【系列专题】页岩油的创新时代：生产回忆录（6）

TUBULAR HANDLING SYSTEM HELPS ELIMINATE CORROSION AND STRESS CRACKING

In addition to the natural generation of H2S through oil and gas upstream production, the anthropogenic processes (e.g., hydraulic fracturing) used to extract hydrocarbons from shale formations release substantial volumes of H2S during production. The vast presence of this toxic gas in regions particularly fraught with sour gas reserves jeopardizes well integrity via tubular corrosion. As a result, corrosion-resistant alloys (CRAs) often are required in such regions to mitigate sour gas-induced damages. Gripping inserts or dies common to most types of tubular handling equipment, however, leave impressions on pipe—including CRAs—that, in sour wells, increase downhole tubular susceptibility to corrosion and sulfide stress cracking. K’s has released its next-generation 27?-in. Collar Load Support technology as a solution. The fully nonmarking handling system features an above-the-rotary shock table with the ability to interface rotaries of 27?-in. or smaller, which is ideal for land rigs. With improved roll and pitch stability, the 250-ton-rated shock table provides optimum support of the tubular string over the entire coupling load-face as well as ample load capacity for land operations.

ARTIFICIAL LIFT SLICKLINE SYSTEM PROTECTS AGAINST FRACTURE HITS

For oil and gas producers in active shale fields, fracture hits are a growing concern. A fracture hit occurs when an offset well is fractured and the fracture communicates with another producing wellbore. A fracture hit can cause the well to fill with fracture sand, resulting in productivity losses. The impact can result in severe damage to the artificial lift system and possibly a well control event with excessive pressures at surface. HEAL Systems’ Horizontal Enhanced Artificial Lift, or HEAL Slickline System, offers economical fracture hit protection with greater access to the wellbore and easy installation.

The HEAL Slickline System incorporates a retrievable separator prong that is replaced with a deep barrier to protect the wellbore from the consequences of a fracture hit. Before the offset well is fractured, a slickline unit pulls the HEAL separator prong and installs a standard profile blanking plug. After offset well fracture operations are complete, the blanking plug is removed and the well is put back on production. Without the System, operators often pull the full artificial lift system and production string to run a deep bridge plug. With the HEAL Slickline System all operations are performed with the production tubing left in place, significantly reducing cost over the conventional solution.

NEW PROPPANT CONTAINERS ENHANCE SITE SAFETY AND EFFICIENCIES

Getting the most out of shale wells relies on many factors, including the ability to safely, consistently and efficiently receive high volumes of proppant. At many well sites 500 truckloads of proppant are required to arrive within days, gridlocking surface operations. Unloading traditional pneumatic trucks can take up to an hour each, and there are additional hazards in addition to congestion such as dust and noise. SandBox Logistics has developed patent-protected equipment and processes to mitigate wellsite congestion and ensure a safer, cleaner environment. Specialized containers are unloaded in less than five minutes without the noise and dust concerns of pneumatic trucks. “We fill stackable SandBox containers at transload facilities or regional mines,” said Zach Carusona, SandBox vice president of business development. “We then stage 40 to 60 SandBoxes at the well site, where they are placed onto a conveyor system that delivers the proppant directly into the blender hopper.” Dan Mullins, executive vice president of operations and sales at Producers Service Corp., said SandBox Logistics has generated significant benefits at his well site. “The process is safe and efficient, which translates into cost-savings,” he said. “Using SandBox, we eliminate a main bottleneck in the system. We also greatly reduce the risk of silica dust exposure for our crew, which is foremost in our HSE program.”

GAS TURBINES OFFER FUEL FLEXIBILITY, EXTENDED OPERATING LIFE

Vericor’s TF50F and TF40F gas turbines designed for oilfield and other tough-environment portable applications are compact, powerful (5,000 hp) and light (2,000 lb). The turbines feature hydraulic fracturing capabilities, power for drilling rigs, mobile electric power, gas compression stations and cogeneration for oil and gas processing plants. The turbines also offer reduced weight and size as well as fuel flexibility. The engines can run on natural gas or liquid fuel and switch between the two fuels during operation if needed. In comparison to current diesel engines, Vericor’s gas turbines are lighter and smaller, offering cost savings in logistics and diesel transportation. The systems also minimize disturbances, reduce the environmental impact through less emissions, lower noise and offer a smaller carbon footprint. In the case of hydraulic fracturing such a scenario can represent a doubling of the power of each fracturing unit, leading to additional savings of reduced personnel needed to operate the equipment onsite. Vericor’s gas turbines also could be used with field flared gas, transforming the gas into electrical energy and heat. The engines often exceed 100,000 hours of operation, with a first major overhaul occurring at 30,000 hours, an advantage in terms of downtime and maintenance cost over diesel engines.