修井作业的不确定性会延迟生产的进行，NOV的新技术可改善这一问题！ 编译 | 惊蛰 由于修井作业具有独特性、偶发性，同时成本极高，因此开发商需要在作业前反复验证技术的可行性。不同于钻井作业的重复性，修井任务更加多样化，需要定制解决方案。在方案部署前，若能反馈作业需求，并在模拟条件下进行测试，这将为开发定制化的修井产品铺平道路。 为满足铣削与修井需求，******（NOV）投资开发了卧式铣床（HMM），有助于评估铣削组件与其他修井工具的性能。在模拟环境中进行测试，可创建量身定制的解决方案，降低修井作业的风险与成本，提高修井作业的成功率。 卧式铣床位于休斯顿，该机器可将底部钻具组合（比如：铣刀、泥浆马达、减摩工具）推入并在模拟环境中旋转，同时可定量测量这些工具的性能。 可调节的BHA导向器能够模拟出大斜度井眼、水平井眼以及常规尺寸套管的井下环境。HMM与垂直方向夹角为**°，可在短距离内铣削进入模拟地层，模拟大多数油田常见的水平井筒。独立动力装置提供增压液压油，以驱动HMM上的旋转与推力功能，并可驱动虎钳与管子吊架，确保在组装与拆卸时轻松、安全。 在测试中，将参与测试的特定工具或管串置于HMM中。为准确测量机械钻速(ROP)、磨程以及其他测试参数，需安全布置高强度水泥目标、胶结与未胶结套管、实际地层的岩块，并防止其移动与振动。单个目标长度限制为**英尺，最大可用直径为**英寸，该设备可实现模块化配置，总测试长度可达**英尺。未胶结套管用作内铣削测试的目标支撑时，测试长度可达**英尺。 HMM可在测试过程中生成精确的数据。BHA导向器可将BHA与钻头/铣刀定位至测试目标，因此无需钻入目标，即可使BHA吃入并保持稳定。泵、泥浆罐与固控设备可提供一系列作业流体，包括淡水与水基泥浆。位于HMM与测试目标附近的控制室可执行HMM的操控。还可以安装数据采集系统，以监视测试作业并收集性能数据。高架起重机，叉车，导轨或机械定位器有助于定位BHA与测试目标。 测试设备时，可以向HMM提供组装好的底部钻具组合。NOV也可以为其设计、制造与组装定制的解决方案。然后，钻杆与BHA相连，以提供测试所需的推力与旋转。HMM能够承受***** ft-lb的扭矩，可以测试的机械钻速高达***ft/hr，旋转转速高达***rpm。 案例分析 ******想要在近海的油井中下入封隔器。由于安全剪切释放机构存在设计缺陷，需要修井来******利用HMM测试并进行了验证，******解决难题。除了使用HMM进行测试外，NOV还通过实验室测试来协助二次完井作业、洗井作业、打捞作业以及弃井作业。而且，通过调整现有产品，就能够帮助解决特定的作业挑战。 为了提高非常规井完井阶段的作业效率，各公司探索创新出众多产品与技术。其中，服务商可利用大通径桥塞与可溶性球的概念，消除对铣削复合桥塞的需求。但与复合桥塞不同，这些铣刀由铸铁或钢制成。这种方法造成相当大的铣削挑战，延长了常规铣削作业。该案例研究显示，一个项目从**天延长到***天。 位于加拿大西部盆地的一家服务商想要改进射孔桥塞联作的工艺，便向NOV寻求解决方案。利用定制化方法，将Bowen产品与新的磨铣技术相结合。镶齿位置、前倾角以及切削刃材料都是影响机械钻速与铣刀寿命的关键因素。然而，本案例研究的重中之重是碎片管理。 在第一次测试中，V*铣刀连续铣削了不到两小时的时间，产生的切削碎屑尺寸在可接受范围内。测试表明，该铣刀的镶齿位置不对，使桥塞的芯轴低于铣削面，并在磨铣第二个桥塞时切断了切削刃。于是在第二次测试中，改变了镶齿的位置，增加了切削刃的厚度。V*铣刀在相同的铣削时间内，扩大范围，磨铣了多个桥塞。切削碎屑的尺寸更小，有助于实现更有效的井眼清洗。 ******要求NOV参与一个项目，目的是审查当前的弃井方法，并在不完成实际作业的条件下，研发出安全有效地弃井方法。当管柱处于静止时，固井是一个挑战，因为这种固井方式极易产生微环隙通道，从而危及整个弃井作业。NOV研发出一款类似于Agitator?系统的设备，安装于悬挂的生产管柱中，并部署于井况与实际井相似的测试井中，从而在尽可能真实的条件下完成测试。该设备可产生压力脉冲，并将其转化为振动，促使油管产生显著运动。该方案提高了水泥的覆盖率，从而避免产生微环隙。 ******着眼于发生井喷的井，它的目标是从井中打捞出完整的管柱碎片，并将之用来分析油井故障的原因。在为期六周的时间内，NOV设计构建出一个解决方案，该解决方案改进了现有的打捞抓手，用作打捞工具，确保安全的从井中打捞出完好无损的物品。他们还根据操作规范进行了实验室测试。在实验室测试之后，该公司在NOV的帮助下，将该解决方案部署于井场。经过多次尝试，该装置打捞出完好无损的“证物”。 在设备与技术应用于现场之前，利用诸如HMM之类的设备进行实验室测试与模拟，可显著降低技术应用与磨铣作业的成本。模拟出作业环境并创建出相似井特征，可对特定作业进行测试。也许仅需轻微调整现有设备，即可得到新的设计，从而使作业者拥有经过全面测试的定制解决方案。 这些现代化的设计与建模技术可帮助工程师们创建更精确的铣刀设计，与旧技术相比，可实现更高的经济效益。在作业期间，应用预先验证的解决方案可降低作业风险与成本，还可提高铣削与修井作业的成功率，从而实现更安全更有效的打捞、弃井与洗井作业。The unique, sporadic nature and high costs of intervention operations have increased operator demand for technology validation before deployment. Unlike the repetitive nature of drilling rock formations, interventions require varied tasks and more customised solutions. The ability to respond to operational needs and test in simulated conditions before deployment opens new opportunities for the development of fit-for-purpose intervention products. In response to milling and intervention needs, National Oilwell Varco (NOV) has invested in a horizontal milling machine (HMM), which aids in the performance evaluation of milling assemblies and other intervention tools. Testing in simulated environments has enabled the creation of tailored solutions, lowering intervention risks and costs and increasing the success of intervention operations. ?Horizontal milling machine Located in Houston, Texas, the Horizontal Milling Machine (HMM) pushes and rotates a bottomhole assembly (BHA) consisting of tools such as mills, drilling motors, and friction reduction technology into simulated environments while quantitatively measuring the performance of the tools. An adjustable BHA guide provides stabilisation similar to high-angle and horizontal wellbores and casing in common hole sizes. Capable of milling processes for a short distance into a simulated formation