
This paper aims to share a new concept of assets condition assessment knows as Integrated Metal Magnetic Memory (i-MMM) which integrates capability of various Non-Destructive Testing (NDT) technology in determining the current state of deformed pipeline due to external loadings. MMM technology is one of NDT technique which can be used for early failure detection especially for Stress Concentration Zones (SCZ), microcrack and fatigue damage for ferromagnetic components. MMM is a passive technology tools that relies on the measurement of Self-magnetic Leakage Field (SMLF) of the ferromagnetic materials. Most of the traditional NDT method able to inspect the macro defect but incapable to identify micro defect due to the stress concentration zone. Based on this, MMM can be integrated and complimentary in its capability to other well-known NDT testing such as Ultrasonic Testing (UT) and Hardness Test. A case study presented whereby iMMM can be utilized to determined location which are prone to deformation due to stress and detailed assessment from changes of hardness up to development of macro size defect. Based on the findings in the case study, 2 microcrack were found at 2 inspected location of the pipeline. Finally, based on the results and findings from the integrated approach of i-MMM, it can contribute and provide more impact on the simulation analysis by providing focused anomaly area or location and reduced the processing time.
本文旨在分享一种新的资产状态评估概念,即集成金属磁记忆(i-MMM),它集成了各种无损检测(NDT)技术的能力,以确定由于外部载荷而变形的管道的当前状态。MMM技术是一种无损检测技术,可用于铁磁构件的应力集中区、微裂纹和疲劳损伤的早期失效检测。MMM是一种依赖于铁磁材料自漏磁场(SMLF)测量的无源技术工具。传统无损检测方法大多能检测宏观缺陷,但由于应力集中区的存在,无法识别微观缺陷。在此基础上,MMM可以与其他著名的无损检测(NDT)如超声波检测(UT)和硬度测试(硬度测试)相结合和互补。介绍了一个案例研究,其中iMMM可以用来确定容易因应力而变形的位置,并详细评估从硬度变化到宏观尺寸缺陷的发展。根据实例研究结果,在管道的2个检测位置发现了2个微裂纹。最后,基于i-MMM综合方法的结果和发现,它可以通过提供集中异常区域或位置,减少处理时间,为模拟分析做出贡献和提供更大的影响。
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引用次数: 0
Perforating Docking System for Efficient High-Volume Operation 高效大容量作业的射孔对接系统
Pub Date : 2022-03-18 DOI: 10.4043/31571-ms
Mohd Shafie Jumaat, S. Wattanapornmongkol, Sorawit Wattanachai, Kontron Konglumthan
The Gulf of Thailand is developed with a high volume of slim monobore wells, producing from multiple thin reservoirs. The high volume of wells enables sufficient production output, but their costs must be well managed for overall field economics. An important cost component comes from the perforating operation that involves several runs of guns on electric wireline, and on each run consists of several guns that are activated sequentially using switches. This process of perforating multiple zones in a well, if not managed, will lead to extended operational time or worse, leading to serious problems like off-depth perforation. Additionally, the temperature of the wells averaging at 370 degF poses an additional challenge to the operations. The efficiency of operation is paramount in achieving better well economics. Hence, several operational and technology optimizations were performed over the years to achieve several incremental in efficiency. Incremental improvement is always valuable in such a high-volume operation involving thousands of perforating runs annually. However, the gain is even more pronounced when a step change in efficiency is achieved, and this has been observed in the new gun docking system engineered for the high-volume market in Thailand. It enables quicker connection of multiple guns on the surface with better safety and reliability. This paper discusses the background of the high-volume perforating in Thailand and the need for efficiency, which led to the development of this new gun docking system tailored for this market. This docking system technology is presented together with the statistics of its deployment in over 300 perforating runs to date and compared to the statistics of the previous system. The efficiency achieved comes from its quicker connection and arming system, combined with its better safety and reliability that lead to a lower misfire rate. The success of its deployment and more importantly, its step change in efficiency may pave ways for more marginal fields to be developed globally. Additionally, as thousands of perforating runs are performed globally, its efficiency will also play a vital role in shortening operational times and contribute to lower global carbon emission.
