生产测井对于确定整个井眼的流量分布至关重要。井功能诊断、候选增产项目和侧线识别以及其他目的也需要日志。对于较长的 ER 水平井，需要运输测井工具才能实现这些目标。以前提供的实时测井工具的输送方法仅限于较短的 ER 井，因为它们无法有效到达目标深度和/或过于昂贵。SLT 消除了钻杆输送所需的移除井下完井的昂贵过程，因为它在连续油管 (CT) 上运行。尽管一些电缆拖拉机可以在完井中通过狭窄的井下限制，例如电动潜油泵，但它们难以穿越井下碎屑，并且牵引能力低，可能无法达到总深度。SLT 的牵引能力是有线替代方案的两到三倍。现有的CT液压牵引车可以通过狭窄的井下限制并提供足够的CT牵引力；但是，它无法通过有线电缆，因此无法进行实时记录。SLT 允许电子线路通向测井工具。此外，与电缆拖拉机相比，SLT 有助于测井至电缆无法达到的深度。
健康安全环境类别：
越野空气呼吸系统， 沙特阿美公司
在现场或天然气和石油工厂工作的员工容易受到 H 2 S 等有毒气体的影响，这种气体会导致严重的健康问题，低浓度时会刺激眼睛和鼻子，高浓度时会导致死亡。尽管这些工厂配备了空气呼吸系统 (ABS)，以防止 H 2 S 或任何有毒气体泄漏，但有些工作场所却没有。因此，员工必须佩戴自给式呼吸器 (SCBA)，其提供空气的时间约为 30 分钟，不足以完成任务。因此，卡车的想法诞生了，该卡车运载通过软管与面罩连接的气瓶。
Frank 的 International VIGILANCE 监控技术通过统一的实时系统以 10 厘米的精度跟踪设备和人员的移动。该工具是便携式的，并且经过定制，可以适应任何陆上或海上的钻机环境。电池供电的传感器根据为安全操作移动而建立的设定边界来跟踪人员和设备。每个物体的位置坐标都受到实时监控，并且通过单个命令和控制系统执行干扰和/或停止不安全操作的能力。此外，还可以根据作业中不同程度的移动或碰撞危险，建立声光报警和安全联锁装置。
（来源：Devon Energy Corporation 和 Well Data Labs Inc.）
陆上钻机类别：
高温可变内径公羊， 斯伦贝谢
高温可变孔闸板 (VBR) 可为各种直径提供密封。它们适用于符合 NACE MR0175 的 H 2 S 服务，并与斯伦贝谢的 U 表面闸板型防喷器兼容。柱塞封隔器锁定到位，不会因井流而移动。此外，大量的封隔器橡胶储层可确保在所有条件下和更大的工作温度范围内实现持久密封。VBR 具有独特设计的嵌件，使其能够承受具有挑战性的井场的极端高温。该柱塞适用于 13 英寸 3,000-psi 至 10,000-psi U 型柱塞防喷器。
135/8 英寸、10,000 psi 高温 VBR 经受住了严格的极端温度测试，包括在 300 F 下保持 11 小时。VBR 在低温下也表现良好，成功完成了 30 F 下的 API 测试。（来源：斯伦贝谢）
During qualification, the high-temperature VBR surpassed the minimum API extreme temperature hold of 1 hour. This translates into having more time to make informed decisions during a well control event while pressure is stabilizing. A new elastomer material with improved performance capability at extreme temperature is crucial. The VBR primary insert geometry was also modified, and secondary inserts were added to prevent extrusion of the elastomer during use. The VBR is qualified to meet API 16A 4th edition PR2 criteria for VBRs on 3陆-inch to 5陆-inch mandrels. The high-temperature VBR achieved an 8-h 300 F extreme temperature hold on a 5陆-inch mandrel, and an 11-h 300 F extreme temperature hold on a 3陆-inch mandrel. Although the design was driven by high-temperature requirements, the VBR also performed well at a low temperature of 30 F. It passed all aspects of API 16A 4th edition PR2 criteria, including continuous high-temperature testing to 180 F, sealing characteristics, stripping, hangoff to 150,000 lbf with a 3陆-inch mandrel, hangoff to 450,000 lbf with a 5陆-inch mandrel, and completed 78 fatigue cycles, which exceeded API requirements by 50 cycles.
The published information and research conducted by Trelleborg鈥檚 applied technologies operation in Rochdale, U.K., shows that an RROV/MSV engineered using existing syntactic materials offers a durability of approximately six months. This brings a new challenge to materials scientists and engineers to develop innovative syntactic materials that offer serviceability well beyond six months to support the needs of the industry. Recognizing these new requirements for long-term submersion, Trelleborg鈥檚 applied technologies operation undertook a program of development, testing and qualification of syntactic foam materials to address the specific and more demanding needs in RROV/MSV applications, aiming to ensure robust and reliable performance.
(Source: Trelleborg Applied Technologies)
Trelleborg has released an extensive testing program on its TG range of materials utilizing cube and cylinder specimens with different surface to volume (S/V) ratios. For this purpose, TG3000R syntactic foam material was chosen, undergoing accelerated aging at +50 C under hydrostatic pressure of 310 bar, the pressure at operational depth of 3,100 MSW, until the material reached 2% water absorption; the failure index value. These data were used to build a model for service lifetime prediction. Validation experiments were set to run in parallel with the accelerated aging, with data used to predict the service lifetime based on Arrhenius model. The output of the model using the water absorption data at +50 C predicts a greatly increased service lifetime of two years at +10 C, as opposed to the current six months durability available. Following this discovery, a systematic approach was adopted by Trelleborg to identify other potentially suitable syntactic foam materials. Derived from a combination of thermoset polymer matrices and high-strength hollow glass microsphere technology (HGMS), TG1000R, TG2000R, TG3000R, TG6000R with depth ratings of 1,000, 2,000, 3,000 and 6,000 MSW, respectively, all underwent stringent testing and qualification processes.
