Weir简易压裂管汇系统案例分析
我们可以做到：
•简化压裂现场
•设计更线性的流程
•减少危险状况和潜在的泄漏路径
对客户的好处：
•减少非生产时间(NPT)
•减少装配时间
•提高压裂现场的安全性
•降低成本，优化生产
凭借创新的线性和大孔径设计， Weir简易压裂管汇系统的新配置大大降低了加拿大运营商的管汇数量，连接线路，危险状况和运营成本。
系统
传统压裂现场有许多具有倾斜流道的管线，而Weir Oil & Gas公司的简化压裂管汇系统的压力控制部件采用单一的大孔线性设计。该系统的组件包括Seaboard™垂直拉锁式歧管，正在申请专利的Seaboard™ OSL压裂连接和Seaboard™压裂堆叠。
在这种配置下，所需的管道连接数量从100个减少到12个，消除了88%的潜在泄漏路径(钻台设置会根据总减少量而不同)。在整个设计过程中，Weir使用标准的API-6A连接，以大限度地减少互换性问题，具有可靠的金属密封垫，并且很少需要在现场紧固。
该系统旨在提高安全性和性能，降低压降和侵蚀，从而延长设备使用寿命，减少非生产时间，缩短装配时间以及材料和人工成本。
挑战
Weir的简化系统包括Seaboard™垂直拉锁式歧管，正在申请专利的Seaboard™ OSL压裂连接以及Seaboard™压裂堆叠，初在加拿大使用闸阀进行测试，由以前在三天后安装失败的独立操作员进行。安装失败的设备是竞争对手的单线拉锁式接头版本，在完成了十段后就必须完全拆除。 随后在两口油井上安装了Weir系统试验版，每口井都有40段。开始压裂时的平均流量为12立方米/分钟，压力为11,750 psi。
在操作之前需要进行计算流体力学(CFD)分析以预测设备侵蚀情况。与类似设计的分析相比，预计Weir系统的磨损减少约70%，压降降低900 psi。这些减少主要归因于直线路径设计，这有助于使流体紊流和摩擦小化。
通过歧管的压降(psi)
分析表明，单井压裂期间，5”接头管道的估算侵蚀量仅为0.003”。 而在今天的条件下，整个五口油井压裂项目中，7”主干线的侵蚀量只有0.004”，预估主干线上的7”十字接头的侵蚀量仅为0.039” - 都是可接受的比率。
歧管中大侵蚀量(in)
这些研究结果还预测驱动泵所需的功率减少，预计Weir配置相比其他主要竞争对手更加节能。 线路损耗的减少也有助于确保在地面测得的泵压能更准确地反映输送到地层中的物质。
在维修停工期间，还进行了超声波厚度测量(UTS)，结果表明，对任何部件的腐蚀都很小 - 约为允许极限的12%。
结果
经过14天的运行，Weir系统的配置完成了所有80个压裂段，且管道磨损小。总的来说，相比以前的安装，这个系统持续时间多了三倍多。在提供更高性能的同时，将风险、非生产时间、装配时间、管汇、连接和成本降到低，与传统的管汇配置和目前的单线替代方案相比，显示出明显的优势。
Weir简化压裂管汇系统适合要求苛刻的应用程序，可用于任何油田，可根据任何情况进行定制。设备可供出租，在每项工作完成后进行全面检查和重新认证。
关于鼎恒石油
四川鼎恒石油是Weir SPM的授权代理商，若需要购买SPM产品或需要了解产品详细参数及相关疑问，可直接进入鼎恒石油官网咨询网站客服或者拨打销售热线18000522697。
四川鼎恒石油机械设备有限公司(http://www.dinghengot.com)是一家拥有进出口经营权，长期从事国内外石油天然气设备和配件的专业销售公司。鼎恒石油公司总部设在四川成都，在加拿大大不列颠哥伦比亚省成立了分公司。我公司与多家世界知名制造厂商建立了紧密的合作关系。
注：该文章由鼎恒石油编译，转发须注明出处。
附英文原文：
Simplifying the Frac Site
With an innovative linear, large-bore design, a recent configuration of Weir’s Simplified Frac Iron System dramatically reduced iron, connections, hazards, and costs for an operator in Canada.
WHAT WE ARE DOING
• Simplifying the frac site
• Engineering a more linear flow
• Eliminating hazards and potential leak paths
BENEFITS TO YOU
• Reduce non-productive time(NPT)
• Reduce rig-up time
• Improve safety at the frac site
• Lower costs and optimize production
The System
While traditional frac sites feature numerous iron strings with angled flow paths, the pressure control components of the Weir Oil & Gas’ Simplified Frac Iron System feature a single, largebore linear design. Components of this system include the Seaboard™ Vertical Zipper Manifold, the patent-pending Seaboard™ One Straight Line (OSL) Frac Connection, and the Seaboard™ Frac Stack.
In this configuration, the number of required pipe connections is reduced from 100 to 12, eliminating the potential for leak paths by 88 percent (rig site setup will vary total reduction). Throughout the design, Weir uses standard API-6A connections, which minimize interchangeability issues, feature a reliable metal-seal gasket, and rarely require tightening in the field.
Collectively, this system is designed to improve safety and performance, minimize pressure-drop and erosion–thus extending equipment life–and reduce non-productive time, rig-up time, and material and labor costs.
The Challenge
Weir’s simplified system that included a configuration of the Seaboard™ Vertical Zipper Manifold, the patent-pending Seaboard™ One Straight Line (OSL) Frac Connection, and the Seaboard™ Frac Stack using gate valves was initially put to the test in Canada by an independent operator whose previous installation had failed after three days. The equipment, a competitor’s version of a single line zipper tie-in, had completed only ten stages and had to be completely dismantled. A trial version of Weir’s system was subsequently installed on two wells, at 40 stages per well. Fracking commenced, averaging a flow rate of 12 m3/minute at 11,750 psi.
Prior to operation, a Computational Fluid Dynamics (CFD) analysis was conducted to predict equipment erosion. When compared to analyses of similar designs, Weir’s system estimated approximately 70 percent less wear and 900 psi less pressure drop. The reduction was attributed to the straight-path design, which helped to minimize fluid turbulence and friction.
The analysis showed that the estimated erosion of the 5” tie-in pipeline would only be 0.003” during the single-well frac. The 7” trunk line erosion would only be 0.004” throughout the entire five-well frac program, and the 7” cross in the trunk line was estimated to erode by a mere 0.039”–all acceptable rates in today’s conditions.
These findings also predicted a reduction in the horsepower required to drive the pumps, giving the Weir configuration an estimated power savings over leading competitors. The reduction in line losses would also help ensure that pump pressure measured at the surface would more accurately reflect what was delivered into the formation.
During maintenance shutdowns, an Ultrasonic Thickness Survey (UTS) was also conducted, indicating very little erosion on any of the components–approximately 12 percent of allowable limits.
The Result
After 14 days, this configuration of Weir’s system completed all 80 frac stages with minimal pipe wear. Overall, the system lasted more than three times longer than the previous installation. While delivering greater performance, it minimized risks, non-productive time, rig-up time, iron, connections, and costs—demonstrating a clear advantage over traditional iron configurations and current single-line alternatives.
Fit-for-purpose and ideal for demanding applications, Weir’s Simplified Frac Iron System can be used for any well and tailored to any condition. Equipment is available for rent, fully inspected and re-certified after every job.
