Технологичская надежность. Современные тенденции модернизации буровых установок
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3.2 Digital drilling Well drilling is an expensive process that significantly affects the cost of oil production. And the further it goes, the more complex and expensive it becomes: in order to efficiently develop hard–to–recover reserves, it is necessary to build complex, high–tech wells. Industry 4.0 technologies help to increase drilling efficiency – big data analysis, Internet of things, artificial intelligence. A variety of related digital projects. Domestic producers have been dealing with drilling efficiency for a long time, implementing organizational and technological projects that Siberian Oil has already written about more than once: The Technical Limit project, the Drilling Control Center, the creation of high–tech drilling rigs for the Russian market, etc. Reasons for the increased attention to this in the underdeveloped Russian oilfield services market. The absence of serious competition leads to the fact that market participants are in no hurry to invest significant resources in development and take on additional risks associated with this. Therefore, the introduction of new technologies is often an initiative of the oil producing companies themselves [37]. 3.2.1 Modern data flow sensors In one of the Russian companies, the well design and construction process has already been largely digitized. The location of the wells, their trajectory and design, individual operations (lowering the casing strings, cementing the wellbore, etc.) are calculated in special computer simulators. The software allows you to estimate the expected return from the reservoir and find the best ways to achieve it [38]. During the drilling process, an abundant stream of data comes in from the well. These are readings from geological and technological research (GTI) sensors, logging while drilling data, directional drilling telemetry readings, drilling fluid rheology, etc. A large amount of diverse information for each well is sent to the 125 Geonavigator Drilling Control Center and the main task of the center is to ensure the most efficient use of data while maintaining and monitoring the well construction process. Retrofitting drilling rigs with such sensors is an important task that the company is already implementing in cooperation with the drilling contractors operating them. A common cause of downtime is equipment failure. Sensors enable us to assess wear and tear, prevent failure and reduce non–productive time through timely maintenance. The domestic company stimulates such development in the drilling industry, despite the fact that the rates of drilling companies using high–tech equipment will inevitably grow. But if the changes ultimately result in increased drilling speed, eliminating or significantly reducing downtime, the total cost of the well may be lower, and oil and its sales revenue can be obtained faster. In the future, full automation of drilling rigs and the use of solutions based on artificial intelligence will make it possible to remotely control a drilling rig, create so–called unmanned drilling rigs [38]. 3.2.2 Artificial intelligence will correct the trajectory When drilling wells, artificial intelligence makes it possible to detect if the bit is outside the target (productive) layer even before the telemetry sensors report it. Due to the design features of the drilling equipment, information about the type of rock and its properties based on the readings of logging tools during drilling is received with a delay. As a result, the exit from the reservoir or the target interval is recorded when the bit has moved 15–35 m away from the exit. In some cases, an experienced driller is able to determine by indirect indications (WOB, ROP, etc.) that the bit has penetrated a different formation. The specialists had the idea that such a skill could be developed in artificial intelligence, revealing hidden patterns in the GTI data [39]. The developed prototype uses machine learning to quickly analyze the parameters coming from the drilling equipment – the vibration level, the speed of 126 drilling and rotation of the rotor, the load on the bit, etc. These indicators change depending on the characteristics of the formation, and this allows you to quickly determine the composition of the rock without waiting for data from sensors on the drilling tool itself. Now the program is able to determine three lithotypes (rocks with a certain set of features) – sandstone, clay, carbonated sandstone – and, accordingly, the moment when the bit passes from one rock to another. The probability of detecting a change in lithotype using the created digital solution is at least 70%. Model training continues on new wells: with each well drilled, the accuracy becomes higher. The application of the technique will allow in the future to increase the speed of drilling the horizontal part of the wells, reduce the cost of eliminating errors and improve the quality of penetration, and hence the efficiency of future operation [39]. 