2020年度工程创新特别功绩奖

专家评审团选出了 25 个顶级行业项目,这些项目为全球寻找和生产碳氢化合物的复杂过程开辟了新的更好的途径。

哈特能源员工

[编者注:这个故事的一个版本出现在 2020 年 9 月版 的 E&P Plus中在这里订阅杂志 。]  

E&P Plus 编辑和工作人员自豪地公布了 2020 年工程创新特别优异奖 (MEA) 的获奖者,该奖项旨在表彰在上游石油行业各个领域取得卓越成就和成就的服务和运营公司。接下来的几页重点介绍了由独立评审团选出的 25 名获奖者。

获奖技术代表了广泛的学科,并解决了阻碍高效运营的多项挑战。每个类别的获奖者都是在各自领域带来巨大变化的产品,代表了最有可能改善人工举升、钻头、钻井液/增产、钻井系统、勘探/地球科学、地层评估、HSE、水力压裂/的工艺和技术。压力泵、智能系统和组件、IOR/EOR/修复、海洋施工和退役、非压裂完井、海底系统和水管理。

今年,来自服务和运营公司的一些业内最聪明的人才推出了极其创新的产品和技术,这些产品和技术现已与世界上最好的产品和技术进行了比较,被评为在概念、设计和应用方面最具突破性的产品和技术。

该奖项旨在表彰那些了解需要更新、更好和不断变化的技术创新来安抚能源匮乏的世界的公司和个人所设计的新产品和技术。

评审团由代表全球运营和咨询公司的商业、工程和科学领域的专家组成。每位评委都被分配了一个最能发挥其专业领域优势的类别。其公司具有商业利益的法官被排除在外。 

E&P Plus 衷心感谢这些杰出的评委为评选今年比赛获奖者所做的努力。

哈特能源多边环境协定

2021 年 MEA 竞赛的报名表可在HartEnergy.com/mea上获取。报名截止日期为 2021 年 1 月 31 日。 


人工举升冠军

斯伦贝谢
REDA Continuum 长寿命 ESP 泵

流量急剧下降以及固体和气体产生等具有挑战性的流量特性通常超出传统电动潜水泵 (ESP) 的能力,从而导致故障、生产损失和运行寿命缩短。REDA Continuum 长寿命 ESP 在具有低段塞流、固体产生、频繁停止和启动以及生产不确定性的非常规和传统井中实现了扬程、效率、寿命和功耗的阶跃变化。其结果是运营商在更长时间内生产更多石油的能力显着提高。最新的 Continuum 泵具有扩大的平衡室、优化的平衡孔和坚固的垫圈设计,可在产量超出或低于预期时限制上推力和下推力磨损。该泵专为 5 陆英寸或更大的套管尺寸而设计,可处理 200 桶/天至 7,000 桶/天,与自然流量相比,可实现更快的下降和更大的 IP。


钻头获胜者

沙特阿美
超强无催化剂 PDC

聚晶金刚石复合片(PDC)钻头是石油勘探和钻井必不可少的钻井工具。对于当今的 PDC 钻头来说,在坚硬、高磨蚀性和互层地层中钻井是一项艰巨的挑战。目前的 PDC 刀具技术无法提供足够的耐磨性、抗冲击性或热稳定性来实现单次钻进整个层段的最终目标。当前技术的弱点是由于不可避免地使用了钴催化剂来粘合构成 PDC 切割结构的金刚石颗粒。 

沙特阿美公司的超强无催化剂PDC材料首次合成成功,创下了迄今为止最硬金刚石材料的新世界纪录。其耐磨性比业内使用的最好的金刚石材料高出300%。PDC刀具的热稳定性和抗氧化性也突破了行业记录,提高了约600℃。 

案例研究中,首次在16 GPa的极高压力和2,300 C的超高温下成功合成了具有超高耐磨性的无催化剂PDC。对称评价耐磨性、硬度和热稳定性。结果表明,该新材料具有极高的耐磨性,比业内使用的最佳商用 PDC 材料高出 300% 以上。该材料还在硬度测试中压坏了所有金刚石压头,这表明它是迄今为止世界上最硬的材料。

(来源:沙特阿美公司)
由超强无催化剂 PDC 材料制成的刀具在空气中高达 1,200 C 的温度下具有最高的热稳定性和抗氧化性,比商用 PDC 刀具高 600 C 以上。(来源:沙特阿美公司)

钻头获胜者

SMITH BITS,斯伦贝谢公司的
宙斯盾装甲覆层

(来源:Smith Bits,斯伦贝谢旗下公司)
与传统的硬面相比,宙斯盾装甲覆层直接应用于钻头刀片,改善了刀具保护并提供更高的耐腐蚀性。(来源:Smith Bits,斯伦贝谢旗下公司)

在聚晶金刚石复合片 (PDC) 钻头市场中,钻井人员可以选择两种钻体选项:碳化钨基 PDC 钻头和钢体钻头。虽然钢体钻头采用的几何形状更有利于有效排屑,但与基体 PDC 钻头相比,它们的耐侵蚀性较差。即使添加了传统的硬面,钢体钻头也缺乏承受大多数钻井应用的恶劣井下环境所需的耐用性。

Aegis 装甲覆层由单独的碳化钨材料条组成,
采用电子束增材制造工艺应用于钢体钻头的刀刃面。与传统矩阵 PDC 钻头相比,Aegis 装甲覆层将钻头的抗侵蚀性提高了 400%,强度提高了 40%。这种新型 PDC 钻头结构使钻井人员能够认识到钢体钻头和胎体钻头的优点,因此他们不必再因传统钻头体的限制而牺牲钻井性能。Aegis 装甲覆层经过了广泛的现场测试,在全球范围内累计运行了 70 多次。 


钻井液/增产方案获胜者

BAKER HUGHES
Delta-TEQ 低压冲击钻井液

在具有挑战性的海上油井中,孔隙压力、裂缝梯度和复杂的几何形状相结合,形成了狭窄的操作窗口。许多操作问题——例如过高的波动压力、泵启动压力引起的压力峰值、复杂的等效循环密度(ECD)管理以及无法有效控制钻井参数——可能会导致成本高昂且耗时的事件。

