正在为分层充填一次次的下钻头痛不已？还是在为小内径的多层充填系统不能满足井下工具下入寻找答案？看这里，高效、安全、智能的TORRENT单次下钻多层砾石充填系统也许是你的绝佳选择。
来自 | Baker Hughes
编译 | 钱佳成
贝克休斯的TORRENT™单次下钻多层充填（MST）完井系统是一种可以一次下钻选择性的压裂或砾石充填多层的完井系统。这种系统可以通过大幅缩短油气井作业时间来大幅提升作业项目的经济性。很多作业油公司通过使用这套系统，一次下钻完成两层甚至更多层的施工，与使用单次下钻单层充填的工具相比节省了45%以上的作业开支。作业者还可以通过MST系统有选择性的开采不同的层位、开采边缘层并使得长产层的开采和施工变得更加经济。
MST砾石充填完井系统为油气井的产量最大化提供了多层同采或是选择性开采两种灵活的选择。工具系统单次下钻完成下部防砂管柱的坐封为充填做好准备。这种完井方式节约了作业时间、减小了作业风险和作业中的非生产时间（NPT）并且有效的提升了作业的安全性。MST砾石充填完井系统可以以任何顺序对井内不同层段进行施工，这种工具的施工特性在很大程度上消除了等待时间。同时这种灵活的特性也有效的解决了施工材料的运输和作业中的非生产时间的问题。
在这套系统的工具系列中，9-5/8in 套管封隔器悬挂5-1/8in尾管的MST完井工具系统和9-5/8in 套管封隔器悬挂3-3/4in尾管的MST完井工具系统，可以在容纳贝克休斯同心智能油气井系统（IWS）的同时提供油井控制能力。本套砾石充填系统也可以与其它贝克休斯完井系统配合使用，使油气井获得最优的防砂效果。系统安装后，油气井每一层都有相互独立并带有生产滑套的砾石充填筛管；在每个可测试隔离封隔器上，都有一套用于充填砂砾或陶粒的挤压充填或砾石充填滑套，另外还有一套可以配合任何封隔器系列一同使用的销钉剪切式安全接头。
MST砾石充填系统通过服务工具提供的大面积流动通道，克服了同类系统内径的限制，使得在产层的生产管柱内加入智能传感器成为可能。这种大内径的设计保证用户可以在上部完井生产管柱中选择安装温度计、压力计、液压控制阀和其它智能生产系统。本系统可提供7in~10-3/4in套管尺寸范围内的三种不同尺寸内径选择。
MST砾石充填系统经过了深海和浅海环境油气井作业的验证，可以在高压环境下安全有效地使用。这种单次下钻完井系统，可以在保证作业安全有效的前提下，为油气井提供有效的解决方案。
应用案例
墨西哥湾的石油公司选择使用TORRENT MST完井系统对下第三纪地层的深水开发油田井进行挤压充填作业。本次作业仅仅使用一次下钻就完成了3层的挤压充填作业。TORRENT MST系统有效的通过单次下钻对多层油藏进行施工，与传统完井一趟下钻只能完成一层充填的方式比，本系统具有更好的经济性并且能更有效的降低作业的非生产时间（NPT）。
这口井的井深为27,460-ft（8370-m），所在区域水深为8,149 ft（2484 m）。完井采用10 1/8in的油层套管。这口井的完井选择了3段产层，在对产层进行射孔后，油公司下入了贝克休斯TORRENT单次下钻多层砾石充填完井系统进行施工，施工过程使用了带有双滑套开关工具的96-37 TORRENT服务工具、带有筛管交互系统（SCS）的TORRENT MST筛管、带有选择性开关功能滑套的TORRENT多用途服务阀（MSV)和TORRENT隔离封隔器。
作业前，公司相关人员使用InQuest PayZonePro?软件对充填服务工具的井下受力情况进行模拟，保证服务工具在每一段的作业时有足够的下压力。
TORRENT MST完井系统的正显示定位系统可以在压裂作业时确认服务工具的井下位置；系统拥有承受高钻压的能力，可以保证设计的密封在高压压裂施工时不会被泵出密封筒导致作业失败；砾石充填服务工具的设计可以承受充填服务过程中的高作业压力、高充填速率以及不同的砂比；服务工具的设计同时也可以保证在多层施工时，服务工具能承受大量陶粒泵入时所产生的冲蚀。
在层间隔离封隔器坐封并测试后，操作人员将TORRENT充填的服务工具定位在最下层的位置上来对此层进行挤压充填作业。在完成充挤压充填作业之后上提服务工具，一次性关闭本层留井管柱上的监测滑套和压裂滑套。这种在服务工具上优化后的双滑套开关工具配置有效的减少了作业时间，同时也降低了多次操作活动工具所产生的风险。在将服务工具提到测试位置后，作业人员可以在地面进行打压测试，确认油井的压力整体性，而后可以相同的方法继续进行第二层和第三层的施工。
本次压裂充填施工使用的高强度陶粒砂比为8 ppa，泵速为32bpm，井口施工压力高达13,000 psi （896 bar）。 三层施工累积泵入陶粒量共达100万磅，充填服务工具在起出后仍然处于较好的状态。
在本次作业中，5,000-ft（1524-m）的分层隔离管柱被成功下入，整套留井管柱包括：一支API V0 级别的SC-XP?中间隔离封隔器、 选择性滑套开关工具、一个油管隔离球阀和一个可再关闭的环空流动阀(X-AFV)。环空流动阀(X-AFV)使用井口压力控制顺利实现了开关。SC-XP隔离封隔器可以与ZX?密封单元配合使用。ZX密封单元是一种为深水井高温/高压环境设计的密封单元。这种密封单元的设计在服务工具移动时可有效防止胶环的脱落。
在SC-XP隔离封隔器坐封后，留井管柱上的生产滑套被打开。使用智能完井系统(IWS)的上部完井管柱，在不进入产层的情况下对油层上部的两个独立产层进行生产。这套上部完井系统包括：4-1/2in，12,000psi InForce HCM-Plus液压滑套、10,000psi Premier封隔器、一支文丘里管流量计、井下压力和温度计和化学药剂注入阀。在打开上部产层的油管隔离阀和下部X-AFV环空流动阀后，油井顺利投产。
油公司通过使用TORRENT MST砾石充填系统大大提升了作业效率，与普通的单次单层的挤压充填完井作业预计工期相比，该系统为这口井的作业节约了12天的工期，就本次作业而言为油公司节省了价值1200万美元的油井作业成本。交井后，油公司对这口井的首次测试也同时确认了，实际产量明显高于预期。
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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