TCP Riser, Strohm
Strohm has been at the forefront of thermoplastic composite pipe (TCP) technology for SURF applications. Recently, Strohm developed the concept of the TCP Riser for deepwater application鈥攑robably the most disruptive, high-end product developed for deepwater and corrosive environments, according to the company. The TCP Riser is designed and developed specifically for the challenging presalt conditions in Brazil. There, crude oil and natural gas contain various corrosive contaminants such as CO2 and H2S, which, especially when dissolved in water, create an extremely corrosive mixture. The high concentration of CO2 is thought to accelerate corrosion ultimately leading to failure of steel-based flexible pipes, a phenomenon commonly known as stress corrosion cracking.
Strohm engaged with end users Petrobras and Shell Brazil, understanding their preferences for the installation and operation of flexible risers as well as their specifications and requirements for service fluids, design life and the like. (Source: Strohm)
The full, solid wall TCP Riser takes corrosion completely out of the equation by removing the steel tensile armor layers and replacing them with a carbon fibre based composite. The design of the TCP Riser includes an inner liner, a carbon fiber-based composite layer, a coating and a weight stabilizing coating. The liner, matrix and coatings are based on the PVDF polymer, proven in the oilfield for many years of service life. All layers are melt-fused together to form a solid wall, while still being spoolable in long lengths by virtue of using one polymer in all layers. The carbon fiber is completely insensitive to CO2, H2S and has a superior fatigue performance. The product has been developed in close collaboration with the end users and Strohm's supply chain partners. The company has taken the end client鈥檚 preferences for installation method and subsea configuration as starting point for product and material development. This has led to a TCP Riser product that does not corrode, fatigue and has a superior service life of 30 years; can be installed using currently available installation vessels, with only modest modifications; uses the most cost-effective free hanging catenary configuration, without any requirement for buoyancy elements and requiring only two sections of pipe; and has the smallest carbon footprint The TCP Riser is based on the field-proven TCP technology.
WATER MANAGEMENT CATEGORY:
Flow-Sync Water Management Platform, Flow-Sync and Bedrock Automation
Flow-Sync has developed skid-based automation technology that has been proven to improve water management productivity by more than 50%. To use it, operators open Flow-Sync鈥檚 Transfer Calc software, which analyzes transfer line hydraulics to model the number of pumps required to satisfy the design flow rate and route topography. On startup, the software reconciles readings from pressure sensors, level sensors and flowmeters to identify equipment problems that could cause downtime and sends readings to a programmable control system that optimizes flow based on the data.
Detecting problems immediately minimizes costly downtime. Reporting is another advantage of a secure automation system. (Source: Flow-Sync and Bedrock Automation)
为了确保控制器有足够的带宽来安全地处理复杂的泵控制计算，Flow-Sync 部署了来自 Bedrock 开放式安全自动化 (OSA) 远程工业控制系统的 PLC 功能。OSA Remote 系统利用开放技术的经济性并消除网络攻击的脆弱性。它还采用坚固的全金属外壳，可承受典型压裂环境的极端条件和设备的移动特性。Flow-Sync 将 OSA Remote 模块部署在获得专利的独立式便携式滑橇的接线柜中。撬块可以轻松连接到泵，因此可以从任何具有互联网连接的位置有效地监控和控制整个传输操作。具有通用 IO 的 OSA Remote 配置为从滑橇传感器读取和写入标签，其 OPC UA 功能使其能够非常高效地将这些数据传送到更广泛的系统。
E&P's 2021 'Meritorious Awards for Engineering Innovation' Winning Technologies
An expert panel of judges has selected the top 20 upstream oil and gas industry projects and technologies that open new and better avenues to the complicated process of finding and producing hydrocarbons around the world.
The MEAs program recognizes new products and technologies designed by companies and people who understand the need for newer, better and constantly changing technological innovation to appease the energy-hungry world. (Source: Hart Energy/Shutterstock.com)
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The E&P editors and staff proudly present the winners of the 2021 Special Meritorious Awards for Engineering Innovation (MEAs), which recognize service and operating companies for excellence and achievement in every segment of the upstream petroleum industry. The following technology showcase highlights 20 winners picked by an independent team of judges.
The winning technologies represent a broad range of disciplines and address several challenges that pose roadblocks to efficient operations. Winners of each category are products that provided monumental changes in their sectors and represented techniques and technologies that are most likely to improve artificial lift, carbon management, digitalization, drill bits, drilling fluids/stimulation, drilling systems, exploration/geoscience, formation evaluation, HSE, hydraulic fracturing/pressure pumping, IOR/EOR/remediation, nonfracturing completions, onshore rigs, subsea systems and water management.
This year some of the brightest minds in the industry from service and operating companies entered exceptionally innovative products and technologies that have now been measured against the world’s best to be distinguished as the most groundbreaking in concept, design and application.
The awards program recognizes new products and technologies designed by companies and people who understand the need for newer, better and constantly changing technological innovation to appease the energy-hungry world.
The panel of judges comprised experts in business, engineering and the sciences representing operating and consulting companies worldwide. Each judge was assigned a category that best utilized his or her area of expertise. Judges whose companies have a business interest were excluded from participation.
E&P would like to thank these distinguished judges for their efforts in selecting the winners in this year’s competition.
R G Bailey, Chairman and Interim CEO, Petroteq Energy
Abby Ballard, Senior Data Engineer, Validus Energy
Jack Blears, Director, E&P Technology Research, Darcy Partners
John R. Durand, President and Chief Sustainability Officer, XRI Water
David Johnston, Managing Director, Differential Seismic LLC
Peter Lovie, Consultant
Emeakpo Ojonah, Wireline Logging Expert, Energy Quest
Ian Dexter Palmer, Consultant, Higgs-Palmer Technologies
John Thorogood, Consultant, Drilling Global Consultant LLP
Nancy Zakhour, Well Design Lead, Occidental
ARTIFICIAL LIFT CATEGORY:
ForeSite Edge, Weatherford
Weatherford ForeSite Edge is an artificial lift automation technology that optimizes oil and gas production and involves field personnel only when necessary. It does this by incorporating industry 4.0 concepts, such as artificial intelligence, Internet of Things (IoT) infrastructure and edge computing.
