正在為分層充填一次次的下鉆頭痛不已？還是在為小內徑的多層充填系統不能滿足井下工具下入尋找答案？看這里，高效、安全、智能的TORRENT單次下鉆多層礫石充填系統也許是你的絕佳選擇。
來自 | Baker Hughes
編譯 | 錢佳成
貝克休斯的TORRENT?單次下鉆多層充填（MST）完井系統是一種可以一次下鉆選擇性的壓裂或礫石充填多層的完井系統。這種系統可以通過大幅縮短油氣井作業時間來大幅提升作業項目的經濟性。很多作業油公司通過使用這套系統，一次下鉆完成兩層甚至更多層的施工，與使用單次下鉆單層充填的工具相比節省了45%以上的作業開支。作業者還可以通過MST系統有選擇性的開采不同的層位、開采邊緣層并使得長產層的開采和施工變得更加經濟。
MST礫石充填完井系統為油氣井的產量最大化提供了多層同采或是選擇性開采兩種靈活的選擇。工具系統單次下鉆完成下部防砂管柱的坐封為充填做好準備。這種完井方式節約了作業時間、減小了作業風險和作業中的非生產時間（NPT）并且有效的提升了作業的安全性。MST礫石充填完井系統可以以任何順序對井內不同層段進行施工，這種工具的施工特性在很大程度上消除了等待時間。同時這種靈活的特性也有效的解決了施工材料的運輸和作業中的非生產時間的問題。
在這套系統的工具系列中，9-5/8in 套管封隔器懸掛5-1/8in尾管的MST完井工具系統和9-5/8in 套管封隔器懸掛3-3/4in尾管的MST完井工具系統，可以在容納貝克休斯同心智能油氣井系統（IWS）的同時提供油井控制能力。本套礫石充填系統也可以與其它貝克休斯完井系統配合使用，使油氣井獲得最優的防砂效果。系統安裝后，油氣井每一層都有相互獨立并帶有生產滑套的礫石充填篩管；在每個可測試隔離封隔器上，都有一套用于充填砂礫或陶粒的擠壓充填或礫石充填滑套，另外還有一套可以配合任何封隔器系列一同使用的銷釘剪切式安全接頭。
MST礫石充填系統通過服務工具提供的大面積流動通道，克服了同類系統內徑的限制，使得在產層的生產管柱內加入智能傳感器成為可能。這種大內徑的設計保證用戶可以在上部完井生產管柱中選擇安裝溫度計、壓力計、液壓控制閥和其它智能生產系統。本系統可提供7in~10-3/4in套管尺寸范圍內的三種不同尺寸內徑選擇。
MST礫石充填系統經過了深海和淺海環境油氣井作業的驗證，可以在高壓環境下安全有效地使用。這種單次下鉆完井系統，可以在保證作業安全有效的前提下，為油氣井提供有效的解決方案。
應用案例
墨西哥灣的石油公司選擇使用TORRENT MST完井系統對下第三紀地層的深水開發油田井進行擠壓充填作業。本次作業僅僅使用一次下鉆就完成了3層的擠壓充填作業。TORRENT MST系統有效的通過單次下鉆對多層油藏進行施工，與傳統完井一趟下鉆只能完成一層充填的方式比，本系統具有更好的經濟性并且能更有效的降低作業的非生產時間（NPT）。
這口井的井深為27,460-ft（8370-m），所在區域水深為8,149 ft（2484 m）。完井采用10 1/8in的油層套管。這口井的完井選擇了3段產層，在對產層進行射孔后，油公司下入了貝克休斯TORRENT單次下鉆多層礫石充填完井系統進行施工，施工過程使用了帶有雙滑套開關工具的96-37 TORRENT服務工具、帶有篩管交互系統（SCS）的TORRENT MST篩管、帶有選擇性開關功能滑套的TORRENT多用途服務閥（MSV)和TORRENT隔離封隔器。
作業前，公司相關人員使用InQuest PayZonePro?軟件對充填服務工具的井下受力情況進行模擬，保證服務工具在每一段的作業時有足夠的下壓力。
TORRENT MST完井系統的正顯示定位系統可以在壓裂作業時確認服務工具的井下位置；系統擁有承受高鉆壓的能力，可以保證設計的密封在高壓壓裂施工時不會被泵出密封筒導致作業失??；礫石充填服務工具的設計可以承受充填服務過程中的高作業壓力、高充填速率以及不同的砂比；服務工具的設計同時也可以保證在多層施工時，服務工具能承受大量陶粒泵入時所產生的沖蝕。
在層間隔離封隔器坐封并測試后，操作人員將TORRENT充填的服務工具定位在最下層的位置上來對此層進行擠壓充填作業。在完成充擠壓充填作業之后上提服務工具，一次性關閉本層留井管柱上的監測滑套和壓裂滑套。這種在服務工具上優化后的雙滑套開關工具配置有效的減少了作業時間，同時也降低了多次操作活動工具所產生的風險。在將服務工具提到測試位置后，作業人員可以在地面進行打壓測試，確認油井的壓力整體性，而后可以相同的方法繼續進行第二層和第三層的施工。
本次壓裂充填施工使用的高強度陶粒砂比為8 ppa，泵速為32bpm，井口施工壓力高達13,000 psi （896 bar）。 三層施工累積泵入陶粒量共達100萬磅，充填服務工具在起出后仍然處于較好的狀態。