泰国湾开发了大量的单井,从多个薄储层中生产。大量的油井可以保证足够的产量,但为了油田的整体经济效益,必须对其成本进行良好的管理。射孔作业的一个重要成本组成部分来自于射孔作业,该作业涉及在电缆上多次下入射孔枪,每次下入由多个射孔枪组成,这些射孔枪通过开关顺序激活。这种在一口井中对多个区域进行射孔的过程,如果不加以管理,将导致作业时间延长甚至更糟,导致严重的问题,如非深度射孔。此外,井的平均温度为370华氏度,这给作业带来了额外的挑战。作业效率对于获得更好的油井经济效益至关重要。因此,多年来进行了一些操作和技术优化,以提高效率。在这种每年有数千次射孔作业的大容量作业中,渐进式改进总是有价值的。然而,当实现效率的阶跃变化时,收益更加明显,这已经在为泰国大批量市场设计的新型炮对接系统中观察到。它可以更快地连接地面上的多个枪,具有更好的安全性和可靠性。本文讨论了泰国大规模射孔作业的背景以及对效率的需求,这导致了针对该市场量身定制的新型射孔枪对接系统的开发。该对接系统技术连同迄今为止300多次射孔作业的部署统计数据,并与之前系统的统计数据进行了比较。效率的实现得益于其更快的连接和解除系统,以及更好的安全性和可靠性,从而降低了失火率。它的成功部署,更重要的是,其效率的逐步改变,可能为全球更多边缘油田的开发铺平道路。此外,由于全球范围内进行了数千次射孔作业,其效率也将在缩短作业时间和降低全球碳排放方面发挥至关重要的作用。
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引用次数: 0
DroneBox: A Fully Automated Drone System for Surveillance Application DroneBox:用于监视应用的全自动无人机系统
Pub Date : 2022-03-18 DOI: 10.4043/31685-ms
Pattawut Manapongpun, Chanon Karoonkornsakul, Krittin Peechaphand, Pakpoom Kriengkomol, Amin Rajawana, Pawarit Ritmetee, Narongsak Lounsrimongkol, Napat Chenchai
Unmanned aerial vehicle (UAV) technology has recently improved in terms of robustness and reliability to be utilized industrially such as site patronage, monitoring and surveillance missions. On the contrary, the delayed development of competent UAV pilots and operators is slowing down operational expansion, resulting in everyday UAV usage costly and unfeasible. The fully automated and completely independent "DroneBox" will act as the drone storage and self-maintenance base for a surveillance operation with no direct human involvement. The drone will be capable of taking- off, performing missions, landing precisely, and recharging automatically while utilizing collected real-time data to perform with the safest configuration through DroneBox. When compared to the industry’s conventional method, the risk, cost, and time of surveillance operation will be reduced with the application of the DroneBox system offshore. According to realistic estimates, deploying the DroneBox system on 20 unmanned wellhead platform platforms can cut operator visits up to one-third of the trips, resulting in saving 22% fuel of crew boat vessels or up to 1.82 million USD operating cost in Artit (ART) and Great Bongkot North (GBN) wellhead platforms.
无人机(UAV)技术最近在鲁棒性和可靠性方面得到了改进,可用于工业上,例如现场赞助,监测和监视任务。相反,有能力的无人机飞行员和操作员的延迟发展正在减缓作战扩张,导致日常无人机使用成本高昂且不可行。完全自动化和完全独立的“无人机箱”将作为无人机存储和自我维护基地,进行无人直接参与的监视行动。无人机将能够起飞,执行任务,精确着陆,并自动充电,同时利用收集的实时数据,通过DroneBox以最安全的配置执行。与行业的传统方法相比,在海上应用DroneBox系统将降低监控操作的风险、成本和时间。根据实际估计,在20个无人井口平台上部署DroneBox系统可以减少操作人员多达三分之一的行程,从而节省22%的船员船燃料,或在Artit (ART)和Great Bongkot North (GBN)井口平台上节省高达182万美元的运营成本。
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引用次数: 2
Holistic Sand Management in Malaysia Assets; Successful Case Studies and Lessons Learnt 马来西亚资产的整体防砂管理成功案例研究及经验教训
Pub Date : 2022-03-18 DOI: 10.4043/31370-ms
Zulkifli B M Zin, Jennyfer Joseph Kuanji, Nik Zarina Bt Nik Khansani
Sand production is a common issue, especially in a depleting field as water production commences, and sand strength weakens. Conventional sand management focuses on downhole sand exclusion from the wellbore either through completion design or production reduction by choke optimisation as passive sand control. The objective of the paper is to share the company's journey in sand management in collaboration of various supporting units. The Holistic Sand Management methodological process adopts a 5 keys action plan, namely: Establishment of dedicated focus sand team with multidisciplinary support covering surface and subsurface activities Situational Assessment to develop baseline in sand management preparedness in each field, identifying gaps and developing an intervention plan Development and utilisation of an in-house erosion prediction tool, Continuous upskilling in sand management best practices, and Technology review and active pilot testing utilising digital enhancement to assist in sand management activities. Establishment of a dedicated and collaborative focus group, Integrated Sand Management (ISM) team in the centre which is replicated at the region as Regional Sand Team (RST), has allowed for continuous communication on sand management matters. Situational Assessment consists of 13 integrated subsurface and surface elements to evaluate a field capability to manage sand production. These 13 elements include sand management philosophy and organisation setup, sand prediction, sand control design, sand sampling and monitoring as well as surface sand handling and