贝克休斯发布了 DELTA-TEQ 低压冲击钻井液,这是一种非水配方,使操作员能够在狭窄的压力窗口中工作,通过显着降低与此活动相关的风险来实现其钻井目标。在狭窄压力窗口钻井的典型解决方案是使用低 ECD 钻井液。DELTA-TEQ 流体能够通过在井的正确区域保持正确的粘度来管理水力冲击,从而实现最佳的孔清洁和渗透率,而不会对地层施加过大的压力。就像“粘度离合器”一样,它在低剪切速率下接合粘度并在高剪切速率下脱离。

(来源:贝克休斯)
DELTA-TEQ 流体采用先进的特种粘土和聚合物配方,形成非渐进式凝胶结构,通过快速凝固/易断裂的轮廓减少液压冲击。(来源:贝克休斯)

钻井液/增产方案获胜者

TETRA 技术
TETRA CS NEPTUNE 流体系统

对于复杂的高压井,运营商需要一种既不含锌也不含甲酸铯的致密完井液系统,但对环境无害且具有商业可行性。锌盐水被归类为海洋污染物,在墨西哥湾 (GoM) 受到限制,在北海、巴西和其他地方被禁止。由于加拿大中部世界最大矿山的矿石储量耗尽,用于甲酸铯的铯盐现在价格昂贵得令人望而却步。

TETRA 开发了 TETRA CS Neptune 完井液套件,作为锌盐水和甲酸铯的替代品。这些高密度、清澈的盐水符合墨西哥湾、北海和其他地区的环境法规,具有中性或碱性 pH 值,接近溴化锌和甲酸铯的密度,但不含锌、甲酸盐和固体。

TETRA CS Neptune 液体的配制密度可高达 17.5 ppg,并可使用标准的透明盐水设备进行混合。它们在高温下和储存期间保持稳定。这些流体与大多数弹性体和金属相容,腐蚀风险低,并且可以设计用于在低温和高压下运行而不会结晶。

(来源:TETRA 技术)
TETRA CS Neptune 流体用途广泛,因为它们可以配制为低固体含量的油藏钻井液,并使用标准设备回收再利用。(来源:TETRA 技术)

钻井系统获胜者

GYRODATA
OMEGA X固态测量系统

(来源:陀螺数据)
全姿态固态水滴陀螺仪测量系统集成了两个独立的三轴传感器探头。(来源:陀螺数据)

定向钻井并不总是一件容易的事。现代油井固有的挑战有很多,包括具有不同硬度水平的多层、互层岩层;井下条件更加恶劣,压力和温度更高;长支管和大位移钻井应用;和更多。

解决这些挑战的一种途径是陀螺仪测量技术。Gyrodata 启动了一项全面的研发计划,开发固态陀螺仪技术,该技术使用先进的新型传感器套件来测量地球的自转速率,精确确定倾角和真北。

该技术为该公司的 Omega X系统提供动力,该系统是一种全姿态、固态落体陀螺仪测量系统,集成了两个独立的三轴传感器探头。传感器封装和电子设备(包括存储器和数据处理)只有 19 英寸长,显着缩短了井底组件的总长度。该系统可以在 302 F 的温度下运行,没有时间限制,非常适合井下条件更恶劣的应用。与传统陀螺仪系统和 MWD 测量相比, Omega X在管道连接过程中无缝收集测量数据,消除质量不平衡误差并大幅减少不确定性椭圆。 


钻井系统获胜者

WEATHERFORD
AlphaST 单行程裸眼水泥和侧轨系统

Weatherford 的 AlphaST 单行程裸眼水泥和侧钻系统一次行程即可完成水泥、锚和钻机的操作。与当前需要两次行程才能启动侧线的传统斜向器系统相比,这种功能可以节省数天的钻机时间。

在一次行程中,AlphaST 系统可以输送水泥,如有必要,可以锚定斜向器并立即启动支管。该系统不使用水泥进行侧钻,而是使用封隔器,从而消除了与堵塞故障相关的重新固井和重新钻井操作。该系统还可以钻过鱼、拉直弯曲的孔以及绕过塌陷的钻孔。该系统由注射生产封隔器 (IPP) 组成,它取代了用于锚固目的的水泥塞。IPP 锚能够在裸眼井眼中定位横向偏离,无需假底或水泥屏障。该系统还包括专门设计的流量管、小角度造斜器和双磨钻钻井底组件 (BHA)。流管输送水泥以在原始井眼中形成屏障。单角度 3 度斜向器可平滑过渡到侧钻,无需台阶或凸缘,从而能够使用带有短齿或多晶金刚石紧凑型钻头的钻井 BHA。

(来源:威德福)
铅磨机和柔性磨机是斜向器组件的一部分,并通过剪切螺栓连接到管柱上。(来源:威德福)

勘探/地球科学获奖者

沙特阿美公司
SPICERACK

(来源:沙特阿美公司)
沙特阿美公司使用 SpiceRack 技术作为行业首次实验的一部分,使用 20 台 AUV 进行海底地震采集。下一步部署计划使用 200 艘 AUV 进行海底地震采集。(来源:沙特阿美公司)

沙特阿美公司的 SpiceRack 是与 EXPEC ARC 和 Seabed GeoSolutions 合作的一个多年研究合作项目,旨在设计、开发、制造和商业化一种高效、完全自动化且经济高效的海底地震采集解决方案。这种类型的海底采集采用机器人 AUV 来部署、记录和检索海底地震传感器。

传统的海底地震采集使用位于海底的地震传感器,这些传感器要么连接到电缆/绳索,要么是无电缆节点。对于电缆类型的部署和回收,需要多艘船只,使得此类调查的成本极其昂贵。为了部署和检索节点传感器,需要 ROV,这增加了此类调查的总持续时间,从而显着增加了采购成本。