or other target of interest, the HMM is **? from vertical, mimicking the horizontal wellbore common in most oilfields. A standalone power pack provides pressurised hydraulic fluid needed to drive rotary and thrust functions on the HMM, as well as the make and break vices and pipe cradles for ease and safety while assembly and disassembly take place. During testing, the target designed and constructed for the specific tool or tool string being tested is positioned in the HMM. High-strength cement targets, cemented and uncemented casing, or blocks of actual formation are securely positioned and prevented from movement and vibration to provide accurate rates of penetration (ROP), mill advancement, and measurement of other test parameters. With individual target lengths limited to ** ft with a maximum usable diameter of ** in., the device is modularly configurable to provide a total test length of up to ** ft. Uncemented casing used as a target holder for internal milling tests can measure up to ** ft long. The HMM provides accurate data generation during operation. The BHA guide positions the BHA and bit/mill to the target without needing to drill into it to bury and stabilise the BHA. Pumps, tanks, and solids-handling equipment provide a range of working fluid types, including freshwater and water-based mud. A control cabin positioned near the HMM and target enables operation of the HMM. The data acquisition system may be installed to monitor the test operation and collect performance data. An overhead crane, forklift, guide rails, or mechanical positioners aid in positioning the BHA and target. Companies wishing to test equipment can deliver a made-up BHA to the HMM, or NOV can design, manufacture, and assemble a custom solution. The BHA is then attached to the drillpipe to be used for thrust or rotation. Capable of handling a torque capacity of ** *** ft-lb, the HMM can test ROP up to *** ft/hr and a maximum rotary speed of *** rpm. The machine has aided in the testing and development of milling solutions. ?Case studies Milling A company in Mexico had an objective to run packers in wells off the coast. A design flaw in the safety shear release mechanism required an intervention to enable retrieval. NOV combined a simplex packer retriever with an internal cutter, which was ready for testing within six weeks. The solution was tested and proved using the HMM. The hybrid solution helped solve the company’s problems in one trip. The tool string latched packer made a cut and retrieved a packer in the same run, creating a solution for the company’s challenges and a new milling product. Lab testing In addition to testing with the HMM, NOV has aided in recompletions, well cleanouts, and recovery and abandonment operations through lab testing. The modification of existing products has helped solve operation-specific challenges. ?Recompletions/well cleanouts In a quest for greater efficiencies during the completion phase of unconventional wells, service companies explore and innovate products and techniques. In these cases, service providers used a large bore plug and a dissolvable ball concept to eliminate the need for milling composite plugs. Unlike a composite plug, these mills consisted of cast iron or steel, requiring companies to re-access the well. This method led to considerable milling challenges and lengthened typical milling operations. This case study showed a project extend from ** days to *** days. A service provider in the Western Canada Basin seeking improvements in the perf-and-plug process approached NOV for