Delivering and analyzing data at the edge of the production ecosystem (i.e., the well site) enables continuous real-time, data-driven production optimization. This intelligent optimization technology harnesses the power of Weatherford ForeSite and CygNet IoT platforms and places these capabilities at the well site—also known as on the edge. Installed as a standalone automation device or paired with existing automation equipment from any major manufacturer, ForeSite Edge manages well optimization without human input, sends instantaneous alerts, and locally stores and pushes real-time, high-frequency data through Google cloud or an on-premise IoT network. Together, these capabilities significantly boost asset profitability, productivity and uptime.
ForeSite Edge creates an intelligent well that autonomously adjusts lift settings, performs well diagnostics and instantaneously calls for human intervention when a problem arises. Through real-time high-frequency data with engineering-model analysis, ForeSite Edge autonomously determines and enacts the optimal settings for everyday set points, such as pump idle time and gas-injection rates. The device can adjust these settings as needed per stroke or second, which reduces downtime, improves meantime between failures (MTBFs) and maximizes artificial lift uptime and production. With real-time data availability, operators can better understand well behavior and make informed decisions that improve production, extend MTBFs and reduce nonproductive time for wells and nearby assets.
CARBON MANAGEMENT CATEGORY:
EcoCell, Patterson-UTI
The EcoCell hybrid battery system is an energy management technology that leverages battery-stored energy to optimize fuel efficiency and reduce emissions. The system stores more than 500 kW hours of energy and is capable of providing 1.5 times more power than a generator at full load, delivering a sustainable solution in any drilling application regardless of other alternative power infrastructure limitations.
A case study showed that deploying the EcoCell energy management system reduced annual CO2 emissions by an average of 1,000 metric tons on diesel rigs, and nearly 1,400 metric tons on natural gas rigs and reduced hydrocarbon emissions by more than 40% on both rig types. (Source: Patterson-UTI)
The system is compatible with diesel, dual fuel and natural gas engines, and it is particularly effective when used with dual-fuel engines because its ability to maximize substitution rates dramatically improves diesel consumption. The EcoCell system provides a way to optimize the power provided by their existing prime movers with battery energy storage, significantly reducing greenhouse gases (GHG) and other types of emissions produced during operations. With a typical high-spec land rig consuming 550,000 to 650,000 gallons of fuel per year, the ability to reduce consumption can deliver considerable, quantifiable savings. And for every gallon of fuel saved, there is an associated reduction in GHG emissions and a smaller carbon footprint.
The built-in logic of this fully automated energy management system seamlessly stops and starts engines to maintain optimal load ranges to achieve the best possible fuel economy and emission levels. Because it senses power demand needs, it is particularly useful in crucial drilling situations, providing improved and immediate power to keep engines running optimally to prevent fluctuations in power that could result in dangerous operating conditions. EcoCell also extends the maintenance intervals for the engines onboard because it decreases engine run hours, which reduces engine wear. By efficiently managing fuel allocation and consumption, EcoCell reduces the cost of consumables and improves carbon management, and it also has the potential to reduce capital costs.
DIGITALIZATION CATEGORY:
GumboNet, Data Gumbo
Data Gumbo's industrial blockchain network, GumboNet, connects companies, suppliers and vendors to automate and execute smart contracts across commercial relationships using a validatable, immutable record of truth as the basis for business transactions.
Deployed by the Offshore Operators Oil & Gas Blockchain Consortium, Data Gumbo’s GumboNet network resulted in reducing current processes from 90 to 120 days down to one to seven days with 85% of all volume measurements automatically validated to enable a 25% to 35% reallocation of resources due to cost savings. (Source: Data Gumbo)
By forging trust between counterparties, Data Gumbo solves challenges surrounding fragmented workflows, managing complex assets and siloed technology systems that result in outrageous DSOs, payment disputes and admin-heavy reconciliations. By radically transforming how companies in oil and gas interact, Data Gumbo frees up working capital, reduces contract leakage, improves real-time cash and financial management, and delivers provenance. GumboNet’s key differentiators include the capability for subscribers to create, configure, negotiate and manage smart contracts that work in tandem with natural language contracts. The network is a purpose-built private, permissioned blockchain with no cryptocurrency, tokens or mining. It operates as a single network of ledgers rather than non-interoperable point solutions, can store massive datasets for complete visibility and auditability, integrate with existing legacy or Industrial Internet of Things data sources, and guarantees interoperability with other subscribers.
Key business values of GumboNet include radical transparency—service providers get paid for exactly what is delivered and buyers pay only for what is measurably delivered—and payment automation taking a typical 90-day invoice process down to as little as two days.
Advanced Diagnostic and Prognostic Technology (ADaPT), PETRONAS
Advanced Diagnostic and Prognostic Technology (ADaPT) offers real-time monitoring and prediction of mechanical damages or cracks using combination of acoustic emission (AE) technology and stochastic prognostic model. The prediction can allow the plant authority to manage their equipment suffered from cracks before it ruptures and causes unplanned shutdown to the facility. The ADaPT Prognostic prediction model is based on the equipment historical data coupled with finite element analysis (FEA)-FFS and probabilistic statistical analysis. It utilizes an FEA model to establish a physics-based predictive model for equipment of interest. During operation, the historical data as well as any changes in future equipment’s operating conditions will be incorporated into the predictive model for real-time prediction of the remaining life span due to crack growth and the cumulative stress/strain limit. The ADaPT diagnostic system is used to validate the prediction model. It employs an AE bespoke data acquisition tool with an integrated data filtering algorithm, and it features analytics for interpretation of induced waveforms signal from field environment. The combined ADaPT diagnostic and prognostic system provides a digital twin technology in which the real-time data from the sensor is fed into the prediction model. The diagnostic system will trigger the information of any damage occurrence to the prediction model, which then updates the current remaining life prediction. Moreover, with the combined system, the remaining life is predicted with a higher confidence level as it is supported by physical evidence/data at real time at 99%.