disposal. Findings from the assessment are used to gauge the field's readiness and ability to manage sand operation and develop gaps closure plan to achieve the optimum holistic sand management. The Sand Erosional and Transportation (SET) tool, an in-house developed tool, is used to evaluate sand erosion and deposition risk in the production system. The tool is used extensively to generate a safe operating envelope for sand producing well during open-up and continuous production. This has allowed the company to shift from limiting production up to a specific sand concentration to erosion risk-based approach, which in turn creates production optimization opportunities. Regular and continuous upskilling sessions ensure the frontline operations are updated and abreast with best practices in sand management. In addition, the ISM team reviews and leverages on latest technology, actively organises pilot test at a selected site supported with digital enhancement to assist in sand management activities. The application of a Holistic Sand Management methodology is seen to reduce erosion related Loss of Primary Containment (LOPC), sustain production, and minimise unplanned deferment. However, this is just the beginning and the battle in sand operation will continue to be very challenging in balancing between production while ensuring asset integrity. The methodology is a novel approach f
出砂是一个常见的问题,特别是在枯竭油田,随着采水开始,砂的强度减弱。传统的防砂管理侧重于通过完井设计或通过节流优化来减少产量,即被动防砂。本文的目的是在各个支持单位的协作下分享公司在治沙方面的历程。整体治沙方法过程采用5项关键行动计划,即:建立专门的重点防砂团队,提供覆盖地面和地下活动的多学科支持,对每个油田进行态势评估,制定防砂准备基线,确定差距并制定干预计划。开发和利用内部侵蚀预测工具,不断提高防砂管理最佳实践技能。利用数字增强技术进行技术审查和积极的试点测试,以协助防砂活动。中心成立了一个专门的协作焦点小组,即综合防砂小组(ISM),该小组在该地区作为区域防砂小组(RST)复制,以便就防砂问题进行持续沟通。情景评估包括13个综合的地下和地面元素,以评估油田管理出砂的能力。这13个要素包括砂管理理念和组织设置、砂预测、防砂设计、砂取样和监测以及地面砂处理和处置。评估结果用于评估油田的准备情况和管理出砂作业的能力,并制定缺口关闭计划,以实现最佳的整体出砂管理。砂蚀与运移(SET)工具是公司内部开发的工具,用于评估生产系统中的砂蚀与沉积风险。该工具在开井和连续生产过程中广泛应用于出砂井的安全作业包层。这使得公司能够从限制生产到特定的砂浓度,转变为基于侵蚀风险的方法,从而创造了生产优化的机会。定期和持续的技能提升课程确保前线作业与砂管理的最佳实践保持同步。此外,ISM团队审查并利用最新技术,在选定的地点积极组织试点测试,并支持数字增强,以协助防砂活动。整体防砂方法的应用可以减少与侵蚀相关的初级密封层损失(LOPC),维持生产,并最大限度地减少计划外延迟。然而,这仅仅是一个开始,在确保资产完整性的同时平衡产量,砂石作业的战斗将继续非常具有挑战性。该方法对公司来说是一种新颖的方法,公司组建了一个专门的协作团队,带头进行砂管理计划,其中包括由内部侵蚀建模工具支持的缺口识别情况评估。
{"title":"Holistic Sand Management in Malaysia Assets; Successful Case Studies and Lessons Learnt","authors":"Zulkifli B M Zin, Jennyfer Joseph Kuanji, Nik Zarina Bt Nik Khansani","doi":"10.4043/31370-ms","DOIUrl":"https://doi.org/10.4043/31370-ms","url":null,"abstract":"\u0000 Sand production is a common issue, especially in a depleting field as water production commences, and sand strength weakens. Conventional sand management focuses on downhole sand exclusion from the wellbore either through completion design or production reduction by choke optimisation as passive sand control.\u0000 The objective of the paper is to share the company's journey in sand management in collaboration of various supporting units.\u0000 The Holistic Sand Management methodological process adopts a 5 keys action plan, namely:\u0000 Establishment of dedicated focus sand team with multidisciplinary support covering surface and subsurface activities Situational Assessment to develop baseline in sand management preparedness in each field, identifying gaps and developing an intervention plan Development and utilisation of an in-house erosion prediction tool, Continuous upskilling in sand management best practices, and Technology review and active pilot testing utilising digital enhancement to assist in sand management activities.\u0000 Establishment of a dedicated and collaborative focus group, Integrated Sand Management (ISM) team in the centre which is replicated at the region as Regional Sand Team (RST), has allowed for continuous communication on sand management matters. Situational Assessment consists of 13 integrated subsurface and surface elements to evaluate a field capability to manage sand production. These 13 elements include sand management philosophy and organisation setup, sand prediction, sand control design, sand sampling and monitoring as well as surface sand handling and disposal. Findings from the assessment are used to gauge the field's readiness and ability to manage sand operation and develop gaps closure plan to achieve the optimum holistic sand management. The Sand Erosional and Transportation (SET) tool, an in-house developed tool, is used to evaluate sand erosion and deposition risk in the production system. The tool is used