Ideal ****是一款新型陆地钻机，新的设计让操作员具有更灵活的作业选项。 作者 | 二丫 随着页岩开采的兴起，钻机升级也顺势而起。在北美，越来越多的钻机被改造用于非常规油藏水平井钻探，这是也是当前油气行业的一大趋势。在低油价背景下，油气行业需要新的效率点来推动陆地井大规模转变，最终实现非常规井的经济高效开采。为了完成非常规油藏的钻完井，当前业内需要更好的井位布置和水力压裂技术。简而言之，由于页岩开采中水平段更长，地层也更具挑战性，作业需要更大功率和钻进速度的钻机，以满足复杂井结构中高载荷钻柱的驱动。油气行业的发展要求陆地钻机的快速进步，这也是非常规油田发展的理想选择。 随着油价的回升以及市场稳步增长的势头，最快恢复使用的钻机是交流电（AC）和“超规格”钻机，这是由于这些钻机在负载能力方面有大幅改进，功率达到****马力或更高，具有在不同区块间快速移动的能力。精确与控制能力也是超级钻机应用中的主要挑战，保持钻头不偏离设计轨迹达到最佳甜点，钻机稳定性至关重要。此外，非常规油藏的地层构成复杂，钻进过程中阻力情况多变，使得井眼布置和维护更加关键。因此，钻井在高难度大位移井钻探中的定位能力就代表了其主要竞争能力。 除了作业功率和速度优化之外，减少作业中设备占地面积是开发商需求之一，模块化设备可以更容易地布置于钻台上，从而被更广泛地使用。模块化允许操作人员以有利于作业的方式定制钻机的布局，同时优化设备放置，最终降低维护强度。此外，钻井自动控制系统的内置为开发商和操作员提供了进一步的好处。由于这些装备精良超级钻机在北美陆地钻探中的应用，常规机械钻的机竞争力显著降低。类似地，除非AC钻机不可用，否则可控硅整流器（SCR）钻机基本上都在闲置状态。在大多情况下，钻井承包商正努力将SCR钻机转换为AC钻机，以提高钻进性能和市场上的竞争力。 靶向定制 提高效率 Permian盆地对超级陆地钻机的需求尤其强烈，该区块在过去几年经历了多次的快速发展，北美和中东的其他高活动区域也是如此。除了上述提及的超级钻机优势之外，中东还受益于钻机设计的其他变化，包括能够满足更高温度作业和适合沙漠环境应用的轮式移动系统。 纵观全球钻井作业，超级装备的一部分吸引力在于它具有的超高效率，使钻井的经济效益达到了前所未有的高度，即使最简单的变化也会产生影响。例如，新型钻机的顶驱在桅杆导轨上运行，而不是使用扭矩管，使得装配更简单快速。 国民油井（NOV）作为钻机和设备制造商，了解陆地钻探的市场动态。在多年的设计和工程开发基础上，开发具有更高马力、更大载荷、更高垫钻孔能力是当前钻机研究的主要驱动因素。近日，NOV宣布推出Ideal ****，这是一款专用的新型陆地钻机，新的设计允许操作员具有更灵活的作业选项。 钻机运输车辆可以通过简单的操作系统，而管串连接操作也实现了机械化。绞车采用独特设计，可以根据所需马力进行配置。钻机的设计也允许增加第三台泥浆泵，同时最多可容纳四台发电机组。增加一台泥浆泵不仅可提供额外的**** psi的流体循环能力，而且还提高了系统冗余能力，可简化其他两台泵运行时维护，或在其他泵出现故障时提供备用。 增加的发电机组可以提供额外泥浆泵所需的动力，在另一台发动机停机时提供动力保障。辅助发电机可在需求增加时提供电力，第四发电机组使电力系统更灵活地满足这些要求。 快速移动钻机不仅能够帮助钻井承包商获利，还有助于提高油田经济效益和效率，推动新区块产量的提升。通常情况下，钻机移动需要繁琐的装配，这意味着即使是最简单的移动也可能是钻井作业人员的一场“噩梦”，拆卸和装配会浪费大量时间。早期的钻机模型由于各种原因而不适合快速移动，绞车一般都放置在地面上，液压动力单元和布线设置是主要问题。Ideal ****钻机设计具有一个集成的快速装配系统，允许钻机快速完全的移动到相邻的作业区块。绞车一般放置在钻台上，用于顶部驱动和绞车的专用设备室减少了布线复杂性。液压动力单元，防喷器控制单元，钢丝滚筒以及阀门和压井管汇为悬臂式设计，可以与钻机一起快速移动。 自动升级 如果钻井承包商对钻井自动化感兴趣，那么NOVOS的自动升级功能可能具有更大的吸引力，可确保更少的停机时间。NOV的过程自动化平台NOVOS部署在Amphion或Cyberbase控制系统中，可自动执行重复流程，减轻钻井人员的负担，并实现钻井平台的标准化能力。 此外，该平台还提供一系列钻井应用程序，可解决各种钻井问题，操作员能够通过更好地了解作业中发生的问题，可快速改善钻进性能。钻机拥有自动化平台可为钻井作业中的所有参与者带来好处，钻井承包商可以进一步划分钻机登记，运营商可以根据关键性能改进工具和作业软件。此外，应用程序也可以定制开发，******、大学和其他各方面的合作，此方面的研究已经开展。The shale boom transformed the onshore drilling rig fleet as rigs capable of drilling horizontal unconventional wells typical of major North American basins differentiated from their peers and, consequently, more sought after. The downturn demanded new efficiencies, driving a massive shift in well orientation that would ultimately make onshore unconventional wells the most economical and profitable drilling option. To drill and complete these wells, however, required better wellbore placement and hydraulic fracturing technologies. It required rigs with more power and speed that could drive the heavier strings necessary in more complex well construction as laterals got longer and formations more challenging. The industry demanded land rig advances that were ideal for use in this new oil field. As oil prices recovered, and the market steadily gained momentum, the rigs that were coming back online the fastest were alternating current (AC) and “super spec” rigs, which are rigs with massive improvements in load capacities, drilling equipment with *,*** hp or more and the ability to quickly move between well sites in pad drilling applications. Precision and control are also major concerns with super spec rigs, as stability is critical if wells are to be drilled without deviating from their planned trajectory through the oil-producing sweet spot. Lithologically complex formations with multilayered rocks of varying resistances have made wellbore placement and maintenance even more critical, positioning the rigs that are equipped to drill challenging extendedreach wells ahead of the competition. Beyond power and speed upgrades, reducing footprint is a desire for drilling contractors, with modular equipment that can more easily be situated in various places on a drill floor becoming more widely used. Modularity allows the drilling contractor to customize the rig’s layout in a way that benefits the operator while optimizing equipment placement also ultimately lowers maintenance intensity. Additionally, rigs with automation capabilities built into the drilling control system provide further benefit to both the contractor and operator. As a result of the advent of these well-equipped super spec rigs in North American land drilling, mechanical rigs have generally not returned to service. Similarly, silicon controlled rectifier-powered (SCR) rigs have largely remained idle unless AC rigs were unavailable. In many cases, drilling contractors are