ADaPT technology is moving toward Internet of Things instead of relying on conservative manual approaches. Through ADaPT, a step change in maintenance strategy successfully transforms it from reactive to proactive mode and eliminates failures as well as unplanned shutdown. (Source: PETRONAS)
DRILL BITS CATEGORY:
StrataBlade Concave Diamond Element Bits, Smith Bits, a Schlumberger company
Schlumberger's StrataBlade concave diamond element bits improve ROP in a wide range of rock types while withstanding impact damage often associated with drilling interbedded formations. Specifically, they’re a fit-for-purpose solution to cut through layered, medium-strength formations typically ranging from 5,000 to 20,000 psi.
StrataBlade bits have been used in 147 runs in seven countries including the U.S., Canada, Brazil, Norway, Saudi Arabia, Kuwait and Russia. (Source: Schlumberger)
The StrataBlade bits incorporate unique geometry of Strata concave diamond elements across the bit face, which increases cutting efficiency and results in higher instantaneous ROP with the same operating parameters. In deep lateral wells where weight transfer to the bit is a challenge, the StrataBlade bits drill with higher ROP when compared with traditional PDC bits with flat cutters. Improved cutting efficiency also means a better torque response at the bit for superior steerability and conformance to directional plans. The StrataBlade bits increase ROP by up to 35% in medium-strength formations as compared with flat PDC bits, benefitting from the Strata concave diamond cutting elements. Their distinctive concave feature decreases the cutter back-rake angle to cut deeper into rock. It also forms into a tapered geometry with a thicker diamond table that significantly improves cutting efficiency and sustains a higher instantaneous ROP with the same input energy. The tapered ridge tip focuses the bottomhole assembly's energy so the bit pierces farther into the formation layers without increasing weight on bit. The thick diamond layer at the cutting tip and tapered profile toughens the cutter against chipping and breaking.
DRILLING FLUIDS/STIMULATION CATEGORY:
NanoTags, EXPEC ARC, Saudi Aramco
"NanoTagging" is an innovative technology that significantly improves the accuracy of cuttings depth determination to +/- 2 ft in wells that are thousands of feet long. By pumping nanoparticle additives into the drilling mud and tagging the cuttings when generated at the drill bit, the unique barcoded labels on the cuttings correlate to the exact depth of the cutting’s origin in wells that are thousands of feet long with an accuracy of +/- 2 ft. This technology is a unique drilling depth correlation system consisting of 1) barcoded NanoTags, 2) an extraction process and 3) a detection method for precisely and distinctively detecting the tags residing on the drill cuttings. The NanoTagging method injects specially designed nanoparticle “tags” into drilling fluids, which generate a barcode signature upon cuttings analysis that precisely determine the original depth of the drill cuttings precisely.
Saudi Aramco has successfully synthesized a library of polymeric NanoTags using a simple, scalable, flow-to-batch hybrid emulsion polymerization method. Notably, the sizes of the as-made NanoTags are narrowly distributed in the range of 20 nm to 60 nm. These barcoded NanoTags are also proven to be drilling fluid friendly. The NanoTags are safe for handling and disposal due to their low toxicity and long shelf life. Saudi Aramco designed a solvent-extraction and thermal-separation workflow to extract and separate the NanoTags from other small molecule additives and hydrocarbons on the cuttings. The NanoTags are subjected to pyrolysis, which thermally depolymerizes the NanoTags at elevated temperatures for identification by GCMS. The NanoTags for drilling depth correlation technology improves the current mud logging process and is cost-effective, straightforward and environmentally friendly. This technology allows oil and gas operators to improve the quality of lithological and petrophysical analyses, enhance formation evaluation and geosteering practices, and control well placement, thus helping to maximize oil recovery. All of the above advantages can be achieved by injecting only ppm levels of the cost-effective NanoTags into the drilling fluids without any interruption to the drilling operations.
This technology was tested for the first time in December 2019, when Saudi Aramco successfully injected 5-ppm and 10-ppm concentrations of NanoTags into a mudline without any interruption of normal drilling operations. The results showed that this disruptive technology can improve the depth correlation accuracy of cuttings in mud logging, thus improving the quality of lithological and petrophysical analyses. (Source: Saudi Aramco)
DRILLING SYSTEMS CATEGORY:
Welltec Annular Barrier (WAB), Welltec
An offshore Norway operator was trying to drill three wells from a single well slot: the main horizontal bore and two lateral wells. Once the main horizontal well was completed, the operator wanted to move on to the two lateral wells but was experiencing losses when drilling the main bore. These losses to the main bore were deemed as not acceptable in terms of milling and drilling the laterals from the 9 5/8-inch casing. Prior wells had used swell packers on the liner to stop such losses, but these required 25 days for the swells to achieve sealing—even after that period, satisfactory sealing had not always been achieved and laterals therefore not drilled. On these early wells, the 9 5/8-inch casing was cemented but not sealing. Therefore, it was decided that there would be no cementing on this well.