另外,SpiceRack 是一项颠覆性技术,它使用机器人和自动化来部署和检索 AUV 作为地震传感器。通过自动化海底采集,预计成本可降低 30%,生产率可提高 50%。SpiceRack 通过使用自动化和机器人,创建了更高效、更安全的操作来生成高分辨率地下图像。


队形评估获胜者

HALLIBURTON
EarthSTAR 超深电阻率服务 3D 反演

Halliburton 的 EarthStar 超深电阻率服务 3D 反演在钻井时进行钻孔周围的电磁场测量,并使用先进的基于网格的计算反演方法将其转换为地质结构的 3D 模型。油藏的 3D 模型使操作员能够看到真实油藏结构的真实表现,这有助于他们做出明智的井位决策,并更好地了解油藏的形状、大小和产能。EarthStar 服务可照亮并绘制储层和流体边界图,经过验证,能够绘制距井眼 225 英尺的这些特征图,将敏感范围扩展至以前的 10 倍。

EarthStar 服务的 3D 反演能力将对勘探与生产行业产生重大影响,因为它能够揭示否则会被忽视的结构细节。 (来源:哈里伯顿)
EarthStar 服务的 3D 反演能力将对勘探与生产行业产生重大影响,因为它能够揭示否则会被忽视的结构细节。(来源:哈里伯顿)

队形评估获胜者

威瑟福德
智能输送系统

(来源:威德福)
ICS 旨在节省时间并向地面提供详细信息,以便客户能够做出明智的决策。(来源:威德福)

Weatherford 智能输送系统 (ICS) 提高了裸眼测井的自主性和通信能力,以改善作业结果。ICS 旨在将紧凑型测井工具输送至总深度 (TD),适用于水平井、倾斜钻机和偏远地区。

目前,大多数裸眼测井作业都使用流体机械系统。尽管流体力学方法高度可靠、故障很少且运行效率高于 95%,但它缺乏地面工程师和井下工具之间的双向通信。ICS 旨在提供相同的可靠性,同时改进工具通信和内存功能。ICS 使用双向通信,包括钻杆旋转与井下工具通信以及压力脉冲回复上行链路。ICS 的另一个优势是井下内存子系统,它充当测井机器人,自动发出命令以打开测径器、记录数据、与地面通信并减轻潜在的故障条件,从而实现更可靠的测井采集。记忆子根据所需的智力水平将任务分为两个不同的级别。 


健康安全环境优胜者

CRUSOE ENERGY SYSTEMS INC.
数字耀斑缓解

Crusoe Energy Systems Inc. 的数字火炬缓解 (DFM) 系统将模块化、移动、能源密集型数据中心直接部署到井场,以消耗原本会因火炬燃烧而浪费的天然气。该系统可在每个地点扩展到每天数百万立方英尺,为伴生气提供急需的有益用途,促进对气​​体捕集要求的监管合规性,并实现 CO 2 当量温室气体排放量减少 30% 至 40%,与开放式燃烧​​相比,空气质量和视觉冲击力得到显着改善。DFM 系统在几天内即可投入使用,并且随着油井成熟过程中天然气量下降,可以重新部署到新地点。相对于其他火炬缓解技术,Crusoe 的系统为运营商的伴生气流提供了完整且可扩展的解决方案,具有经济吸引力。在许多情况下,DFM 系统的交付成本较低或免费。对于具有足够规模、期限和供应冗余的项目,Crusoe 可以向以前没有收入的运营商提供天然气收入,同时提供关键的监管和环境合规价值。

Crusoe 于 2019 年 1 月在怀俄明州保德河流域安装了第一个 DFM 系统,并在接下来的一年中增加到 10 个部署。Crusoe 的每项部署都可以帮助上游运营商减少现场天然气燃烧,同时为 Crusoe 数据中心运行的计算流程提供低成本能源。

(来源:克鲁索能源系统)
Crusoe 在北达科他州、蒙大拿州、怀俄明州和科罗拉多州运营着 10 个 DFM 系统。(来源:克鲁索能源系统)

健康安全环境优胜者

FRANK 国际
后背控制台

弗兰克国际
机架后控制台包含视觉指示器,可通知控制面板操作员控制台程序的当前顺序步骤。(来源:弗兰克国际)

为了降低机架后退操作过程中接头或管架掉落的风险,弗兰克国际公司开发了机架后退控制台,这是一种专门的控制台,旨在控制气动升降机和蜘蛛架,以在机架中进行机架后退的气动升降机和蜘蛛架。德里克。尽管这些编程功能可以通过电子方式控制,但采用气动逻辑的机械编程允许在钻台上工作,而无需进行昂贵的危险区域认证。机架后控制台编程将只允许在管状支架建造过程的每个操作步骤中激活正确的工具(升降机或星形轮)控制阀,从而防止工具在操作顺序之外被激活。机架后控制台根据完成双管、三管或四管支架所需的步骤数自动重置每个支架搭建周期。它还包括用于构建和布置展台的运行和拉动模式。如果必须拆卸管状支架,此功能允许颠倒操作顺序。

回架控制台于 2019 年 1 月首次成功部署,用于为墨西哥湾双作业钻井船上的一家主要运营商的多孔井项目中的各种支架进行回架。Rack Back 控制台成功运行了 180 多个站和多口井。


水力压裂/压力泵获胜者

BJ 服务
THINFRAC MP 减摩剂

(来源:北京服务)
ThinFrac MP 的分子结构可实现干净、高效的破碎,几乎不会对地层或支撑剂充填层造成损害。(来源:北京服务)

BJ Services 的 ThinFrac MP 减摩剂是一种流体解决方案,用于从非常规油藏中有效提取碳氢化合物。它旨在提供泵送效率、复杂的裂缝网络和精确的破碎性,以提高产量和提高运营效率。

ThinFrac MP 是一种经济高效的聚丙烯酰胺聚合物减摩剂,具有卓越的支撑剂承载性能。这种合成工程聚合物可在 8 至 10 秒内快速水合,从而瞬间减少摩擦。由于其粘弹性特性,它在滑溜水压裂作业中提供卓越的支撑剂输送能力,将支撑剂输送到裂缝。由于其高分子量和快速水合作用,它可以在较低负载下更大程度地减少管道摩擦。