extensively to generate a safe operating envelope for sand producing well during open-up and continuous production. This has allowed the company to shift from limiting production up to a specific sand concentration to erosion risk-based approach, which in turn creates production optimization opportunities. Regular and continuous upskilling sessions ensure the frontline operations are updated and abreast with best practices in sand management. In addition, the ISM team reviews and leverages on latest technology, actively organises pilot test at a selected site supported with digital enhancement to assist in sand management activities. The application of a Holistic Sand Management methodology is seen to reduce erosion related Loss of Primary Containment (LOPC), sustain production, and minimise unplanned deferment. However, this is just the beginning and the battle in sand operation will continue to be very challenging in balancing between production while ensuring asset integrity.\u0000 The methodology is a novel approach f","PeriodicalId":11011,"journal":{"name":"Day 3 Thu, March 24, 2022","volume":"19 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-03-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"91125587","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 0
Open Hole Gravel Pack with Mechanical Open Hole Isolation Packer: Cost Effective Alternative Solution for Water Influx Deferments in Sand Prone Multizone Gas Well 裸眼砾石充填与机械裸眼隔离封隔器:经济有效的解决多层含砂气井水侵延迟的替代方案
Pub Date : 2022-03-18 DOI: 10.4043/31470-ms
Asba Madzidah Binti Abu Bakar, M. M. H. B. Amjath Hussain, M. F. B. Bakar, Fuziana Binti Tusimin, A. Abdullah, Chee Seong Tan, Nicholas Moses
Originally, an infill well from project H was approved in 2013 to be completed as a single zone Open Hole Gravel Pack (OHGP) to produce gas commingled from three sands located at the shallowest reservoir in that field. Interpretation of recent logs from a nearby producing well indicated that there was significant water threat at two of the sands which would lead to water influx from the beginning of production if the well was to be completed as a single zone OHGP. The well was then redesigned to be completed as a Cased Hole Gravel Pack (CHGP) in order to have mechanical isolation from the water zones with an inner string and internal isolation packers to allow feasibility of zonal isolation to shut off the water producing zone in the future. This feature however resulted in higher well cost as compared to the approved design. Due to recent hostile low oil price, a more cost-effective sand control design was evaluated to reduce the well cost while maintaining similar performances as a CHGP design in terms of the capability to delay water breakthrough. Design feasibility study was performed on multizone OHGP with open hole mechanical packer and an inner string design to evaluate its performance and magnitude of cost reduction relative to a CHGP design. Skin analysis was performed for both OHGP and CHGP completion designs to evaluate any additional pressure loss for each sand. Prior to compartment optimization, an OHGP completion without packer placement was simulated in a dynamic simulation to generate the production profile as a base case. This was followed by a compartment optimization that was performed with OH mechanical packer placement at various standoff distances from the Gas-Water Contact (GWC) such as 5ft, 10ft, 15ft, 20ft and 30ft respectively. Subsequently, similar analysis was then performed on the CHGP completion design with a higher skin value estimated for the CHGP completion to reflect a higher degree of damage resulting from the cementing and perforation operations. Several production sensitivities were simulated by varying the perforation length and standoff from the GWC to replicate the same scenario of the open hole mechanical packer placement in the OHGP design analysis. Finally, analysis on the effectiveness of the base case (OHGP with no packer) against the cases of OHGP with optimum packer placement and CHGP with optimum perforation depth were compared and ranked over cumulative gas production, cumulative water production, operational complexity, and risk as well as total well cost. Based on the dynamic modelling, the base case (OHGP without packer) showed water breakthrough occurring right at the start of production as expected. Once breakthrough occured, water production would rapidly dominate production. On the other hand, packer placement sensitivity analysis for the OHGP design showed that the optimum depth for packer placement was 20ft or 30ft above the GWC depth where it provided highest gas cumulative and low