A sealing solution from Welltec allowed a client to drill a main bore with two laterals without the typically associated drawbacks of this type of operation. By deploying WAB instead of the traditional swell packers, improved sealing was achieved, losses reduced and the lengthy delays associated with swell packers were avoided. (Source: Welltec)
One of the challenges for the main bore was the high-formation permeability, at three to four Darcy. The agreed solution was to deploy Welltec Annular Barrier (WAB) technology to seal against the rock face and divert the mud through the rock, with the aim that the mud with LCM would then reduce the rock permeability and simultaneously build a mud cake. At short notice, the 812WAB was mobilized and deployed, and it hydraulically expanded below the 9 5/8-inch shoe within the main bore. This was successful in achieving good sealing, thereby curing the losses and allowing the rig to progress with the drilling of the first of two laterals. The annular loss rate was resolved, indicating that the WAB packer was successfully sealing and providing annular isolation as planned. This allowed the operator to continue drilling the laterals without waiting on the swell time. More importantly, the laterals could be drilled to maximize the well’s recoverables. Once the main bore had been drilled and the liner deployed, the first lateral window could be milled and the lateral drilled into the depleted reservoir. Once again, no losses were incurred when drilling the lateral due to the 812WAB installed on the main bore. An additional 812WAB was installed as part of the first lateral completion, the purpose of which was to prevent losses when drilling the second lateral. The second window was milled, and the second lateral drilled with no losses incurred due to the two previously installed WABs. This operation represents the first application of WAB technology for the purpose of isolating losses during the drilling of laterals, with the successful installation of two 812 WABs as liner hangers.
EXPLORATION/GEOSCIENCE CATEGORY:
Surface-Consistent Full Waveform Inversion (pQC-FWI), Saudi Aramco
Recent trends in the exploration of land oil and gas resources are targeting low-relief structures and stratigraphic traps. Such targets present marginal structural relevance, often in the range of a few tens of milliseconds in time domain and a few tens of meters in depth domain. The gentle structures can be easily missed or wrongly interpreted (e.g., leading to dry holes) if the near surface variable velocity is not retrieved accurately. Another parallel trend is the merging of large numbers of blocks to interpret low-relief structures and stratigraphic traps over large areas. These two recent developments in exploration trends lead to the necessity of high-resolution velocity models of the near surface through full waveform inversion (FWI) and to the capability of seamlessly analyzing and inverting tens of billions of seismic traces in one go, also considering the continuously growing number of seismic channels. Current seismic processing and inversion frameworks are breaking down when facing such challenges. As a result, daily land production processing for near-surface analysis is still relying on technology developed two to three decades ago that cannot cope with the expected resolution. Saudi Aramco has developed a novel surface-consistent processing framework based on the transmitted portion of the seismic waves (e.g., refractions, diving waves) that enables fully automated pre-conditioning of the seismic data directly from raw gathers to prepare the data for the FWI step. The automatic preconditioning enables surface-consistent phase and amplitude corrections, deconvolution of the viscoelastic near-surface response, with phase and amplitude-preserving signal-to-noise (S/N) enhancement of seismic data through the generation of virtual super gathers (VSG). 1.5D FWI, developed for the purpose, provides robust and high-resolution velocity models of the near surface. The whole process runs automatically on massive seismic datasets totaling several billions of seismic traces. The preconditioned and S/N enhanced seismic data are then fed through a robust FWI process, working in a surface-consistent framework, to derive detailed velocity models of the near surface. The results obtained in this way benefit the successive steps of reflection processing and imaging as well as 3D velocity model building and true amplitude processing for reservoir characterization. Billions of traces are analyzed automatically, providing enormous benefits in the execution time and in the accuracy and robustness of obtained results. The transmission-based surface-consistent framework provides a new paradigm for near-surface analysis. It solves several current and long-standing bottlenecks in depth-domain seismic velocity modeling in near-surface description.
(Source: Saudi Aramco)
EarthStar 3D ─ Ultra-Deep Resistivity Service for Halliburton Sperry Drilling, Halliburton
Halliburton Sperry’s EarthStar ultradeep resistivity service gives E&P operators more real-time LWD value than ever before. By delivering superior insight into the reservoir, it helps oil and gas exploration projects be successful with geostopping, geosteering and geomapping their wells. EarthStar further enhances subsurface knowledge with the 3D inversion processing technique, an advanced technology that provides real-time visualization of the geology and fluids in place, in 3D, for much higher accuracy in well placement and decision-making. Clearer downhole pictures provide reservoir insights before, during and after the drilling operation, due in large part to the high-measurement quality (derived from electromagnetic wave propagation) that allows for clear delineation of geological features, such as faults and low-contrast or transitional boundaries. This exploration technology illuminates and maps the reservoir using LWD techniques to reveal formation and fluid boundaries around the wellbore over twice the depth of investigation of the previous industry standard. With the ability to map such large volumes of the reservoir, operators can position their wells accurately to maximize production, while evaluating reserves in place for future field development. Formation measurements from the EarthStar service are easily integrated into Halliburton Sperry’s RoxC real-time reservoir modeling tool, with fast calculation speeds and a real-time visualization of the reservoir structure. Geosteering experts can use these measurements to help optimize well placement, reduce wellbore tortuosity and maximize reservoir contact for better drilling outcome. The EarthStar ultradeep resistivity service, combined with advanced 3D inversion processing, is designed to be a step change in geostopping, geosteering and geomapping capabilities that enhance an operator’s toolkit.
(Source: Halliburton)
FORMATION EVALUATION CATEGORY:
World Slimmest Tractor for Production Logging & Well Intervention of Extended Reach Wells, Saudi Aramco, Western Well Tools
The paradigm changing availability of a coiled tubing Slim Logging Tractor (SLT) provides a new capability to live-logging long extended-reach (ER) and horizontal wells, including those with restrictive completions.