操作员发现管道摩擦压力降低了 85%,事实证明这可以降低液压马力和地面设备要求。聚合物减摩剂与淡水、盐水和低 pH 流体兼容。


水力压裂/压力泵获胜者

九能服务
突破套管浮选装置

九能源服务
 (来源:九号能源服务)

Nine Energy Service 的 BreakThru 套管浮选装置是一种技术先进的屏障,旨在将套管漂浮在长横向延伸至井眼底部。

BreakThru 的工作原理是根据井眼建模将套管下入预定深度,与传统套管浮选设备相比,使用少两个连接和两个螺纹组。然后,流体被泵入屏障上方的套管中,产生将套管一直推至目标深度所需的力。

一旦套管完全着陆,额外的流体就会积聚,直到达到将屏障分解成细小的沙状颗粒所需的激活压力。

这些细小颗粒很容易通过套筒、趾阀和浮动设备循环出去,从而无需碎片收集器、流体冲洗或额外行程来回收设备部件。

因此,操作员可以立即开始泵送水泥,从而节省时间并提高效率。BreakThru 的耐用性可在磨合过程中遇到的极端温度和轴向载荷下提供可靠的密封,但一旦套管着陆,就会可靠地破碎。 


智能组件优胜者

Halliburton
Immersiv 增强和虚拟现实解决方案

传统的海上钻井现场调查通常需要数周时间。借助哈里伯顿的全新 Imersiv 增强和虚拟现实解决方案,操作员可以节省至少两天的钻机时间,并提高海上固控和流体管理的钻机测量和审核的准确性。使用 Microsoft HoloLens,用户可以将精确的 1:1 比例的设备 3D 模型以数字方式叠加到现有的物理钻机空间上,同时对相应的钻机空间和访问路线进行高分辨率扫描。Imersiv 增强和虚拟现实解决方案提供的这种组合使用户能够及时识别可能妨碍安装的障碍物,并确保所选设备实时符合操作员的钻机设计和加工要求,从而提高信心。调查专家不再需要跨时区前往钻机,这可能会增加数天或数周的非生产时间 (NPT) 和严重的成本超支。现在,这些专家可以为世界不同地区的多个操作提供远程调查帮助,而无需离开办公室。最终结果是降低运营成本、减少员工数量、减少 NPT 和降低风险。

(来源:哈里伯顿)
扫描的设备被加载到 Hololens 上的应用程序中,可以通过语音或手势命令进行访问。然后,用户可以在真实空间中操纵和放置分离设备的 3D 全息图,并虚拟测量所有间隙,以帮助确保最佳放置。(来源:哈里伯顿)

智能组件优胜者

西门子
增材制造技术实现燃气轮机无化石燃烧

来源:西门子
增材制造使燃气轮机部件的设计成为可能,以支持石油、天然气和发电行业的脱碳。(来源:西门子)

作为一种燃料来源,氢气能够很好地满足市场对采用干式低排放 (DLE) 燃烧系统的低排放燃气轮机的需求。这些涡轮机采用了最新一代的 DLE 燃烧器,可有效燃烧氢气或氢气/燃气混合物,以降低 CO 2和 NO x排放。近年来,通过采用增材制造 (AM) 技术来实现快速设计、原型设计和制造,开发工作得到了加速。增材制造生产的原型比传统制造的交付速度更快,这使得不同组件的测试更加高效,并将测试和开发时间缩短了 75%。增材制造还可以将燃烧器喷嘴等部件的维修速度提高 60%,将备件和完整燃烧器套件的交货时间缩短 40% 至 50%,并在新零件的设计中提供本质上无限的灵活性。

西门子中型燃气轮机可使用多种燃料规格。SGT-800 型燃气轮机运行时燃料混合物中的 H 2含量高达 50 vol% ,SGT-700 型燃气轮机的燃料混合物中的 H 2含量高达 55 vol% ,SGT-600 型燃气轮机的燃料混合物中的 H 2含量高达 60 vol% 由于柏林西门子清洁能源测试中心对100 vol% H 2运行的单个燃烧器的测试结果令人鼓舞,提供 100 vol% H 2的最终目标更接近实现。


智能组件优胜者

美国油井服务
电力路径

US Well Services (USWS) PowerPath 为距离涡轮发电机数英里的远程平台提供 13,800 伏电力。这一技术进步使涡轮机能够安装在一个位置,并使用微电网向多个发电站供电,从而减少发电站之间的移动时间。这种微电网和涡轮机的集中位置还消除了在油井增产之前每个平台都需要现有的现场天然气管道,或者在压裂作业期间必须用卡车将 CNG 或 LNG 运送到每个位置。PowerPath 不仅限于压裂操作。在集中区域开发油田时,运营商可以利用 PowerPath 为钻机等其他油田设备供电。USWS 于 2019 年 6 月首次部署 PowerPath 技术,成功为 2.5 英里外的远程水力压裂作业提供电力。该技术允许发电集中位于五个水力压裂垫之间,并通过架空线路将电力传输到数英里之外的现场 Clean Fleet 泵送设备。利用高压电力可以将电力输送多英里,而不会出现低压和中压系统造成的电力损失。 

(来源:美国油井服务公司)
US Well Services 的 PowerPath 系统缩短了压裂作业区之间的移动时间,并且无需在压裂作业之前将气体管线连接至每个作业区。(来源:美国油井服务公司)

智能系统获胜者

BEDROCK 自动化
BEDROCK 开放式安全自动化

来源:基岩自动化
Bedrock OSA 产品系列提供高性能 PLC、RTU、DCS 和 EFM 功能,并增强了在数字时代保持竞争力所需的内置网络安全和通信功能。(来源:基岩自动化)