3.3 New equipment 3.3.1 Casing running system Successful running of production casing strings to planned depths, as well as for high–quality well cementing, requires the involvement of the most modern developments in this area. The CDS ™ system (pic. 2) expands the capabilities of the top drive of the drill and can be used for make–up of casing threads. The CDS ™ system completely replaces the standard set of equipment for running casing strings. The presence of a hydraulic swivel in the CDS ™ system allows the casing to be rotated while running, circulating and reciprocating (for example, at high friction coefficients, rotation allows them to be reduced by a factor of several), and also makes it possible to circulate and top up while running the casing. Additionally, thanks to the CDS ™ system, you can start reaming the wellbore at the landing site. The presence of an additional independent TеsTork ™ torque gauge (with wireless data transmission WTTS) provides the ability to register and monitor in real time and with recording in memory on some electronic carrier make–up torque indicators through an adapted 127 computer system. The system is equipped with adjustable links in length, allowing for most drilling rigs to take the pipe directly from the walkway. The lifting capacity of the single pipe hydraulic elevator is 5t, which is more than enough for one pipe. Carrying capacity of the CDS ™ itself is 350–750 tons. The latest compact systems are also available with a length of just 2 m. Since CDS ™ is automated and remotely controlled, there is no need to involve riding workers when working with it, unlike the Fill Up Tool and spider elevators. Accordingly, the risks associated with working with keys are eliminated, since this is not required with CDS ™. The benefits of using CDS ™ are clear. The system excludes the use of bulky spider–elevators, the involvement of a riding worker, the use of circulation equipment (Fill–Up Tools), the use of power keys. Thus, the use of CDS ™ significantly reduces the amount of equipment and personnel required to run the casing string, provides a high level of mechanization of the work and eliminates the need for personnel to work in particularly hazardous conditions [39]. 128 Picture 2 – Casing Driving System ™ (CDS ™) 3.3.2 Upgraded multifunctional directional drilling rigs The multipurpose directional drilling rig (pic. 3) is a new type of drilling depth at an angle of 8° to vertical. The inclined MNBU mast with a rack and pinion mechanism for moving the power swivel provides new opportunities for the construction of deviated horizontal wells with large deviations at extremely shallow depths. Drilling at an angle of 45° in combination with a variable bottomhole force makes it possible to create wells of increased length. This increases the productivity of the drilling process when drilling for coalbed methane and hard–to–reach hydrocarbons. A high–performance hydraulic drive system allows you to set with high precision all created forces, moments and speeds using a control system. The 129 crawler drive of the unit gives it freedom of movement on the jobsite and also makes it easy to transport by trailer over long distances [40]. MNBU is used in construction: vertical wells; horizontal wells; directional wells; deviated horizontal wells; horizontally branched wells; vertical and inclined wells of large diameter. The installation of the MNBU allows with high technical, economic and quality indicators to build directional, horizontal and multilateral wells for the development of various natural resources in any, even as close to the surface as possible, formations, including for: extraction (degassing, production) of methane from coal seams; production of hard–to–recover (heavy) oils and bitumen using SAGD, TAGD technologies; restoration of idle oil and gas wells by construction of an additional directional or horizontal wellbore; reconstruction of production wells by drilling a sidetrack with a horizontal end; overhaul of operational oil and gas oil and gas stations; exploration and production of hydrocarbons in the coastal zone of the shelf from the shore; hydrogeological purposes: construction of drainage systems to protect objects and built–up areas from flooding by groundwater, underground water intakes, dewatering, disposal of contaminated water, to protect water bodies from pollution by industrial wastewater; extraction of other natural resources: technical, shale gas, oil sands, "old" fields, rich iron ores; 130 geological exploration purposes: exploration of hydrocarbon raw materials: oil (including heavy oils and bitumen), gas (including shale and coal methane); laying pipelines under rivers, with a significant difference in the height of the banks; conducting mine rescue operations: construction of roadways for emergency evacuation of mine personnel, elimination (jamming) of open fountains; arrangement of exits to the sea for oil terminals; devices for injection pipelines at hydroelectric power plants [40]. Picture 3 – Inclined drilling rig 131 3.3.3 Automated hydraulic drilling tong with programmed control GKSh–8000 Automated hydraulic drill tong with programmed control GKSh–8000 "Timerkul" (pic. 4) is designed for fast, safe, high–precision make–up and breakout of drill