在鉆井作業中，溢流是一種高發問題，常規檢測器響應時間較長，操作人員無法及時發現、解決問題，Weir推出的新型智能檢測器可以極大改善這一現狀。
來自丨Weir
編譯丨白小明?驚蟄
Weir油氣公司是一家領先的壓力泵和壓力控制設備和服務提供商。近期，該公司宣布在智能傳感器領域取得了重大突破，其研發的傳感器可以實時準確地測量泥漿氣體液位，防止溢流，并最大限度地提高安全性，同時提供主動溢流管理，降低清理成本并減少非生產時間。
溢流是氮氣充氣鉆井作業中的一種高發風險，在Wyoming的一次作業中，鉆井公司使用了Weir的傳感器。之前，操作人員在溢流發生時緊急處理時間不足20分鐘，而現在他們有3.5小時的時間來防止溢流，并避免流體進入副安全保護罐，從而減少停機時間和成本。過去幾年中，這項增強技術為已安裝設備的井隊節省了數十萬美元。
Mathena泥漿氣體分離器智能液位傳感器是Mathena泥漿氣體分離器智能系統（MGS-ISC）的一部分，可精確測量泥漿氣體分離器內的液位，適用于控壓鉆井和欠平衡鉆井，能夠在鉆井現場精確控制溢流并提供實時數據。為操作人員提供了更多時間，避免氣體進入使用中的泥漿系統，并防止出現液體從點火器系統溢出的情形。
傳感器系統中可以添加控制閥自動操作功能，實現智能排液控制，進一步提高溢流處理能力。利用這種能力，泥漿排放可以完全封閉進行，以保持液體密封防止氣體到達泥漿振動篩，同時降低泥漿罐溢出的風險并確保實現固液分離所需的理想氣體流速?？刂崎y自動操作還有助于優化勞動效率。
采用Weir久經考驗的系統方法，智能液位傳感器也可以應用于副安全保護罐的全方位監控。Weir油氣公司壓力控制工程經理Matt Green表示，“目前，人工故障識別和響應時間不足以讓操作人員避免溢流和泄露。提供實時數據可以防止事故發生，并最大限度地延長正常運行時間?！?/span>
Mathena智能液位傳感器和MGS-ISC可與Weir的壓力控制智能系統以及Mathena系統的其他模塊集成，包括Mathena排氣分析儀、智能流量儀表系統（VGA-ISF）和Mathena ECO-Tank智能系統（ECO-ISL），核心技術來源于Mathena Frac Flowback智能系統（FFB-ISL）。
Weir的智能系統產品在北美每個主要作業盆地都有技術支持，并與其他鉆井平臺數據管理系統集成，使鉆井工程師能夠在一個地方匯總所有數據。
在北美，鉆井作業中經常會發生鉆井液溢出到MGS排氣管線中的情況。人工故障識別和響應時間通常不足以防止流體進入點火系統，從而造成溢出事故。為了改善識別能力和響應時間，Weir安裝了泥漿氣體分離器智能系統（MGS-IS），用于連續監測MGS中的實時液位。實時數據使決策制定更快、更明智。通過采用系統方法，Weir應用其基于波雷達液位測量的智能系統液位（ISL）技術來監控MGS和副安全保護罐，通過WITS將信息傳輸到本地EDR、本地物理警報系統，并通過云進行遠程傳輸。
該系統避免了排氣口溢流。預測MGS鉆井液填充速率大大提高了人工響應的準備時間，從大約15分鐘提高到近2.5小時。除了降低相關的HSE風險，該系統每月還減少了大約十幾起溢出事件，節省了數千美元的清理成本和非生產時間。如果將Mathena IS技術推廣應用到該地區的其他井，那么節約的成本將成倍增長。
監控應用的成功為增加控制閥自動操作功能奠定了基礎，從而實現智能主動排放控制，這將進一步提高溢流處理能力。借助主動排放控制，泥漿排放可以完全封閉進行，以保持液體密封防止氣體到達泥漿振動篩，同時降低泥漿罐溢出風險并確保實現固液分離所需的理想氣體流速。
使用WM-IS獲得的其他鉆井液流量數據和控制，為提高安全性和理解鉆井作業提供了新的機會。傳輸到鉆機電子鉆井記錄儀后，數據可以協同閥門自動操作功能獲得泵速數值，增強流體系統控制。WM-IS平臺建立了一個節流與壓井監測和控制系統，并可擴展包含排氣流量監測和節流性能監測和控制。此外，Weir的Synertrex狀態監測、過程效率和生產優化舉措可以直接向鉆井工程師或數據中心提供基于云的MGS數據報告。長期數據評估為提高安全性和效率提供了新的思路。
MGS-ISC可以作為單個產品使用，也可以與多種IS產品結合使用，如Mathena排氣分析儀（VGA-ISF）。該系統還提供通過WITS通信協議與Pason、MD Totco和其他EDR平臺集成的功能。
應用特性
- 主動溢流控制和液封保護，在不到18秒的時間內將完全打開的閥門關閉
- 適用于高壓地層和環境敏感區域
- 波雷達技術用于監測MGS液位，并可與其他傳感器集成來監測副安全保護罐
- 更準確的MGS液位傳感和實時液位變化分析和性能監測
- MGS條件分析和報警
- 自動MGS液體排放控制
- 本地和遠程性能監控，通過文本、電子郵件或基于云的門戶將客戶與數據連接起來
- 可存儲、共享和報告實時數據，以供將來參考
- 可選的傳感器和軟件集成包，將MGS-ISC/F作為井筒返液流量計
- 電動控制系統，可優化性能并最大限度地減少執行器循環
- 手動執行器超控
- 可同時確保MGS排氣分離效果，與Mathena?排氣分析儀ISF集成
- 簡化診斷和故障排除
- 可供出租，每個盆地都有服務中心；每次工作后都要經過全面檢查和重新認證
- 安裝和部署的交付周期為2-4周
適用作業