最初,H项目的一口井在2013年被批准完成,作为单层裸眼砾石充填(OHGP),从该油田最浅的储层中开采三种砂岩的混合天然气。对附近一口生产井最近的测井资料的解释表明,如果将这口井作为单层OHGP完成,那么其中两口砂层存在严重的水威胁,从生产开始就会导致水涌入。随后,该井被重新设计为套管井砾石充填(CHGP)完井,通过内管柱和内部隔离封隔器与含水层进行机械隔离,从而实现分层隔离的可行性,从而在未来关闭产水层。然而,与认可的设计相比,这一特点导致了更高的钻井成本。由于最近的低油价,研究人员评估了一种更具成本效益的防砂设计,以降低钻井成本,同时保持与CHGP设计相似的延迟水侵能力。对采用裸眼机械封隔器和内管柱设计的多层OHGP进行了设计可行性研究,以评估其性能和相对于CHGP设计的成本降低幅度。对OHGP和CHGP完井设计都进行了表皮分析,以评估每种砂的额外压力损失。在进行隔室优化之前,在动态模拟中模拟了一次没有放置封隔器的OHGP完井,以生成生产剖面作为基本情况。随后进行了隔室优化,将OH机械封隔器放置在距离气水界面(GWC)不同的距离处,分别为5英尺、10英尺、15英尺、20英尺和30英尺。随后,对CHGP完井设计进行了类似的分析,估计CHGP完井的表皮值更高,以反映固井和射孔作业造成的更高程度的损害。通过改变GWC的射孔长度和距离来模拟几种生产敏感性,以复制OHGP设计分析中裸眼机械封隔器放置的相同场景。最后,对基本情况(无封隔器的OHGP)、最佳封隔器位置的OHGP和最佳射孔深度的CHGP的有效性进行了比较,并对累积产气量、累积产水量、操作复杂性、风险以及井总成本进行了排名。基于动态建模,基本情况(不带封隔器的OHGP)显示,在生产开始时就出现了水侵。一旦突破,水产量将迅速占主导地位。另一方面,对OHGP设计进行的封隔器放置敏感性分析表明,封隔器的最佳放置深度是在GWC深度以上20英尺或30英尺,在整个井寿命期间,该位置的累积产气量最高,累积产水量最低。在距GWC至少20英尺的偏移距离下,OHGP和CHGP的累积产气量相似,而OHGP的累积产水量略低于CHGP。考虑到可膨胀封隔器隔离不充分的风险,可能会导致早期水侵,进而降低累积产气量,因此推荐使用机械裸眼封隔器而不是膨胀封隔器。因此,采用带有裸眼机械封隔器和内管柱的OHGP是该井的最佳设计,与CHGP相比,成本降低了近13%。一般来说,在距离GWC 20英尺或30英尺处安装OH机械封隔器的OHGP,在累积产气量增加和低产水量方面对填充井有利,同时消除了出砂。
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引用次数: 0
Deployment of Small Area Exposure Radiography S.A.R Technology to Maximise Multiple Work Fronts in Operating Offshore Facility 应用小区域曝光射线成像S.A.R技术,最大限度地提高海上设施作业的多个工作前沿
Pub Date : 2022-03-18 DOI: 10.4043/31511-ms
Jothi Sivarajah, E. Hassan, J. Toh, Tee Bin Lim
Malikai Phase 2 project is a brownfield infill drilling project consisting of 5 new infill wells with 1 sidetrack scope. These new wells are tied into existing Malikai Tension Leg Platform (TLP) production facilities for offshore processing prior to export. Offshore execution activities were heavily congested with multiple works fronts from Drilling, Mooring, Hook-up Commissioning alongside existing production and maintenance operations of the Malikai facility requiring prioritization via simultaneous operations (SIMOPS) activities. The paper highlights the challenges of conventional radiography for inspection activities post pipework welding, which is usually scheduled within windows of low activities i.e. in the night with lower risk of personnel exposure to possible radiation. Since drilling operations runs 24 hours continuously, it renders almost impossible for conventional radiography inspection activities to take place as required. This paper also describes the benefits with the introduction of SAR technology, the radiation exclusion zone can be set to less than 5 meters, thus allowing the topsides facilities pipework welding to take place concurrent with drilling and operation activities, achieving project success factors of optimized manning requirement and earlier than plan First Oil Date (FOD). Advanced NDT technologies in the market like small area radiography and phased-array ultrasound were evaluated. Considering the piping diameter/wall thickness & material being Stainless Steel/Duplex SS (coarse grain welds – requires more extensive PAUT qualification), the final decision was to use SAR. A demo was conducted onshore with representation from various internal stakeholders. Necessary approvals from local regulatory bodies were obtained to facilitate the use of this technology for offshore assets. The team further evaluated the implementation in our offshore facilities in a HAZID workshop, collaborating with several contractors and asset counterpart to assess the hazards and risks associated with SAR. Results were then compared and used by the execution team to develop procedures suitable for offshore use. The paper compares past experiences of hook-up and commissioning activities using conventional radiography methods. By using SafeRad technology, the project can continue with the topsides' fabrication work simultaneously during drilling instead of conducting the pipework fabrication activities in series after drilling is completed. This allowed project team to be able to continue the fabrication works and subsequent pre-commissioning and commissioning activities whilst drilling in progress. As a result, project is able to liquidate the critical path in hook-up and commissioning activities and ultimately contributed to the project delivering early project ahead (circa 6 months) of the first oil milestone.
