SES推出的井口处理系统可以大幅提高开发商开采安全性和维护效率！ 编译 | TOM 惊蛰 Stress Engineering Services（SES）为Noble公司的超深水钻井船Noble Tom Madden提供了最先进的实时钻井隔水管、井口监测系统（RFMS）以及维护（CBM）服务。 RFMS为钻井隔水管和井口系统提供高度精确的动态海底测量，通过实时同步方式精确记录钻井隔水管、井口和套管系统在离散点处的运动状态，确定这些部件的疲劳损坏状况，并且可以将这些工具的健康状况及可操作信息传递给钻井队作业人员。 SES的CBM工艺支持钻井隔水管的结构完整性评估和维护评估，以评估钻井隔水管接头的状况，确定何时需要维修或更换重要部件，并评估部件的剩余寿命。评估周期是根据功能情况进行调整，而不是固定某个时间或周期，这可以改善整个行业运营商的经济效益。对于该项目，CBM系统将在MODU上部署并应用一个完整周期。 SES副总裁Chuck Miller说道：“我们CBM工艺通过了ABS认证，可以消除隔水管接头损坏的不确定性。我们很自豪CBM流程和RFMS技术为钻井工程师提供了创新的自动化、数字化和数据分析技术，使他们能够做出更明智的决策。” Noble ******的海底维护全球总监Orlan Lyle表示，“将SES的CBM流程与其RFMS技术结合使用，将使我们能够根据设备状况做出数据驱动决策。技术结合形成的风险洞察有助于我们聚焦于安全，识别可衡量的风险，通过供行动参考的数据提升我们的经济效益，并最终为我们提供有关设备健康状况的更好信息。 实时疲劳监测系统（RFMS） SES的实时疲劳监测系统RFMS是一种可以实时地提供钻井隔水管、井口和其他海底系统的应力和疲劳状况的技术。RFMS通过以下方式显着提高了隔水管完整性管理：在较少的位置使用测量数据；使用先进的算法重建整个隔水管的应力和疲劳损伤；将此方法集成到一个完全自动化的实时检测平台中。 RFMS为掌握井口系统的所有疲劳载荷提供了基础。井口是井筒与外在环境之间的最后一道压力屏障。了解并管理系统上的负载可确保系统的完整性不受影响，避免任何潜在的烃类排放从而保护环境。因此，钻井工程师可以使用一种工具，就可以提供钻井隔水管完整性的实时数据，能够在不利的环境中做出明智的决策，从而提高钻井作业的安全性和效率。 RFMS还可以通过显著减少停机时间节约相应的成本。随着隔水管设计下深的增加，以及结构完整性管理成为深水钻井和生产作业中的一个重要问题，RFMS提供的实时应力和疲劳信息将至关重要。最终，预计足够数量的高质量现场数据将进一步验证改进模型并提高模拟精度，并形成重点更为突出的检验和完整性管理计划。 RFMS通过沿隔水管关键位置放置的*~**个加速度传感器和角速率传感器的测量结果以及分析得到的隔水管模态信息，计算隔水管系统/井口/导管中任何位置的应力和疲劳强度。只需要在线输入隔水管动态响应数据、顶部张力和泥浆密度，因此可以在不考虑未知碰撞洋流或其他意外事件的情况下计算疲劳估计。振动传感器和数据采集电子设备安装在海底振动数据记录仪（SVDL）中，SVDL单元通过海底光纤电缆连接到位于甲板的中央数据采集系统。 来自每个SVDL的数据获取后都会显示，并使用复杂的在线计算机算法进行处理，使用隔水管动态模型的数据库来模拟沿整个隔水管长度的应力估计。然后通过雨流计数法按时间顺序处理估计值，记录在部署期间累积的疲劳损伤。疲劳估计数据每隔**分钟跟新一次，从而实时向钻井队给出可供行动参考的信息。 钻井隔水管全周期监测（CBM） 激光轮廓钻孔腐蚀测量和检测系统（BEMIST）已被国防部和美国国家航空航天局广泛使用，扫描头以*** rpm的速度旋转，每次旋转收集超过****个测量点，从而生成组件表面的高分辨率内部图。激光内径测量收集主钻孔和井之间辅助线的内径数据，以表征钻井隔水管接头的状态。系统产生数百万个高分辨率数据点，利用LaserViewer软件进行分析准确地绘制和确定材料损失，表征特征以确定分析原因的方法并对整个管进行详细的尺寸分析。针对符合鉴定测量标准的异常点及其在管上特征的位置形成一份汇总报告。 该系统通过安装在海底振动数据记录仪（SVDL）中的振动传感器和数据采集电子设备确定隔水管系统/井口/导管中任何位置的应力和疲劳强度。 数据采用最先进的SES专利技术进行处理，旨在为钻井作业人员提供关键可供行动参考的信息。 SVDL可以通过ROV单独安装在隔水管接头、井口和BOP上，并处于“离线”模式，在测量结束后可以恢复记录的振动数据（可以持续保存数周），通过离线处理数据以估算压力和疲劳。操作人员可以在钻井活动期间随时评估系统完整性。当钻井隔水管接头上提到表面后，使用LaserStream BEMIS进行检查。将BEMIS系在绳索上穿过隔水管内径进行检查。当隔水管在甲板上收集这些数据时，可以在一天内检查八个接头，现场检测结果可随时获得，并在一周内得到最终报告。Stress Engineering Services (SES) has delivered a state-of-the-art real-time drilling riser and wellhead monitoring system (RFMS), in conjunction with its Condition Based Maintenance (CBM) process for Noble Corporation’s ultra-deepwater drillship Noble Tom Madden. The RFMS provides dynamic subsea measurements with a high degree of reliability for the drilling riser and wellhead systems. By precisely recording the motion of the drilling riser, wellhead and casing system at discrete points in a time synchronous manner, fatigue damage of these components are determined and actionable information on the health of the drilling riser, wellhead and casing system can be delivered to the rig crew. SES’s CBM process supports structural integrity evaluation and maintenance assessments of drilling risers to assess the condition of drilling riser joints, determine when important components will need service or replacement and assess the remaining life of the component. This process is function-based on a tailored period, rather than time-based, improving performance economics for operators throughout the industry. For this project, a life cycle CBM system will be deployed and performed on the MODU. Chuck Miller, V.P., Stress Engineering Services, said, “Our ABS-qualified CBM process will remove uncertainties surrounding damage of the riser joints. We are proud that our CBM process and RFMS technology arms drilling engineers with innovative automation, digitalization and data analysis techniques and empowers them to make more informed decisions.” Orlan Lyle, director-worldwide subsea & maintenance, Noble Drilling Services Inc., said, “Using SES’s CBM process together with their RFMS technology will allow us to make data driven decisions concerning the condition of our assets. The associated insight helps us focus on safety, identify measurable risks, manage our economics with actionable data and ultimately provides us with better information on the health of our assets.” Realtime Fatigue Monitoring System (RFMS) Stress Engineering Services developed the Realtime Fatigue Monitoring System (RFMS*) as a method of providing field measurements of stress and fatigue on drilling risers, wellheads and other subsea systems in near real time. The RFMS significantly advances riser integrity management by Using measured data at a fewer locations Using advanced algorithms to reconstruct stress and