The SLT was trial tested in multiple horizontal wells over the past months of 2021, for logging and subsequent acidizing. The SLT successfully eliminated 100% of traditional rig costs, reduced intervention time by 80%, increased production an average of 8,000 bbl/d of oil for each well and increased the openhole coverage by 80% reaching up to 25,000 ft. (Source: Saudi Aramco, Western Well Tools)
Production logging is essential to determine the distribution of flow along an entire wellbore. Logs are also required for well function diagnosis, identification of stimulation candidates and sidetracks, and other purposes. For longer ER horizontal wells, conveyance of the logging tools is required to achieve these objectives. Previously available conveyance methods of delivering live logging tools are restricted to shorter ER wells because they are ineffective at reaching target depths and/or are excessively expensive. The SLT eliminates the costly process of removing downhole completions necessary with drillpipe conveyance because it operates on coiled tubing (CT). Although some wireline tractors can pass narrow downhole restrictions in a completion, such as electric submersible pump, they have difficulty traversing downhole debris and have low pulling capacity that can prevent reaching total depth. The SLT has two to three times more pulling capacity than wireline alternatives. An existing CT hydraulically operated tractor can pass narrow downhole restrictions and provides adequate CT pulling force; however, it is unable to pass wireline cable and therefore cannot live-log. The SLT allows passage of e-lines to logging tools. Additionally, when compared to wireline tractors, the SLT facilitates logging to depths unachievable by wireline.
HSE CATEGORY:
Off Road Air Breathing System, Saudi Aramco
Employees who work in a field or at a gas and oil plant are susceptible to toxic gases, such as H2S, which causes serious health issues varying from eye and nose irritations at low concentrations to death at high concentrations. Although these plants are equipped with air breathing systems (ABS) in case of H2S or any toxic gases leakage, some work locations are not. Therefore, employees have to wear self-contained breathing apparatus (SCBA) that provides air for a duration of approximately 30 minutes that is insufficient to complete the task. Therefore, the idea of a truck that carries cylinders connected to a mask by a hose was born.
When the off-road ABS has been implemented inside Saudi Aramco, it has shown staunching contribution to the reduction of the fatality incident and near-death situation. (Source: Saudi Aramco)
For example, when opening a production line, there is a need to wear SCBA, but since it does not last for more than 30 minutes, other ABS should be available on the work site that can be easily maintained, managed and mobilized inside a facility. However, when the job is off-road, this becomes a challenge. It can be suggested to transport the required ABS to the work site, but when the work is off road, it involves rough terrain and the need for a 4x4 vehicle. In addition, towing is prohibited and an off-road transporting vehicle is limited. Saudi Aramco's solution is to redesign the air compressor truck to have a built-in breathing system.
This system reduces personal and property risk, allows multiple users at the same time, continues with longer working duration, there is no need to carry a heavy gas cylinder, and it is useful at heights. The systems also minimizes vehicle presence, and it offers a source of ignition, more resources and logistics. Cost savings result from no changing empty cylinder, eliminating the need for a truck to transport cylinders only, and the designed system is cheap. The system is used as backup to facilities whenever a major activity is experienced.
VIGILANCE, Frank's International
The Frank's International VIGILANCE surveillance technology tracks equipment as well as personnel movement through a unified real-time system with 10-cm accuracy. This tool is portable and customized to suit any rig environment onshore or offshore. The battery-powered sensors track personnel as well as equipment with respect to the set boundaries established for safe operational movement. The location coordinates for each object are monitored live, and the ability to interfere and/or stop unsafe operations is executed from a single command and control system. In addition, audible and visual alarms and safety interlocks can be established based on different levels of moving or collision hazards in operations.
(Source: Frank's International)
VIGILANCE was run on the field during 2020 to 2021 on an offshore rig in the Asia-Pacific for the casing and completions phase of the well. A total of 275,552 datapoints were captured during an 18-hour continuous run. It was observed that during the pulling out of hole operations, the system has halted operations in approximately 20% of operational time frame where personnel entered the red-zone area. To conclude, the system proved itself with increased safety measures.
Another field operations data in offshore Gulf of Mexico indicated that the system was able to stop the tong system twice during operations when personnel entered the critical area in the red zone with multiple moving equipment, therefore, avoiding a potential incident twice.
Translating this per OSHA’s data, the potential savings of $17,000 per job can be observed by preventing one incident per 100 jobs.
Spontaneous Leak Detection, Siemens Energy, powered by ProFlex Technologies
Siemens Energy and ProFlex Technologies have partnered to provide pipeline operators with spontaneous (i.e., real-time) leak detection as a service. The tool combines ProFlex Technologies’ proven Enhanced Negative Pressure Wave (NPW)-based leak detection with Siemens Energy’s expertise in cloud computing, Internet of Things (IoT) and data analytics to detect the presence of a leak within a pipeline in a matter of seconds and with accuracy in the range of 20 ft to 50 ft. Because it utilizes a subscription-based model, the technology is easily scalable and requires little upfront capex. In addition, it can be deployed on virtually any type of pipeline asset (newbuild or brownfield), including those carrying products, such as oil and gas, produced water, hydrogen or hazardous materials. Specific applications include long-distance transmission lines, production gathering networks at well sites and offshore production risers.
The tool represents a highly accurate and economical means of detecting and localizing very small unplanned product releases in pressurized lines. It overcomes many inherent disadvantages of other leak detection methods used across the industry today, including mass-volume transfer (which often cannot be used for detecting small leaks) and fiber-optic sensing (which is reliable but highly cost-prohibitive). It also uses advanced signal processing to address what has historically been one of the most oft-cited concerns of NPW-based detection: a high rate of false positives. Once ProFlex Technologies’ remote monitoring system identifies a leak, Siemens Energy’s cloud-based IoT system analyzes the leak data in real time, notifying users through mobile devices, laptops or desktop, or SCADA systems. In addition, leak location in the form of latitude and longitude coordinates is presented on a pipeline asset map.