looking to convert SCR rigs into AC rigs to improve performance and make them more competitive in the marketplace. New purpose-built land rig Much of the demand for super spec land rigs has come from the Permian Basin, which has experienced a renaissance of sorts over the past several years, as well as other high-activity areas in North America and the Middle East. Beyond the previously discussed benefits of these rig types in North America, the Middle East benefits from additional changes to rig design, including being able to handle higher temperatures and having wheeled moving systems suitable for desert applications. Across regions, part of the appeal of a super spec rig is that it has efficiencies that make drilling economical where it otherwise might not have been, and even the simplest of changes can have an impact. For example, having a top drive that runs up and down the mast rails instead of using a torque tube means the top drive can travel within the mast during rig moves, making rigup and rigdown simpler and faster. National Oilwell Varco (NOV), as a manufacturer of rigs and equipment, understands market dynamics in the land drilling arena. The need for higher horsepower, larger hookload capacities, increased setback capacity and pad drilling capabilities were the primary drivers as the company builds on years of design and engineering efforts to develop a new rig. NOV announced its new Ideal ****, a purpose-built land rig, not one upgraded from its original *,***-hp configuration. The design of the rig allows operators to have configurable options. An optional stand transfer vehicle can be included in the fingerboard, while pipehandling can be mechanized. The design of the drawworks enables its configuration to needed horsepower capacities. The rig’s design also is ready for the addition of a third mud pump and can accommodate up to four generator sets. A third mud pump not only provides an additional *,*** psi of fluid circulating capacity for deeper wells but also makes the system more redundant—streamlining maintenance when the other two pumps are running or providing a backup in a case of failure in one of the other pumps. The added generator set accommodates the power needed by the third mud pump and provides added redundancy in case another engine goes down. The auxiliary generator provides power as requirements increase, with the fourth generator set giving the power system more flexibility to accommodate those requirements. Walking rigs not only benefit drilling contractors but also help to improve oil field economics, boosting efficiency and driving the output of the newer units higher. Typically, rig movement has required rigging up and rigging down, meaning that even the simplest of moves could be a nightmare because of time lost disassembling and reassembling the rig. Earlier rig models have not been ideal for walking applications for a variety of reasons, with the drawworks’ placement on the ground and the hydraulic power unit and cabling setup being the primary issues. The Ideal **** rig design has an integrated walking system, allowing the rig—with a full setback—to move to an adjacent well. Placement of the drawworks on the drill floor, along with a dedicated local equipment room for the top drive and drawworks, reduces cabling. The hydraulic power unit, BOP control unit, drill line spooler, and choke and kill manifold are cantilevered off the substructure to travel with the rig. Automation upgradable If the drilling contractor is interested in drilling automation, then the NOVOS-enabled rig equipment ensures less downtime for an upgrade. NOVOS, NOV’s process automation platform, is deployed within the Amphion or Cyberbase control system to automate repetitive processes, taking the burden away from the driller and standardizing performance at the rig and fleet levels. Also, the platform hosts a selection of drilling performance applications that address various drilling dysfunctions, allowing the operator to improve performance through better understanding of what’s going on in the well. Having the automation platform presents a benefit to all participants in the process; drilling contractors can further differentiate their fleet, and operators have access to critical performance-improving tools and software. Applications also can be custom developed, an endeavor already pursued by several oil and gas companies, universities and other interested parties.