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Weir Oil & Gas, a leading upstream provider of pressure pumping and pressure control equipment and services, today announced it is achieving significant success in the field with intelligent sensors designed to accurately communicate mud gas liquid levels in real time to prevent overflows and maximize safety while providing active kick management, reducing cleanup costs and lowering non-productive time.
The sensor has been used in the Wyoming region in nitrogen-aerated drilling operations in which overflow is a constant risk. Where operators previously had less than 20 minutes of response time, they now have 3.5 hours to prevent overflow and eliminate liquid in the secondary containment vessel – thus reducing downtime and direct costs. This technology enhancement has generated hundreds of thousands of dollars in savings for installed sites over the course of a few years.
Mathena? Mud Gas Separator Intelligent Level Sensor, part of the?Mathena? Mud Gas Separator Intelligent System (MGS-ISC), accurately measures the liquid levels within the mud gas separator for managed-pressure drilling and underbalanced drilling operations, providing accurate kick control and real-time data on-site. This gives operators much more time to avoid gas carryover to the active mud system and prevent an overflow scenario creating a fluid spill from the igniter system.
Control valve automation can be added to enable intelligent active discharge control that further improves kick-handling capacity. With this capability, the mud discharge can be completely closed to maintain the liquid seal needed to prevent gas from reaching the shale shakers while reducing the risk of vessel overflow and ensuring an ideal gas velocity for liquids and solids separation. The control valve automation also helps optimize labor efficiency.
Intelligent level sensors can also be applied to the secondary containment vessel for comprehensive monitoring with Weir’s proven systems approach.
“Manual event recognition and response time is insufficient for today’s operators to prevent overflows and spills,” said Matt Green, Pressure Control Engineering Manager of Weir Oil & Gas. “Providing real-time data prevents incidents and maximizes uptime.”