a solution. Through an engineered approach, Bowen? products were combined with new milling technology. Insert placement, rake angle, and blade material are all key components that contribute to ROP and mill life; however, the most important component of this case study was debris management. In the first test, the V* mill yielded suitable milling times at just under two hours and with acceptable cutting debris. Testing showed the inserts were not positioned properly, allowing the plug mandrel to go below the milling plane and cut the blade off while milling the second plug. In the second test, the insert positioning was modified and the blade thickness was increased. The V* mill yielded similar mill times with extended range to include multiple plugs. The cutting debris size and shape lessened to aid in more effective hole cleaning (Figure *). ?Safe, efficient abandonment A major producer in the UK requested NOV’s involvement on a project with an objective to review current abandonment philosophies, and determine ways to safely and efficiently abandon wells without de-completing them. A challenge involved cementing tubulars when the tubular is static, as cementing in this manner can cause the creation of micro annulus flow paths to compromise the entire abandonment operation. A device was created that was similar to the Agitator? system, installed in the suspended production tubing, and used to complete tests in as real life conditions as possible by deploying in a test well with tubular and casing sizes that matched the actual well characteristics that would be commonly encountered. The device created pressure pulses, converting into vibration to generate significant movement of the tubing. The solution improved cement coverage and eliminated the possibility of microannulus occurrence. The displacement potential exceeded lateral restriction of a * ? in. casing drift. The lateral vibration magnitude accentuated from **** ft to **** ft, but it provided sufficient vibration of the tubing within maximum lateral restriction. ?Recovery of evidence A company working on a blowout well in California had objectives to ensure pieces of pipe recovered from the well were maintained and could be used to discover causes of well failure. Within a six-week timeframe, NOV designed, engineered, and built a solution consisting of modified existing finger-catcher technology to be used as a catching device and to ensure items recovered from the well were intact and safe. They conducted lab testing according to the specifications of the operation. Following lab testing, the company deployed the solution with NOV’s assistance at the wellsite. After several attempts, the device recovered the evidence intact with no damage. ?Conclusion Lab testing and simulation using equipment such as the HMM prior to deployment leads to significant reduction in the application of technology and cost of milling operations. Testing for specific operations using simulated environments and matched well characteristics enables the creation of new designs through the slight modification of existing equipment, allowing operators to deploy fully tested, customised solutions. These modern engineering and modelling techniques assist engineers in creating a more precise design of mills, yielding cost improvements compared to older technology. The use of pre-proven solutions during operation reduces risks and costs, increasing the success rates of milling and intervention operations and leading to safer, more efficient evidence recovery, abandonment, and well cleanout.