Weir簡易壓裂管匯系統案例分析
我們可以做到：
•簡化壓裂現場
•設計更線性的流程
•減少危險狀況和潛在的泄漏路徑
對客戶的好處：
•減少非生產時間(NPT)
•減少裝配時間
•提高壓裂現場的安全性
•降低成本，優化生產
憑借創新的線性和大孔徑設計， Weir簡易壓裂管匯系統的新配置大大降低了加拿大運營商的管匯數量，連接線路，危險狀況和運營成本。
系統
傳統壓裂現場有許多具有傾斜流道的管線，而Weir Oil & Gas公司的簡化壓裂管匯系統的壓力控制部件采用單一的大孔線性設計。該系統的組件包括Seaboard™垂直拉鎖式歧管，正在申請專利的Seaboard™ OSL壓裂連接和Seaboard™壓裂堆疊。
在這種配置下，所需的管道連接數量從100個減少到12個，消除了88%的潛在泄漏路徑(鉆臺設置會根據總減少量而不同)。在整個設計過程中，Weir使用標準的API-6A連接，以大限度地減少互換性問題，具有可靠的金屬密封墊，并且很少需要在現場緊固。
該系統旨在提高安全性和性能，降低壓降和侵蝕，從而延長設備使用壽命，減少非生產時間，縮短裝配時間以及材料和人工成本。
挑戰
Weir的簡化系統包括Seaboard™垂直拉鎖式歧管，正在申請專利的Seaboard™ OSL壓裂連接以及Seaboard™壓裂堆疊，初在加拿大使用閘閥進行測試，由以前在三天后安裝失敗的獨立操作員進行。安裝失敗的設備是競爭對手的單線拉鎖式接頭版本，在完成了十段后就必須完全拆除。 隨后在兩口油井上安裝了Weir系統試驗版，每口井都有40段。開始壓裂時的平均流量為12立方米/分鐘，壓力為11,750 psi。
在操作之前需要進行計算流體力學(CFD)分析以預測設備侵蝕情況。與類似設計的分析相比，預計Weir系統的磨損減少約70%，壓降降低900 psi。這些減少主要歸因于直線路徑設計，這有助于使流體紊流和摩擦小化。
通過歧管的壓降(psi)
分析表明，單井壓裂期間，5”接頭管道的估算侵蝕量僅為0.003”。 而在今天的條件下，整個五口油井壓裂項目中，7”主干線的侵蝕量只有0.004”，預估主干線上的7”十字接頭的侵蝕量僅為0.039” - 都是可接受的比率。
歧管中大侵蝕量(in)
這些研究結果還預測驅動泵所需的功率減少，預計Weir配置相比其他主要競爭對手更加節能。 線路損耗的減少也有助于確保在地面測得的泵壓能更準確地反映輸送到地層中的物質。
在維修停工期間，還進行了超聲波厚度測量(UTS)，結果表明，對任何部件的腐蝕都很小 - 約為允許極限的12%。
結果
經過14天的運行，Weir系統的配置完成了所有80個壓裂段，且管道磨損小。總的來說，相比以前的安裝，這個系統持續時間多了三倍多。在提供更高性能的同時，將風險、非生產時間、裝配時間、管匯、連接和成本降到低，與傳統的管匯配置和目前的單線替代方案相比，顯示出明顯的優勢。
Weir簡化壓裂管匯系統適合要求苛刻的應用程序，可用于任何油田，可根據任何情況進行定制。設備可供出租，在每項工作完成后進行全面檢查和重新認證。
關于鼎恒石油
四川鼎恒石油是Weir SPM的授權代理商，若需要購買SPM產品或需要了解產品詳細參數及相關疑問，可直接進入鼎恒石油官網咨詢網站客服或者撥打銷售熱線18000522697。
四川鼎恒石油機械設備有限公司(http://www.zg-gj.com)是一家擁有進出口經營權，長期從事國內外石油天然氣設備和配件的專業銷售公司。鼎恒石油公司總部設在四川成都，在加拿大大不列顛哥倫比亞省成立了分公司。我公司與多家世界知名制造廠商建立了緊密的合作關系。
注：該文章由鼎恒石油編譯，轉發須注明出處。
附英文原文：
Simplifying the Frac Site
With an innovative linear, large-bore design, a recent configuration of Weir’s Simplified Frac Iron System dramatically reduced iron, connections, hazards, and costs for an operator in Canada.
WHAT WE ARE DOING
• Simplifying the frac site
• Engineering a more linear flow
• Eliminating hazards and potential leak paths
BENEFITS TO YOU
• Reduce non-productive time(NPT)
• Reduce rig-up time
• Improve safety at the frac site
• Lower costs and optimize production
The System
While traditional frac sites feature numerous iron strings with angled flow paths, the pressure control components of the Weir Oil & Gas’ Simplified Frac Iron System feature a single, largebore linear design. Components of this system include the Seaboard™ Vertical Zipper Manifold, the patent-pending Seaboard™ One Straight Line (OSL) Frac Connection, and the Seaboard™ Frac Stack.
In this configuration, the number of required pipe connections is reduced from 100 to 12, eliminating the potential for leak paths by 88 percent (rig site setup will vary total reduction). Throughout the design, Weir uses standard API-6A connections, which minimize interchangeability issues, feature a reliable metal-seal gasket, and rarely require tightening in the field.
Collectively, this system is designed to improve safety and performance, minimize pressure-drop and erosion–thus extending equipment life–and reduce non-productive time, rig-up time, and material and labor costs.
The Challenge
Weir’s simplified system that included a configuration of the Seaboard™ Vertical Zipper Manifold, the patent-pending Seaboard™ One Straight Line (OSL) Frac Connection, and the Seaboard™ Frac Stack using gate valves was initially put to the test in Canada by an independent operator whose previous installation had failed after three days. The equipment, a competitor’s version of a single line zipper tie-in, had completed only ten stages and had to be completely dismantled. A trial version of Weir’s system was subsequently installed on two wells, at 40 stages per well. Fracking commenced, averaging a flow rate of 12 m3/minute at 11,750 psi.
Prior to operation, a Computational Fluid Dynamics (CFD) analysis was conducted to predict equipment erosion. When compared to analyses of similar designs, Weir’s system estimated approximately 70 percent less wear and 900 psi less pressure drop. The reduction was attributed to the straight-path design, which helped to minimize fluid turbulence and friction.
The analysis showed that the estimated erosion of the 5” tie-in pipeline would only be 0.003” during the single-well frac. The 7” trunk line erosion would only be 0.004” throughout the entire five-well frac program, and the 7” cross in the trunk line was estimated to erode by a mere 0.039”–all acceptable rates in today’s conditions.
These findings also predicted a reduction in the horsepower required to drive the pumps, giving the Weir configuration an estimated power savings over leading competitors. The reduction in line losses would also help ensure that pump pressure measured at the surface would more accurately reflect what was delivered into the formation.
During maintenance shutdowns, an Ultrasonic Thickness Survey (UTS) was also conducted, indicating very little erosion on any of the components–approximately 12 percent of allowable limits.
The Result
After 14 days, this configuration of Weir’s system completed all 80 frac stages with minimal pipe wear. Overall, the system lasted more than three times longer than the previous installation. While delivering greater performance, it minimized risks, non-productive time, rig-up time, iron, connections, and costs—demonstrating a clear advantage over traditional iron configurations and current single-line alternatives.
Fit-for-purpose and ideal for demanding applications, Weir’s Simplified Frac Iron System can be used for any well and tailored to any condition. Equipment is available for rent, fully inspected and re-certified after every job.