Bedrock 开放式安全自动化 (OSA) 是一种具有内置网络安全功能的高容量控制系统。以前仅在军事和航空航天电子设备中可用的身份验证和加密功能已嵌入到 Bedrock 的控制系统平台中。为了克服这种数字纵深防御,恶意代码必须通过系统电子设备所有部分实时发生的众多身份验证和加密步骤。这实际上是不可能的。这些模块通过封装在密封的防篡改金属和无引脚背板中,进一步防止网络入侵,这还提供了极端的电磁和热硬化,以实现现实世界的可靠性。OSA 包含 PLC、RTU、DCS 和 EFM 功能,但它通过保持竞争力所需的网络安全和更高性能来增强这些功能。通过内置安全性,Bedrock OSA 消除了网络安全成本这一部署 IIoT 架构的障碍。


智能系统获胜者

DATA GUMBO 公司
GUMBONET

Data Gumbo Corp.鈥檚 GumboNet blockchain-based network automates smart contracts and transactions for industry leaders by utilizing the combination of distributed ledger technology with contract terms confirmed with operating field data. In providing a single, industry-agnostic immutable record of truth across participants, GumboNet solves long-standing issues of trust and data inaccuracies to reduce barriers associated with doing business. By forging trust between stakeholders, automating transactions and mitigating contract leakage, GumboNet is significantly changing how businesses transact. Old World business methodologies often include processes modeled on paper trails, isolated corporate views, rigid IT infrastructure, siloed systems, enterprise resource planning and transactional friction. With Data Gumbo, this approach is replaced by operational transparency, contractual flexibility and frictionless transactions. As a simple, intuitive and subscription-based blockchain network, companies are freed from building and sustaining standalone, siloed blockchain technologies that require resources and continuous oversight.

数据冈博公司
GumboNet has been adopted for a water haulage pilot program by the Offshore Operators Committee Oil & Gas Blockchain Consortium. (Source: Data Gumbo Corp.)

IOR/EOR/REMEDIATION WINNER

SAUDI ARAMCO
NANO-ENCAPSULATED RESERVOIR CHEMICAL TREATMENTS

(来源:沙特阿美公司)
Nano-surfactant is persistently stable in high salinty and temperature. (Source: Saudi Aramco)

More than 50% of hydrocarbon resources in subsurface reservoirs are unrecoverable by current operations. Chemical EOR is one of the most promising and widely studied methods to help recover remaining hydrocarbons. Successful EOR formulations need to be low cost and accessible
at large quantities.

Saudi Aramco has developed a nano-surfactant technology that offers a one-step highly economic process for stabilizing and target-delivering hot brine-incompatible surfactants. The developed nano-encapsulation technique extends the use of a large variety of reservoir chemical treatments that are otherwise inoperative in high salinity and temperature reservoirs. At the same time, it improves their performance and depth of penetration as well as reduces the amount of chemicals needed without affecting performance. The method was inspired by formulations widely used in nanotechnology for medicine and successfully translated into the oil field by a multidisciplinary team of scientists and engineers. Studies demonstrated that this method of nano-encapsulation of surfactants represents one of the industry鈥檚 first formulations that can be scaled up and synthesized in the field, can be used for various applications in reservoirs with various salinity and temperature brines, and provides high-efficiency mobilization of the remaining oil.


IOR/EOR/REMEDIATION WINNER

WELL-SENSE
FIBERLINE INTERVENTION SYSTEM

威尔森
The FLI technology can contain single-point sensors in its probe to deliver 鈥渁ctive鈥� real-time measurements that complement the distributed sensing. (Source: Well-SENSE)

Well-SENSE鈥檚 FiberLine Intervention (FLI) System is designed to deliver faster, smarter well intelligence. The technology has demonstrated efficiency gains and the rapid acquisition of high-quality, richer downhole data compared to conventional wireline methods. FLI is a self-contained, portable system using a pressure containing 鈥渓auncher鈥� connected to the wellhead. It deploys the probe into the well, which lays bare optical fiber to total depth. The fiber gathers instant, distributed data simultaneously across the entire length of the fiber-optic cable. Temperature and acoustic profiles can be captured, plus any changes over time, resulting in a rich picture of the complete well. As it does not rely on wireline, slickline or coiled tubing for deployment, results are obtained faster, more economically, using less personnel with reduced wellsite personnel on board, footprint and operational risk. FLI operations on average can take up to 3 hours of logging, compared to up to 24 hours for single-point wireline logging.

Just one Well-SENSE engineer is required to transport and operate FLI. Its lightweight, compact size means it is delivered to the well site in the back of a truck or via a small shipping box. This opens up new opportunities, allowing operators to acquire data from more challenging, less accessible wellsite locations, such as unmanned offshore satellite platforms with little or no deck space.

As a plug-and-play system, FLI is ready for rapid implementation. It takes just one person about 30 minutes to an hour to rig up, while rigging down is almost immediate. The probe is sacrificial or retrievable depending on the client鈥檚 preference. Compared with onshore data acquisition in the U.S., FLI could offer up to 50% to 75% cost savings, whereas this can potentially reach 90% in the offshore environment, depending on the application.


MARINE CONSTRUCTION & DECOMMISSIONING WINNER

SCHLUMBERGER
CEMFIT HEAL FLEXIBLE SELF-HEALING CEMENT SYSTEM

Schlumberger鈥檚 CemFIT Heal flexible self-healing cement system helps ensure well integrity from drilling to abandonment, providing a competent annular pressure seal and protecting against hydrocarbon leaks and sustained casing pressure (SCP). Using the CemFIT Heal system eliminates SCP at the construction phase and minimizes risks and operational challenges at decommissioning. Conventional cement systems expand after setting only in the presence of water coming from the formation; however, these systems cannot self-heal subsequently if the cement matrix is damaged. The CemFIT Heal system heals upon interaction with hydrocarbons, improving cement bonding and sealing
micro-annuli that can cause unwanted gas migration. A low Young鈥檚 modulus enables it to withstand cement sheath stresses from drilling, perforating, stimulation treatments, and temperature and pressure changes, which help prevent cement sheath failure.