在本次作業中，5,000-ft（1524-m）的分層隔離管柱被成功下入，整套留井管柱包括：一支API V0 級別的SC-XP?中間隔離封隔器、 選擇性滑套開關工具、一個油管隔離球閥和一個可再關閉的環空流動閥(X-AFV)。環空流動閥(X-AFV)使用井口壓力控制順利實現了開關。SC-XP隔離封隔器可以與ZX?密封單元配合使用。ZX密封單元是一種為深水井高溫/高壓環境設計的密封單元。這種密封單元的設計在服務工具移動時可有效防止膠環的脫落。
在SC-XP隔離封隔器坐封后，留井管柱上的生產滑套被打開。使用智能完井系統(IWS)的上部完井管柱，在不進入產層的情況下對油層上部的兩個獨立產層進行生產。這套上部完井系統包括：4-1/2in，12,000psi InForce? HCM-Plus液壓滑套、10,000psi Premier封隔器、一支文丘里管流量計、井下壓力和溫度計和化學藥劑注入閥。在打開上部產層的油管隔離閥和下部X-AFV環空流動閥后，油井順利投產。
油公司通過使用TORRENT MST礫石充填系統大大提升了作業效率，與普通的單次單層的擠壓充填完井作業預計工期相比，該系統為這口井的作業節約了12天的工期，就本次作業而言為油公司節省了價值1200萬美元的油井作業成本。交井后，油公司對這口井的首次測試也同時確認了，實際產量明顯高于預期。
The Baker Hughes multizone, single-trip (MST) completion system delivers selective frac- or gravel-packing treatments to multiple zones in a single downhole trip, which improve project economics by drastically reducing completion time and cost. For many operators, being able to treat two or more zones in one trip has resulted in a cost savings of 45% or more, compared to treating the multiple zones in individual trips. With the MST system, you can selectively produce zones, access marginal zones, and treat and produce longer zones more economically.
The MST system provides flexibility while maximizing hydrocarbons recovery by enabling selective or commingled production. The one-trip process and predeployment preparation saves time, reduces risk and nonproductive time (NPT), and maximizes safety. The MST system can treat zones in any order, with the ability to change the order, eliminating standby time. This flexibility can also solve costly logistical problems and NPT.
The 9-5/8in. x 5-1/8in. and the 9-5/8in. x 3-3/4in. MST systems accommodate Baker Hughes’ Intelligent Well Systems? (IWS) concentric completion while offering well control capabilities. The systems also work with other Baker Hughes systems to achieve optimum sand control. Each zone contains isolated gravel-pack screens with integral production sliding sleeves; a frac-/gravel-pack sleeve for placing sand (gravel) or proppant, which is enabled by testable isolation packers; and innovative shear-out safety joints, conveyed on any of Baker Hughes’ comprehensive packer portfolios.