and casing pipes with outer diameters from Ø73 mm (2 7/8 ") to Ø219 mm (8 5/8 "), controlled by an industrial PC – controller with real–time operating system Windows CE 7.0 [40]. The use of a retractable arm, PLC control and the ability to use a pedestal console allow for safe and efficient operation, as well as extending the service life of the drilling tool. Features and Benefits Control is carried out from the driller's remote control using a PLC; High–precision tightening, which significantly extends the service life of the drilling tool; Using a special program for specifying pipe profiles, which allows you to enter the values of the moments for subsequent quick selection with one click of a button on the operator panel; Control in automatic mode and in manual mode, when it is necessary to perform non–standard operations; Possibility of instant shutdown in case of emergency; The remote control provides control and monitoring of the key from various points of the drilling site, at a distance from potential sources of danger; Universal jaws allow you to work with pipes of various diameters without replacing the dies; Unique retractable manipulator allows you to adjust the position of the key in length and height; Takes up minimal space on the drilling site; 132 The key is mounted on the regular place of the drilling key, type AKB, without changing the design of the drilling site, which allows to exclude the procedure of approval for use; Small number of spare parts and easy maintenance in repair; For joint operation of the automated hydraulic tongs GKSh–8000, it is possible to use the hydroelectric power station GSE–200R manufactured by OOO Ufagidromash. Not inferior, and in some cases even superior to foreign counterparts [40]. Picture 4 – GKSh–8000 «Timerkul» 3.3.4 Modern heating systems for drilling rigs The drilling rig heating system in its most general form is a three–stage heating system, consisting of: heat generator; heating radiators; communications for the divorce of the coolant. 133 Heat generators supply hot air to the drilling rig. The heated air is evenly distributed through the air duct system throughout the entire drilling echelon and sub–surface area. The block of additional tanks of the drilling rig can be heated either by hot air or by heat generated by generator sets. Container–type heat generators are especially widespread [40]. They are capable of: work in low temperatures (up to –45 degrees); supply air with a temperature of up to +100 degrees through insulated air ducts up to 45 m long; provide high air performance with a large specific temperature difference; use crude oil, heating oil, diesel fuel, light fuel oil fractions as fuel. Heating radiators used on drilling rigs must be characterized by high specific heat outputs, which can be equally successfully achieved by both convection and radiation. Recently, however, drilling rigs have most often used a combined drilling rig heating system, which includes: boiler plant; steam generators; electric heaters; heat guns; electric heating elements. Electric heaters play an important role, since they prevent moisture condensation in drilling lines, thereby reducing the weight of the drilling unit. The moving parts of the drilling elevator are heated in a special way: a collector is attached to the links of the elevator, and heat steam is supplied to the collector. However, the elevator wedges are heated by a conventional heating unit, especially used in winter [40]. 134 Table 1 – Technical characteristics of GKSh–8000 «Timerkul» Spinner torque, Nm (kgf ∙ m) 2940 (300) Minimum torque before fastening, Nm (kgf ∙ m) 4000 (408) Maximum tightening torque, Nm (kgf ∙ m) 80000 (8150) Maximum breaking torque, Nm (kgf ∙ m) 116000 (11820) Range of pipes, mm. 73–219 Discharge pressure, MPa (kgf/cm 2 ) 20 (200) Pressure in the drain line, MPa (kgf/cm 2 ) не более 0,5 (5) Volumetric feed into the hydraulic tong, m 3 / s (l/min) 33,3×10–4 (200) Rotation frequency of spinner rollers, rpm 120 Number of spinner rollers, pcs 4 Rotation around its axis, degrees 360 Weight, kg 3000 Overall dimensions, mm 1600x1200x2400 135 Приложение Б Способы модернизаций буровых установок Буровые вышки Многофункциональные наклонные буровые вышки Разработка небольших вышек, с целью уменьшения габаритов и массы Разработка удлиненных вышек с двумя балконами верхового Буровые вышки с облегченным оборудованием упрощающие монтаж и демонтаж Спуско-подъемный комлекс Буровые ключи Автоматизированный гидравлический буровой ключ с програмным упавлением Автоматизированный ключ-механизм захвата бурильных свечей Автоматизированное оборудование спуско-подъемных операций Автоматизированны е приемные мостки Система спуска обсадных колонн Силовой верхний привод с динамометрическим ключом Насосно- циркуляционный комплекс Современные системы обогрева трубопроводов Технология очистки бурового раствора screen pulse Безамбарное бурение Использование 3-х поршневых насосов одностороненго действия triplex pump Современные датчики потоков данных Датчик выхода долота за пределы продуктивного пласта Датчики геолого- технологичесаких исследований Датчик гамма- каротажа Датчик телеметрии ННБ Азимутный датчик плотности |