Malikai二期项目是一个棕地填充钻井项目,包括5口新填充井和1口侧钻范围。这些新井与现有的Malikai张力腿平台(TLP)生产设施相连,在出口前进行海上加工。海上执行活动严重拥挤,包括钻井、系泊、连接调试以及Malikai设施的现有生产和维护操作等多个工作,需要通过同步操作(SIMOPS)活动进行优先排序。本文强调了管道焊接后常规放射线检查活动的挑战,这些活动通常安排在低活动量的窗口,即夜间,人员暴露于可能辐射的风险较低。由于钻井作业是24小时连续进行的,因此几乎不可能按照要求进行常规的射线照相检查。本文还介绍了引入SAR技术的好处,可以将辐射隔离区设置在5米以内,从而使上层设施管道焊接与钻井和作业活动同时进行,实现了优化人员配置要求和提前计划首次采油日期(FOD)的项目成功因素。评估了市场上先进的无损检测技术,如小面积射线照相和相控阵超声。考虑到管道直径/壁厚和材料为不锈钢/双相SS(粗晶粒焊接-需要更广泛的pat资格),最终决定使用SAR。在陆上进行了演示,来自内部各利益相关者的代表进行了演示。已获得当地监管机构的必要批准,以促进该技术在离岸资产中的使用。该团队在HAZID研讨会上进一步评估了海上设施的实施情况,与几个承包商和资产对应方合作,评估与SAR相关的危害和风险。然后,执行团队将结果进行比较,并使用该结果制定适合海上使用的程序。本文比较了以往使用常规射线照相方法进行连接和调试活动的经验。通过使用SafeRad技术,该项目可以在钻井过程中同时进行上层平台的制造工作,而不是在钻井完成后进行一系列管道制造活动。这使得项目团队能够在钻井过程中继续制造工作以及随后的预调试和调试活动。因此,该项目能够在连接和调试活动中确定关键路径,并最终有助于项目提前(约6个月)交付第一个石油里程碑。
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引用次数: 0
Increasing the Safety and Efficiency of Completions with the Utilization of Remote Manipulation Systems and Elimination of Hanging Sheaves 利用远程操作系统提高完井的安全性和效率,并消除悬挂滑轮
Pub Date : 2022-03-18 DOI: 10.4043/31464-ms
Neil Alleman
The process of running completions typically involves an increased complexity of systems and setups. The running of control lines and umbilicals have historically used hanging sheaves to route the lines from the spoolers to well center and require increased number of personnel in the red zone during operations. These complexities introduce many risks and potential incidents that operators aim to eliminate. Typical procedures for running completions require man-riding operations to hang sheaves in the derrick. Once the control lines or umbilicals are routed through these sheaves, they become overhead loaded objects and subsequently increase the risk of incident to personnel working on the rig floor. Other operational steps include the manual manipulation of lines to clamp the lines/umbilical to the tubular. This traditional clamping procedure not only requires an increased number of personnel in the red zone, but it also introduces inefficiencies to the operation. Through planning and the use of specialized remote manipulation technologies, operators can remove the need for overhead control line/umbilical sheaves and the manual handling of lines in the red zone. Although risks do not always result in incidents, organizations still strive to eliminate risks throughout their operations. By using remote manipulation technologies that eliminate control line/umbilical hanging sheaves, the operators benefit from the following: – Eliminating working at height for sheave installation – Eliminating overhead loaded components and increasing safety of personnel working on the rig floor – Decreasing the number of personnel required in the red zone and reducing manual handling – Increasing the efficiency of the operation By using systems like these, operators have been able to increase average running speeds, improving from 8.8 to 5.9 minutes per joint, as well as eliminate potentially fatal incidents that have occurred during the completions running process.