斯伦贝谢
Conventional offshore well cement barriers (left) can develop cracks and micro-annuli after pressure changes and other stresses. The CemFIT Heal system (right) responds to any contact with oil or gas by automatically repairing and sealing itself, eliminating SCP and adding options to simplify plug and abandonment. (Source: Schlumberger)

SUBSEA SYSTEMS WINNER

SCHLUMBERGER
CASING RECONNECT METAL-TO-METAL, GAS-TIGHT CASING REPAIR SYSTEM

斯伦贝谢
The Casing Reconnect system eliminates sidetracking and fishing operations, keeping drilling programs on schedule. (Source: Schlumberger)

Schlumberger鈥檚 Casing Reconnect Metal-to-Metal, Gas-Tight Casing Repair System is a cost-effective remediation system for well operations. The system seamlessly replaces stuck or damaged casing and provides a robust seal for the life of the well, keeping drilling programs on schedule and securing well integrity for plugging and abandonment operations. The Casing Reconnect system enables cutting and pulling casing anywhere between the wellhead and the stuck point. Replacement casing is then run with a Casing Reconnect system to the receptacle on the bottom鈥攃orrectly spaced out with the casing hanger. The casing stump is then morphed into the Casing Reconnect system receptacle to rejoin the two strings with a high axial-load-bearing, metal-to-metal seal. The system accommodates excess swallow at the connection, simplifying space out for correctly landing the hanger. The system is ISO 14310 VO-rated and contains no moving parts. The full-axial-load-bearing reconnection tool uses Metalmorphology metal-to-metal sealing and anchoring technology.


SUBSURFACE COMPLETIONS WINNER

DEEP IMAGING
DEEP IMAGING REAL-TIME FLUID TRACKING

E&Ps were successful at developing highly productive well designs and then inadvertently spaced them too closely together. Despite technological advancements, teams can鈥檛 precisely evaluate how much rock was treated during a frac, nor can they effectively identify completions issues and whether they were successful in mitigating them. Deep Imaging offers a real-time system for tracking fluid as it鈥檚 pumped through the wellbore and out to the fracture tips during a completion job. While seeing stages form in real time, operators are validating models and successful stages while identifying, fixing or avoiding problem stages as they occur. By spotting issues at inception, companies are reducing waste and boosting well productivity. Lookback efforts to improve well models are important, but well inventories are too valuable to make adjustments solely on the next well. In one example, a customer discovered how to save up to $1 million on future wells by reducing the number of frac stages per well without impacting performance.

深层成像
With the fluid tracking system, deployment does not require access to the well pad. A current is transmitted that creates an electromagnetic (EM) field in the subsurface. During a frac stage, the injected fluid alters the EM field, which is measured at the surface. (Source: Deep Imaging)

WATER MANAGEMENT WINNER

SAUDI ARAMCO
ACOUSTIC OIL-WATER-FINES SEPARATION

沙特阿美石油公司
The Acoustic Oil-Water-Fines Separation concept separates oil and fines simultaneously with no flow intervention or pressure drop. (Source: Saudi Aramco)

Saudi Aramco鈥檚 Acoustic Oil-Water-Fines Separation system separates minute amounts of small oil droplets and solid particles from flowing fluid streams without intervention. The three-phase separation technology can be used to reduce the volumes of water produced from mature oil and gas reservoirs and pumped to the processing plants by several orders of magnitude. It reduces the costs for pumping and treating massive volumes of produced water as well as the health and environmental hazards associated with handling large volumes of produced water. Because of its ability to separate minute volumes of oil and particles, the technology can be utilized in treating produced water prior to injection into the disposal wells, reducing the risk of contaminating groundwater aquifers. The acoustic separation tool increases the oil-to-water ratios in producing wells and also reduces the risk of pore clogging and formation contamination should water be reinjected back in the formation. The tool also can be utilized as a surface separation system to reduce the volume of produced water prior to reaching the gas-oil separation plant (GOSP), thus costs of reconfiguring the GOSP to accommodate increased water cuts.


Enter your new technology into the MEAs competition by Jan. 31, 2021. Entry is free!

原文链接/hartenergy

2020 Special Meritorious Awards for Engineering Innovation

An expert panel of judges has selected the top 25 industry projects that open new and better avenues to the complicated process of finding and producing hydrocarbons around the world.

Hart Energy Staff

[Editor's note: A version of this story appears in the September 2020 edition of E&P Plus. Subscribe to the magazine here.]  

The E&P Plus editors and staff proudly present the winners of the 2020 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 pages that follow highlight 25 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, drill bits, drilling fluids/stimulation, drilling systems, exploration/geoscience, formation evaluation, HSE, hydraulic fracturing/pressure pumping, intelligent systems and components, IOR/EOR/remediation, marine construction and decommissioning, nonfracturing completions, 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 Plus would like to thank these distinguished judges for their efforts in selecting the winners in this year’s competition.

Hart Energy MEAs

An entry form for the 2021 MEAs competition is available at HartEnergy.com/mea. The deadline for entries is Jan. 31, 2021. 


ARTIFICIAL LIFT WINNER

SCHLUMBERGER
REDA CONTINUUM EXTENDED-LIFE ESP PUMP

Challenging flow characteristics such as steep flow declines and solids and gas production often exceed the capabilities of conventional electric submersible pumps (ESPs), leading to failures, lost production and reduced runlife. The REDA Continuum extended-life ESP delivers a step change in lift, efficiency, lifetime and power consumption in unconventional and conventional wells with low and slug flow, solids production, frequent stops and starts, and production uncertainty. The result is a significant increase in operators’ ability to produce more oil for longer. The latest Continuum pumps feature an enlarged balance chamber, optimized balance holes and rugged washer designs to limit upthrust and downthrust wear when production exceeds or drops below expectations. Designed for 5½-inch or larger casing sizes, the pumps can handle 200 bbl/d to 7,000 bbl/d, enabling faster drawdown and greater IP compared with the natural flow.