The Mathena? Mud Gas Separator Intelligent Level Sensor and?Mathena? Mud Gas Separator Intelligent System (MGS-ISC)?can be integrated with Weir’s?Pressure Control Intelligent Systems?as well as other modules of the Mathena system including the?Mathena? Vent Gas Analyzer and Intelligent Flow Meter System (VGA-ISF)?and?Mathena? ECO-Tank Intelligent System (ECO-ISL.)?All modules are available for rent. The core technology has been adapted from the Mathena? Frac Flowback Intelligent System (FFB-ISL).
Weir’s line of intelligent systems is supported in every major basin in North America and integrates with other drilling rig data management systems, allowing drilling engineers to aggregate their data in one place.
Drilling operations in the area frequently experience drilling fluid overflow into the MGS gas vent line. Manual event recognition and response time is often insufficient to prevent fluid from entering the flare system and creating a spill incident. To improve recognition and response, Weir installed its Mud Gas Separator Intelligent System (MGS-IS) for continuous monitoring of real-time fluid levels in the MGS. The data enabled faster and more informed decision making. By taking a systems approach, Weir applied its Intelligent System Level (ISL) technology based on wave radar level measurements to monitor the MGS and secondary containment vessels, and communicated the information via WITS to the local EDR, local physical alarms, and remotely via the Cloud.
The system eliminated vent overflows. Projection of MGS drilling fluid fill rates dramatically increased manual response lead-time from approximately 15 minutes to nearly 2.5 hours. Along with lessening the associated HSE risk, the system mitigated approximately a dozen overflow incidents per month to save thousands of dollars in cleanup costs and non-productive time. The value is multiplied by the ability to extend the Mathena? IS technology to many other wells in the area.
Success of the monitoring application sets the stage for adding valve automation to enable intelligent active discharge control that further improves kick-handling capacity. With active discharge control, the mud discharge can be completely closed to maintain the liquid seal needed to prevent gas from reaching the shale shakers. The control also reduces the risk of vessel overflow and ensures the ideal gas velocity for liquids and solids separation.
The additional drilling fluid flow data and control achieved with the WM-IS provides new opportunities for improving safety and understanding drilling operations.Delivered to the rig’s electronic drilling recorder, the data can inform pump rates in coordination with valve automation for enhanced fluid system control. The WM-IS platform establishes a choke and kill system monitoring and control system, expandable to include vent gas flow monitoring and choke performance monitoring and control. In addition, Weir’s Synertrex? condition monitoring, process efficiency and production optimization initiative can provide cloud-based reporting of MGS data directly to the drilling engineer or data center. Long-term data evaluation offers new insights with the potential of additional safety and efficiency improvements.
Modular and flexible
The MGS-ISC can be deployed as a single product or integrate with multiple IS products, such as the Mathena? Vent-Gas Analyzer (VGA-ISF). The system also offers integration capability with Pason, MD Totco, and other EDR platforms via WITS communication protocol.
Features
- Active kick control and liquid seal protection, with total valve open-to-close actuation in less than 18 seconds
- Ideal for high-pressure formations and environmentally sensitive areas
- Wave-radar technology to monitor MGS fluid levels and can be integrated with additional sensors to monitor secondary containment vessels
- More accurate MGS liquid-level sensing and real-time liquid-level change analysis and performance monitoring
- MGS conditional analysis and alarms
- Automated MGS liquid-discharge control
- Local and remote performance monitoring, connecting customers with data via text, email, or Cloud-based portal
- Real-time data that can be stored, shared, and reported for future reference
- Optional sensors and software integration package that establishes the MGS-ISC/F as a wellbore return flow meter.
- Electric-actuated control system to optimize performance and minimize actuator cycles
- Manual actuator override
- Simultaneously ensures MGS vent-gas separation performance, integrating with the Mathena? Vent-Gas Analyzer ISF
- Simplified diagnostics and troubleshooting
- Available for rent, with service centers in every basin; fully inspected and recertified after every job
- Two-to-four weeks lead time for installation and deployment
Processes
- Drilling
- Low pressure flow control (Industrial)
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