By providing a large service tool flow area, the MST system overcomes inside diameter (ID) restrictions and makes it possible to add sensors to monitor the pay zone. The large ID allows options such as installation gauges, hydraulic valves, and other Intelligent Production Systems configuration on the production string. Three ID sizes are available for casing sizes from 7 in. to 10-3/4 in.
Proven to operate safely and effectively in high-pressure environments, the MST system operates efficiently in both shallow and deep water environments. This one-trip completions system provides an effective solution to optimize each well’s reserves, while safely delivering tangible, proven results.
CASE HISTORY
An operator with a deepwater field development in the Lower Tertiary formation in the Gulf of Mexico chose to use the Baker Hughes TORRENT? multi-zone single trip (MST) completion system to execute three frac-pack treatments in one run. The TORRENT MST system efficiently treats multiple zones in one trip, providing significant cost savings and reducing nonproductive time (NPT) compared with conventional technology, which requires at least one trip for each frac-pack treatment.
The well was drilled to 27,460-ft (8370-m) total depth (TD) in 8,149 ft (2484 m) of water, and 10 1/8-in. casing was installed. The well intersected three pay zones. After perforating, the operator ran the Baker Hughes TORRENT MST system, comprised of a 96-37 TORRENT service tool with dual shifter configuration, TORRENT MST screens with a patented screen communication system (SCS), TORRENT multi-service valve (MSV) sliding sleeves with selective profiles, and TORRENT isolation packers.
InQuest PayZonePro? software was used to model downhole hydraulic forces acting on the service tool to ensure sufficient set-down weights for all stages of the operation. The TORRENT MST system has positive locating mechanisms that fit together to confirm service tool positioning downhole and features high set-down capabilities and designated seals to handle high pressure frac operations. The service tool is engineered to endure high pressures and high treatment rates at varied concentrations. It is also designed to pump the large proppant volumes associated with multiple zone stimulations.
After the zonal isolation packers were simultaneously set and tested, the TORRENT service tool was positioned at the lowermost zone to perform the frac-pack stimulation. Upon completion of the treatment, the service tool was repositioned to close the monitoring sleeve and the frac sleeve in one upward movement. The dual shifter configuration optimizes the operation by reducing rig time, while also reducing the risk associated with excessive tool manipulation. The zone was pressure tested to confirm well integrity and the same process was followed for the second and third zones.
The frac-pack operation used 8 PPA of high-strength proppant pumped at 32 bpm with a surface treatment pressure of 13,000 psi (896 bar). After all three zones were successfully treated with over 1 million lbm of proppant, the service tool was inspected and confirmed to be in good condition.
The 5,000-ft (1524-m) isolation string— consisting of an SC-XP? V0-rated intermediate isolation packer, selective shifting tools, a tubing isolation ball valve, and a recloseable annular flow valve (X-AFV)— was successfully deployed. The X-AFV is opened and closed using hydraulic input, and includes a contingency option for mechanical manipulation if needed. The SC-XP packer features our proven ZX? seal element which resists swab-off, and is designed for use in deepwater HP/HT environments.
The production sleeves were opened and the isolation SC-XP packer was set and tested. The intelligent well system (IWS) upper completion—consisting of 4?-in., 12,000-psi InForce? HCM-Plus hydraulic sliding sleeves, a 10,000-psi Premier? packer, a Venturi flow meter, pressure and temperature gauges, and chemical injection valves—was installed to facilitate interventionless production of the two upper isolated zones. The well was successfully put into production by opening the tubing isolation valve for the upper section (included the two upper zones) and the X-AFV for the lower section (included the deepest zone).
The efficiencies gained through the use of the TORRENT MST system enabled the operator to start production 12 days sooner than would have been expected with a conventional frac-pack completion, saving an estimated USD 12 million considering rig time alone. Initial tests on the well confirmed significantly higher production rates than expected.
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