DRILL BITS WINNER

SAUDI ARAMCO
ULTRASTRONG CATALYST-FREE PDC

Polycrystalline diamond compact (PDC) drill bits are essential drilling tools for oil exploration and drilling. Drilling in hard, highly abrasive and interbedded formations is a difficult challenge for today’s PDC bits. Current PDC cutter technology does not provide sufficient wear, impact resistance or thermal stability to achieve the final goal of a single run to drill the entire interval. The weakness in the current technology is due to the use of unavoidable cobalt catalysts needed to bind the diamond grains that compose the PDC cutting structure. 

Saudi Aramco’s ultrastrong and catalyst-free PDC material has been successfully synthesized for the first time, setting a new world record as the hardest diamond material to date, according to the company. Its wear resistance is 300% higher than that of the best diamond materials used in the industry. The thermal stability and oxidation resistance of the PDC cutter also broke the industry records by an increase of about 600 C. 

In a case study, catalyst-free PDC with ultrahigh wear resistance was successfully synthesized under an extremely high pressure of 16 GPa and ultrahigh temperature of 2,300 C for the first time. The wear resistance, hardness and thermal stability were symmetrically evaluated. The results showed that the new material possesses an exceptionally high wear resistance of more than 300% higher than that of the best commercial PDC materials used in the industry. The material also broke all the diamond indenters during the hardness testing, indicating the world’s hardest material to date.

(Source: Saudi Aramco)
Cutters made from the ultrastrong catalyst-free PDC material feature the highest thermal stability and oxidation resistance at temperatures up to 1,200 C in air, more than 600 C higher than that of commercial PDC cutters. (Source: Saudi Aramco)

DRILL BITS WINNER

SMITH BITS, A SCHLUMBERGER COMPANY
AEGIS ARMOR CLADDING

(Source: Smith Bits, a Schlumberger company)
Aegis Armor Cladding is applied directly to the bit blade, improving cutter protection and delivering increased erosion resistance compared with conventional hardfacing. (Source: Smith Bits, a Schlumberger company)

In the polycrystalline diamond compact (PDC) bits market, drillers have the choice of two bit-body options: tungsten-carbide matrix PDC bits and steel-body bits. While steelbody bits incorporate geometries that are more conducive to efficient cuttings evacuation, they are less resistant to erosion when compared to matrix PDC bits. Even with the addition of conventional hardfacing, steel-body bits lack the durability needed to withstand the harsh downhole environments of most drilling applications.

Aegis Armor Cladding comprises individual strips of a tungsten-carbide material applied to the blade face
of steel-body drill bits using an electron-beam additive manufacturing process. Aegis Armor Cladding increases bit erosion resistance by 400% and strength by 40% when compared to conventional matrix PDC bits. This new type of PDC bit construction enables drillers to realize the benefits of steel- and matrix-body bits, so they no longer have to sacrifice drilling performance based on the limitations of conventional bit bodies. Aegis Armor Cladding has undergone extensive field testing, accumulating more than 70 runs worldwide. 


DRILLING FLUIDS/STIMULATION WINNER

BAKER HUGHES
DELTA-TEQ LOW-PRESSURE-IMPACT DRILLING FLUID

In challenging offshore wells, pore pressure, fracture gradient and complex geometry combine to create a narrow operating window. Numerous operational problems—such as excessive surge pressures, pressure spikes due to pump initiation pressures, complicated equivalent circulating density (ECD) management and the inability to effectively control drilling parameters—can result in costly and time-consuming events.

Baker Hughes has released the DELTA-TEQ low-pressure-impact drilling fluid, a nonaqueous formulation, to enable operators working in narrow pressure windows to meet their drilling objectives by significantly reducing the risks associated with this activity. The typical solution to drilling in narrow pressure windows has been the use of a low-ECD drilling fluid. The DELTA-TEQ fluid has the ability to manage hydraulic impact by maintaining the right viscosity in the right areas of the well for optimal hole cleaning and penetration rates without putting excess pressure on the formation. Like a “viscosity clutch,” it engages viscosity at low shear rates and disengages at high shear rates.

(Source: Baker Hughes)
Featuring an advanced formulation of specialized clay and polymers, the DELTA-TEQ fluid creates a nonprogressive gel structure that reduces hydraulic impact with a rapid-set/easy-break profile. (Source: Baker Hughes)

DRILLING FLUIDS/STIMULATION WINNER

TETRA TECHNOLOGIES
TETRA CS NEPTUNE FLUID SYSTEMS

For complex, high-pressure wells, operators need a dense completion fluid system that contains neither zinc nor cesium formate, yet is environmentally sound and commercially viable. Zinc brines are classified as marine pollutants, restricted in the Gulf of Mexico (GoM) and prohibited in the North Sea, Brazil and elsewhere. The cesium salt used in cesium formates is now prohibitively expensive due to depletion of its ore reserves in the world largest mine in Central Canada.

TETRA developed the suite of TETRA CS Neptune completion fluids as an alternative to zinc brines and cesium formate. Meeting environmental regulations for the GoM, North Sea and other regions, the high-density, clear brines have a neutral or alkaline pH and approach the densities of zinc bromide and cesium formate, yet they’re free of zinc, formates and solids.

TETRA CS Neptune fluids can be formulated with densities up to 17.5 ppg and can be blended using standard clear-brine equipment. They are stable at elevated temperatures and during storage. The fluids are compatible with most elastomers and metals, pose low risk of corrosion and can be designed to perform at low temperatures and high pressures without crystallization.

(Source: TETRA Technologies)
TETRA CS Neptune fluids are versatile, as they can be formulated as low-solids, reservoir drill-in fluids and reclaimed for reuse using standard equipment. (Source: TETRA Technologies)

DRILLING SYSTEMS WINNER

GYRODATA
OMEGAX SOLID-STATE SURVEYING SYSTEM

(Source: Gyrodata)
The all-attitude, solid-state drop gyro surveying system integrates two independent, three-axis sensor probes. (Source: Gyrodata)

Directional drilling is not always an easy proposition. The challenges inherent in modern wells are many, including multistratigraphic, interbedded rock layers with varying levels of hardness; harsher downhole conditions with higher pressures and temperatures; long laterals and extended-reach drilling applications; and more.