The capabilities of the system have been proven in real-world pilot projects. Implementations are underway with multiple customers. (Source: Siemens Energy)
HYDRAULIC FRACTURING/PRESSURE PUMPING CATEGORY:
SPM EdgeX Carbide Seat, SPM Oil & Gas, a Caterpillar company
EdgeX has been shown to drastically reduce maintenance costs and average maintenance cycle times in multiple basins, including the Permian, Western Canada and Haynesville. (Source: SPM Oil & Gas, a Caterpillar company)
Operators across every North American basin are pushing their frac fleets further than ever with well optimization trending toward large bore/zipper fracs that reduce and eliminate maintenance time between wells and fracs. This has led operators to focus on pump utilization and downtime for pump maintenance. Valves, seats and packing are the most significant maintenance expenses on a frac site, making operators focus on reducing costs related to fluid end maintenance and downtime.
The SPM EdgeX carbide seat redefines frac valve seat life to provide six times greater life than legacy valve seats, even in the harshest conditions. The EdgeX carbide seats strategically employ tungsten carbide in key wear areas to deliver dramatically longer life than existing valve seats, including environments with large particles, which means less time spent pulling seats. Operators experience significant resistance to wear, cracking, shattering, washout and catastrophic failure, as the EdgeX combines the wearability of tungsten carbide with the reliability and impact-resistance of steel. Installation error sensitivity is dramatically reduced with the EdgeX.
The technology also offers operators maximum flexibility, because it is compatible with all makes of valves and standard taper fluid ends and allows for infield removal and reinstallation. The tool offers a 30-degree strike angle for maximum interchangeability and enables a standard seat puller to be used.
IOR/EOR/REMEDIATION CATEGORY:
15K MultiStage Frac System (frac sleeves, RockLock packers, WIV, Alpha Sleeve and liner top), Baker Hughes
The Baker Hughes 15,000 psi-rated multistage completion system provides the ability to overcome many challenges associated with traditional OH fracturing equipment. Capable of providing up to 20 stages with 15,000-psi stimulation pressure, this system comprises a holistic top-to-bottom wellbore solution for these tight formations. The system starts with the ZXTreme HP/HT liner-top packers to provide casing isolation used in conjunction with the ControlSet Flex-Lock V liner hanger. This hanger eliminates the risk for preset through the use of two opposing mirrored cylinders to balance the tool and offers exceptional hanging capacity through debris tolerant optimized circumferential slips. As many as 19 FracPoint EXTREME frac sleeves can be installed to provide individual formation access points. These sleeves offer ball-on-seat ratings and allow the use of dissolvable frac balls, greatly enhancing treatment efficiency and eliminating the need to flow balls back to surface. Each FracPoint EXTREME sleeve is isolated by a set of RockLock 15k open-hole packers. Utilizing Baker Hughes‘s Aptum Seal, these packers offer extreme seal expansion ranges to ensure sealing in challenging open-hole conditions. Additionally, they provide high-torque and circulation capabilities while eliminating the need to install costly open-hole anchors. The robust and reliable Alpha Sleeve provides a pressure-activated port for the lowest completion stage even in the most extreme conditions.
(Source: Baker Hughes)
NON-FRACTURING COMPLETIONS CATEGORY:
Sealed Wellbore Pressure Monitoring, Devon Energy Corp. and Well Data Labs Inc.
The Sealed Wellbore Pressure Monitoring (SWPM) process was born through the efforts of innovative completion engineers at Devon Energy. Nearly 10,000 stages have been analyzed with this technique in every major North American and one South American unconventional basin for about 20 operators. This technique utilizes a sealed wellbore (filled with low compressibility fluid) to act like an underground antenna. As hydraulic fractures interact with the sealed wellbore, there are discernable pressure changes that can be picked up from within, providing valuable data.
Proper SWPM execution requires establishing a closed system without perforations connected to the formation being stimulated, along with a sealed casing. With this, a surface or downhole gauge can collect and transmit the necessary data to evaluate interactions with treatment wells that are actively being completed. The primary aim of all fracture diagnostics is to optimize for cluster efficiency. Variations that occur along a lateral can be influenced by any number of constantly changing factors. This, in turn, has repercussions for drainage patterns and the very economics of the well. This is why operators are willing to pay up to and sometimes more than $1 million for certain types of diagnostics within a single project. SWPM has proven to be a valuable, flexible tool for the oilfield over the past year.
(Source: Devon Energy Corporation and Well Data Labs Inc.)
ONSHORE RIGS CATEGORY:
High-Temperature Variable-Bore Rams, Schlumberger
High-temperature variable bore rams (VBR) provide a seal to a range of diameters. They are suited for H2S service per NACE MR0175 and compatible with Schlumberger's U surface ram-type BOP. The ram packers lock into place and are not dislodged by well flow. Additionally, a large reservoir of packer rubber ensures a long-lasting seal under all conditions and increased range of operating temperatures. The VBR has uniquely designed inserts enabling it to withstand extreme heat for challenging well sites. This ram is for the 13⅝-inch 3,000-psi through 10,000-psi Type U ram BOP.
The 135/8-inch, 10,000-psi high-temperature VBR endured rigorous extreme temperature testing, including an 11-h hold at 300 F. The VBR also performed well at low temperature, successfully completing API testing at 30 F. (Source: Schlumberger)
During qualification, the high-temperature VBR surpassed the minimum API extreme temperature hold of 1 hour. This translates into having more time to make informed decisions during a well control event while pressure is stabilizing. A new elastomer material with improved performance capability at extreme temperature is crucial. The VBR primary insert geometry was also modified, and secondary inserts were added to prevent extrusion of the elastomer during use. The VBR is qualified to meet API 16A 4th edition PR2 criteria for VBRs on 3½-inch to 5½-inch mandrels. The high-temperature VBR achieved an 8-h 300 F extreme temperature hold on a 5½-inch mandrel, and an 11-h 300 F extreme temperature hold on a 3½-inch mandrel. Although the design was driven by high-temperature requirements, the VBR also performed well at a low temperature of 30 F. It passed all aspects of API 16A 4th edition PR2 criteria, including continuous high-temperature testing to 180 F, sealing characteristics, stripping, hangoff to 150,000 lbf with a 3½-inch mandrel, hangoff to 450,000 lbf with a 5½-inch mandrel, and completed 78 fatigue cycles, which exceeded API requirements by 50 cycles.