fatigue damage along the entire riser Integrating this approach into a fully automated, real-time environment The RFMS provides a basis for understanding all the fatigue loads on a wellhead system. The wellhead is the last pressure barrier between the well and the environment. Understanding the loads and managing the loads on the system ensures that the integrity of the system is not compromised, and protects the environment from any potential discharge of hydrocarbons. As a result, drilling engineers are empowered with a tool that provides real-time data on the integrity of the drilling riser, enabling informed decisions to be made in adverse environments that increase safety and efficiency of drilling operations. The RFMS can also significantly reduce downtime with commensurate cost savings. The real-time stress and fatigue information provided by the RFMS will prove increasingly useful as riser design boundaries are extended, and as structural integrity management becomes a preeminent concern in deepwater drilling and production operations. Ultimately, a sufficient amount of quality field data are expected to lead to improved model validation and simulation accuracy, and a more focused inspection and integrity management program. The RFMS calculates stress and fatigue at any location in a riser system/wellhead/conductor casing via measurements from *-** accelerometers and angular rate sensors placed at strategic locations along the riser, along with analytical riser mode shape information. Since the only required online inputs are the dynamic riser response, top tension, and mud weight, fatigue estimates may be calculated without knowledge of the impinging currents or other forcing events. Vibration sensors and data acquisition electronics are housed in Subsea Vibration Data Logger (SVDL). The SVDL units are connected via fiber optic subsea cabling to a central data acquisition system, located topside. Data from each SVDL is displayed as it is acquired, and processed with a sophisticated online computer algorithm to synthesize stress estimates along the entire riser length using a database of riser dynamic modes. The estimates are then processed chronologically via rainflow counting, recording fatigue damage accumulated during the deployment. The fatigue estimates are updated at ** minute intervals, thereby providing actionable information to the drilling crew in real-time. Life Cycle Condition Based Monitoring (CBM) for Drilling Risers The Laser Profilometry Bore Erosion Measurement and Inspection System (BEMIST) has been used extensively by the Dept. of Defense and NASA. The scanner head rotates at *** rpm, collecting more than **** points of measurement in each rotation, producing a high resolution internal map of the component surface. Laser ID measurements are collected on the inner diameter of the main bore and auxiliary lines, between wells to characterize the state of drilling riser joints. The system generates millions of high resolution data points, which are harnessed and analyzed using LaserViewer software toaccurately map and determine material loss, characterize features to determine method of causation and perform detailed dimensional analysis of the entire tube. A report summarizing the anomalies that meet the criteria are identified and measured, along with the location of the feature on the tube. The system determines stress and fatigue at any location in a riser system/wellhead/conductor casing with vibration sensors and data acquisition electronics housed in a Subsea Vibration Data Logger (SVDL). The data is processed using state-of-the-art SES patented technology, designed to provide the drilling crew with critical, actionable information. The SVDL can be installed individually by an ROV on riser joints, wellheads and BOPs in `offline mode, where the recorded vibration data is retrieved after the measurement campaign, (which can last several weeks), and processed offline to estimate stress and fatigue. The operator is provided with a useful tool to assess system integrity at any time during a drilling campaign. After the drilling riser joints have been recovered to the surface, the LaserStream BEMIS is used to inspect them. The BEMIS is deployed through the ID of the riser via a tethered crawler. This data is collected while the riser is on the deck and eight joints can be inspected in one day, with the field results being available at the site, and a final report following in a week.