完井的过程通常会增加系统和设置的复杂性。传统上,控制线和脐带缆的运行都是使用悬挂滑轮将管线从卷索机连接到井中心,这就需要在作业期间增加在红色区域的人员数量。这些复杂性带来了许多风险和潜在事故,运营商希望消除这些风险和事故。下完井的典型程序需要人工在井架上悬挂滑轮。一旦控制线或脐带缆穿过这些滑轮,它们就会成为架空负载物体,随后会增加钻井平台上工作人员发生事故的风险。其他操作步骤包括手动操作管线,将管线/脐带夹紧到管柱上。这种传统的夹紧程序不仅需要增加红色区域的人员数量,而且还会导致操作效率低下。通过规划和使用专门的远程操作技术,作业者可以消除对架空控制线/脐带轮的需求,以及对红色区域管线的人工处理。尽管风险并不总是导致事故,但组织仍然努力在其运营过程中消除风险。通过使用远程操作技术,消除了控制线/脐带悬挂滑轮,作业者从以下方面获益:减少了在红色区域所需的人员数量,减少了人工操作,提高了作业效率。通过使用这些系统,作业者能够提高平均作业速度,将每个关节的作业时间从8.8分钟提高到5.9分钟。以及消除完井运行过程中发生的潜在致命事故。
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引用次数: 0
Expanding Acceptance of Normally Unattended Facilities NUF – A Collaborative effort within IOGP 扩大对通常无人看管的设施的接受- IOGP内部的合作努力
Pub Date : 2022-03-18 DOI: 10.4043/31648-ms
Mohd Rizal Mengan, Saiful Azuan Abdul Aziz, Nadirah Khairul Anuar, Grant Veroba, Jean-Michel Munoz
A group of International Oil and Gas Producer (IOGP) members have established the Normally Unattended Facilities (NUF) Task Force aimed to position NUF as safe, cost-effective, widely accepted design and operating method for oil & gas facilities. The establishment of the Task Force was driven by the need to standardize, expand the NUF concept to all type of facilities and ensure industry wide acceptance of NUF standardization. To meet these objectives, the Task Force has produced a white paper to outline the design principles, anticipated challenges and enablers to allow for the implementation of a standard NUF design. NUF will enable oil and gas facilities to be remotely operated in a safe and reliable manner with no crew visitation for determined periods of time. However, this requires a change in the approach to designing, constructing, operating, and maintaining the facility. The NUF Task Force focused on cost compression, unattended duration and sustainability through reduced carbon emissions as key objectives in NUF design optimization. The proposed NUF design will reduce carbon emissions through high reliability, low emission equipment selection and reduction of marine vessels utilization. Technology advancement will allow for lean design, remote control and analysis to efficiently and effectively plan maintenance and optimize operations. Brownfield quick wins will provide avenue for technology maturity, drive for higher reliability and improving overall asset performance. These help in shifting the mindset of personnel involved. Change management is required for governance & procedural changes whilst human retooling will be required for the new skillsets. The main value drivers that support NUF implementation include but, are not limited to, the anticipated reduction in HSE risk exposure to personnel, a substantial reduction in CAPEX and OPEX, and lower greenhouse gases, with reliability better than or equal to attended facilities. Some standards and regulations may need to be revised to enable NUF application. At present, this is being investigated by IOGP under JIP39. NUF concepts can be applied to any facility (onshore and offshore) and will be greatly facilitated by some level of standardization. This would create economies of scale for both the qualification and fabrication of equipment and sub-systems. Substantial potential value drivers supporting the move to a standard NUF approach: HSE Risk reduction due to elimination of personnel during normal operations Potential 20-30% CAPEX reduction in facility cost Potential 20-30% OPEX reduction in operating and logistics expenses Reliability better than or equal to attended facilities Green House Gases (GHG) footprint improvement
国际石油和天然气生产商(IOGP)成员成立了通常无人值勤设施(NUF)工作组,旨在将NUF定位为安全、经济、广泛接受的油气设施设计和操作方法。工作组的成立是由标准化的需要推动的,将NUF概念扩展到所有类型的设施,并确保NUF标准化得到行业广泛接受。为了实现这些目标,工作组编写了一份白皮书,概述了设计原则、预期的挑战和实现标准NUF设计的推动因素。NUF将使油气设施能够以安全可靠的方式远程操作,在确定的时间内无需人员访问。然而,这需要改变设计、建造、操作和维护设施的方法。NUF工作小组将成本压缩、无人值守的持续时间和通过减少碳排放的可持续性作为NUF设计优化的关键目标。建议的NUF设计将通过高可靠性、低排放设备选择和减少船舶利用率来减少碳排放。技术进步将允许精益设计,远程控制和分析,以高效和有效地计划维护和优化操作。布朗菲尔德的快速胜利将为技术成熟、提高可靠性和改善整体资产性能提供途径。这有助于改变相关人员的心态。治理和程序变更需要变更管理,而新技能集需要人力重组。支持NUF实施的主要价值驱动因素包括,但不限于,预期减少人员的HSE风险,大幅减少CAPEX和OPEX,降低温室气体排放,可靠性优于或等于有人值守的设施。一些标准和法规可能需要修订,以使NUF的应用。目前,IOGP正在JIP39下对此进行调查。NUF概念可以应用于任何设施(陆上和海上),并将通过某种程度的标准化大大促进。这将为设备和子系统的鉴定和制造创造规模经济。支持采用标准NUF方法的大量潜在价值驱动因素:在正常操作过程中,由于消除了人员,降低了HSE风险,降低了设施成本20-30%的资本支出,降低了运营和物流费用20-30%的运营成本,可靠性优于或等于参与的设施温室气体(GHG)足迹的改善