The published information and research conducted by Trelleborg’s applied technologies operation in Rochdale, U.K., shows that an RROV/MSV engineered using existing syntactic materials offers a durability of approximately six months. This brings a new challenge to materials scientists and engineers to develop innovative syntactic materials that offer serviceability well beyond six months to support the needs of the industry. Recognizing these new requirements for long-term submersion, Trelleborg’s applied technologies operation undertook a program of development, testing and qualification of syntactic foam materials to address the specific and more demanding needs in RROV/MSV applications, aiming to ensure robust and reliable performance.
(Source: Trelleborg Applied Technologies)
Trelleborg has released an extensive testing program on its TG range of materials utilizing cube and cylinder specimens with different surface to volume (S/V) ratios. For this purpose, TG3000R syntactic foam material was chosen, undergoing accelerated aging at +50 C under hydrostatic pressure of 310 bar, the pressure at operational depth of 3,100 MSW, until the material reached 2% water absorption; the failure index value. These data were used to build a model for service lifetime prediction. Validation experiments were set to run in parallel with the accelerated aging, with data used to predict the service lifetime based on Arrhenius model. The output of the model using the water absorption data at +50 C predicts a greatly increased service lifetime of two years at +10 C, as opposed to the current six months durability available. Following this discovery, a systematic approach was adopted by Trelleborg to identify other potentially suitable syntactic foam materials. Derived from a combination of thermoset polymer matrices and high-strength hollow glass microsphere technology (HGMS), TG1000R, TG2000R, TG3000R, TG6000R with depth ratings of 1,000, 2,000, 3,000 and 6,000 MSW, respectively, all underwent stringent testing and qualification processes.
TCP Riser, Strohm
Strohm has been at the forefront of thermoplastic composite pipe (TCP) technology for SURF applications. Recently, Strohm developed the concept of the TCP Riser for deepwater application—probably the most disruptive, high-end product developed for deepwater and corrosive environments, according to the company. The TCP Riser is designed and developed specifically for the challenging presalt conditions in Brazil. There, crude oil and natural gas contain various corrosive contaminants such as CO2 and H2S, which, especially when dissolved in water, create an extremely corrosive mixture. The high concentration of CO2 is thought to accelerate corrosion ultimately leading to failure of steel-based flexible pipes, a phenomenon commonly known as stress corrosion cracking.
Strohm engaged with end users Petrobras and Shell Brazil, understanding their preferences for the installation and operation of flexible risers as well as their specifications and requirements for service fluids, design life and the like. (Source: Strohm)
The full, solid wall TCP Riser takes corrosion completely out of the equation by removing the steel tensile armor layers and replacing them with a carbon fibre based composite. The design of the TCP Riser includes an inner liner, a carbon fiber-based composite layer, a coating and a weight stabilizing coating. The liner, matrix and coatings are based on the PVDF polymer, proven in the oilfield for many years of service life. All layers are melt-fused together to form a solid wall, while still being spoolable in long lengths by virtue of using one polymer in all layers. The carbon fiber is completely insensitive to CO2, H2S and has a superior fatigue performance. The product has been developed in close collaboration with the end users and Strohm's supply chain partners. The company has taken the end client’s preferences for installation method and subsea configuration as starting point for product and material development. This has led to a TCP Riser product that does not corrode, fatigue and has a superior service life of 30 years; can be installed using currently available installation vessels, with only modest modifications; uses the most cost-effective free hanging catenary configuration, without any requirement for buoyancy elements and requiring only two sections of pipe; and has the smallest carbon footprint The TCP Riser is based on the field-proven TCP technology.
WATER MANAGEMENT CATEGORY:
Flow-Sync Water Management Platform, Flow-Sync and Bedrock Automation
Flow-Sync has developed skid-based automation technology that has been proven to improve water management productivity by more than 50%. To use it, operators open Flow-Sync’s Transfer Calc software, which analyzes transfer line hydraulics to model the number of pumps required to satisfy the design flow rate and route topography. On startup, the software reconciles readings from pressure sensors, level sensors and flowmeters to identify equipment problems that could cause downtime and sends readings to a programmable control system that optimizes flow based on the data.
Detecting problems immediately minimizes costly downtime. Reporting is another advantage of a secure automation system. (Source: Flow-Sync and Bedrock Automation)
To ensure that the controls have adequate bandwidth to handle the complex pump control calculations securely, Flow-Sync has deployed PLC functionality from a Bedrock Open Secure Automation (OSA) Remote industrial control system. The OSA Remote system leverages the economies of open technologies and eliminates vulnerability to cyberattacks. It is also housed in a rugged, all metal enclosure that withstands the extreme conditions of a typical fracturing environment and mobile nature of the equipment. Flow-Sync deploys the OSA Remote modules in the wiring cabinet of patented, self-contained, portable skids. The skids connect easily to the pumps so the entire transfer operation can be effectively monitored and controlled from any location with an internet connection. The OSA Remote with universal IO is configured to read and write tags from the skid’s sensors and its OPC UA capability makes it very efficient to communicate these data to the broader system.
Enabling users to interact with the automation system is Ignition SCADA software from Inductive Automation. The Ignition server integrates with the Bedrock controls and the AWS cloud, where Amazon Elastic Compute Cloud EC2 servers host an SQL database. The architecture is fully scalable in terms of processor memory and disk storage. The OPC UA connection with the Bedrock OSA Remote extends the secure PLC architecture to remote locations via TCP/IP.
An entry form for the 2022 MEAs competition will be available at HartEnergy.com/mea starting Nov. 1, 2021, until July 1, 2022.