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引用次数: 0
Delivering a One Phase Well Under Two Days with a One Inch Cutter PDC Drill Bit: A Record Breaking Performance in Mature Field, Drilling Optimization Case History 使用1英寸切削齿PDC钻头,在两天内完成一期井作业:成熟油田钻井优化案例记录
Pub Date : 2022-03-18 DOI: 10.4043/31638-ms
B. Sayogyo, Aditya Hermawan, Bastian Andoni
Mahakam Block is a huge oil and gas concession managed by PT. Pertamina Hulu Mahakam (PHM) and located in deltaic and offshore environment in East Kalimantan, Indonesia. Until today, the field has produced oil and gas for more than 50 years and categorized as "brown field" due to its declining production and marginal reserve potential. This condition has led to numerous effort to boost efficiency in well delivery from drilling perspective such that the reserve could be produced more economically. One of the effort that has been done to create a well to be more economical is by increasing the Rate of Penetration (ROP). An increase in ROP would directly impact on well duration that could be finished faster in such that it would also impact on much lower well cost. There are several key factors that influence ROP, yet the most crucial part is coming from drilling bit design that is used to drill the formation. Incompatibility between bit design with formation and directional drive type would often result in slow drilling progress and thus would make a well less profitable. To support this idea, the operator has launched a campaign called MAXIDRILL with aim to have a persistent excellent drilling performance from ROP perspective. Selective approach to different bit designs and bit suppliers has brought the operator to conduct the first trial in Indonesia utilizing a one inch PDC cutter drill bit. Besides the effort to increase well economics by increasing ROP using various bit designs through MAXIDRILL Campaign, PHM also tries to implement new set of well architecture dedicated specifically for developing the shallow hydrocarbon zone in Mahakam in general, and in Tunu Field in particular. With this new type of architecture, it allows drilling with 9-1/2″ hole to be done straight from 20″ Conductor Pipe down to well final target depth in single phase, where next 3-1/2″ production tubing will be run and cemented in place. The new design of architecture is called "One Phase Well". This novel innovation was initiated in 2019, where to date, the operator has drilled more than 30 wells without any incident. With the learning curve that has turned into industrialization steps. More and more shorter well duration is born with these two initiatives, MAXIDRILL and One Phase Well. Ultimately, with the spirit of these two initiatives for bringing down well duration in gain for much better well economics has successfully set a two record breaking performance in Mahakam: 1) Being the fastest On Bottom ROP and 2) Being the fastest well ever delivered in Mahakam and Indonesia which is under two days.
Mahakam区块是由PT. Pertamina Hulu Mahakam (PHM)管理的一个巨大的油气特许权,位于印度尼西亚东加里曼丹的三角洲和海上环境中。到目前为止,该油田已经生产了50多年的石油和天然气,由于其产量下降和边际储量潜力,被归类为“棕色油田”。从钻井的角度来看,这种情况导致了大量的努力来提高钻井效率,以便更经济地开采储量。为了提高经济效益,人们所做的一项努力是提高机械钻速(ROP)。机械钻速的提高将直接影响井的工期,从而可以更快地完成作业,从而大大降低井的成本。影响机械钻速的关键因素有几个,但最关键的部分是用于钻入地层的钻头设计。钻头设计与地层和定向驱动类型之间的不兼容通常会导致钻井进度缓慢,从而降低井的利润。为了支持这一想法,作业者发起了一项名为MAXIDRILL的活动,旨在从ROP的角度获得持续优异的钻井性能。通过选择不同的钻头设计和钻头供应商,作业者在印度尼西亚使用1英寸PDC切削钻头进行了首次试验。除了通过MAXIDRILL Campaign使用各种钻头设计提高机械钻速来提高井的经济效益外,PHM还试图实施一套新的井结构,专门用于开发Mahakam的浅层油气带,特别是在Tunu油田。采用这种新型结构,9-1/2″井眼可以直接从20″导电管到井的最终目标深度,在此阶段下入3-1/2″生产油管并进行固井。这种新的建筑设计被称为“一期井”。这项创新始于2019年,迄今为止,运营商已经钻了30多口井,没有发生任何事故。随着学习曲线转变为工业化的步骤。随着MAXIDRILL和One Phase well这两项计划的推出,井的持续时间越来越短。最终,凭借这两项举措的精神,缩短了井的持续时间,获得了更好的油井经济效益,成功地在Mahakam创造了两个破纪录的表现:1)成为最快的底部ROP; 2)在Mahakam和印度尼西亚,在两天内成为最快的交付井。
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引用次数: 0
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