One path to address these challenges involves gyroscopic survey technology. Gyrodata initiated a comprehensive R&D program to develop a solid-state gyroscopic technology that uses an advanced new sensor package to measure the earth’s rotational rate, precisely and accurately determining inclination and true north.

This technology powers the company’s OmegaX system, an all-attitude, solid-state drop gyro surveying system that integrates two independent, three-axis sensor probes. The sensor package and electronics, including memory and data processing, are only 19 inches long, significantly reducing the overall length of the bottomhole assembly. The system can operate to 302 F with no time limitation, making it ideal for use in applications with harsher downhole conditions. OmegaX seamlessly collects surveys during pipe connection, eliminates mass unbalance error and reduces the ellipse of uncertainty by a wide margin versus traditional gyro systems and MWD surveys. 


DRILLING SYSTEMS WINNER

WEATHERFORD
AlphaST SINGLE-TRIP OPENHOLE CEMENT AND SIDETRACK SYSTEM

Weatherford’s AlphaST Single-Trip Openhole Cement and Sidetrack System cements, anchors and drills in one trip. This capability saves days of rig time compared to current conventional whipstock systems that require two trips to kick off a sidetrack.

In one trip, the AlphaST system can convey cement, if necessary, anchor the whipstock and immediately kick off a lateral. Instead of using a cement for sidetracking, the system uses a packer, which eliminates re-cementing and redrilling operations associated with plug failure. The system also enables drilling past a fish, straightening crooked holes and bypassing collapsed boreholes. The system consists of an injection production packer (IPP), which takes the place of a cement plug for anchoring purposes. The IPP anchor enables positioning the lateral departure in the openhole wellbore without the need for a false bottom or cement barrier. The system also incorporates a specially designed flow tube, a low-angle whipstock and a twin-mill drilloff bottomhole assembly (BHA). The flow tube conveys cement to create a barrier in the original wellbore. The single-angle 3-degree whipstock creates a smooth transition into the sidetrack without steps or ledges, which enables the use of drilling BHAs with short-tooth or polycrystalline diamond compact style bits.

(Source: Weatherford)
A lead mill and a flex mill are part of the whipstock assembly and attached to the string with shear bolts. (Source: Weatherford)

EXPLORATION/GEOSCIENCE WINNER

SAUDI ARAMCO
SPICERACK

(Source: Saudi Aramco)
Saudi Aramco used the SpiceRack technology as part of an industry-first experiment using 20 AUVs for seafloor seismic acquisition. The next deployment plans to use 200 AUVs in seafloor seismic acquisition. (Source: Saudi Aramco)

Saudi Aramco’s SpiceRack is a multiyear research collaboration project with EXPEC ARC and Seabed GeoSolutions to design, develop, manufacture and commercialize a highly productive, fully robotized and cost-efficient solution for seafloor seismic acquisition. This type of seafloor acquisition incorporates robotized AUVs for the deployment, recording and retrieval of seismic seafloor sensors.

Conventional seafloor seismic acquisition is using seismic sensors positioned on the seafloor that are either attached to cables/ropes or are cableless nodes. For the cable type deployment and retrieval, multiple vessels are required, making the cost of these type of surveys prohibitively expensive. For the deployment and retrieval of nodal sensors, an ROV is required, increasing the total duration of such surveys and thus increases significantly acquisition costs.

Alternatively, SpiceRack is a disruptive technology that uses robots and automation for the deployment and retrieval of AUVs as seismic sensors. By automating seafloor acquisition, a cost reduction of 30% and increase in productivity of 50% is expected. SpiceRack, by using automation and robots, creates a more efficient and safer operation to produce high-resolution subsurface images.


FORMATION EVALUATION WINNER

HALLIBURTON
EARTHSTAR ULTRA-DEEP RESISTIVITY SERVICE 3D INVERSION

Halliburton’s EarthStar Ultra-Deep Resistivity Service 3D Inversion makes electromagnetic field measurements around the borehole while drilling and converts them into a 3D model of the geological structure using an advanced, mesh-based, computational inversion method. The 3D model of the reservoir allows operators to see a realistic representation of the true reservoir structure, which helps them to make informed well-placement decisions and obtain a far better understanding of the shape, size and productivity of the reservoir. The EarthStar service illuminates and maps reservoir and fluid boundaries, with a proven capability to map these features up to 225 ft from the wellbore, extending the sensitive range up to 10 times farther than was previously possible.

The 3D inversion capability from the EarthStar service will have a significant impact in the E&P industry due to its ability to reveal structural details that would otherwise have been overlooked. (Source: Halliburton)
The 3D inversion capability from the EarthStar service will have a significant impact in the E&P industry due to its ability to reveal structural details that would otherwise have been overlooked. (Source: Halliburton)

FORMATION EVALUATION WINNER

WEATHERFORD
INTELLIGENT CONVEYANCE SYSTEM

(Source: Weatherford)
The ICS is designed to save time and provide detailed information to the surface so clients can make informed decisions. (Source: Weatherford)

The Weatherford Intelligent Conveyance System (ICS) advances autonomy and communication in openhole logging to improve operational outcomes. Designed to convey Compact logging tools to total depth (TD), the ICS applies to horizontal wells, slant rigs and remote locations.

Currently, most openhole logging jobs use a hydromechanical system. Although highly reliable with very few failures and a greater than 95% operating efficiency, the hydromechanical approach lacks two-way communication between the engineer at the surface and the downhole tools. The ICS was designed to provide the same reliability while improving on tool communication and memory capabilities. The ICS uses two-way communication, including drillpipe rotation to communicate to the downhole tools and pressure pulses to reply for the uplink. The other ICS differentiator is the downhole memory sub that acts as a logging robot that autonomously sends out commands to open the caliper, record data, communicate with the surface and mitigate potential fault conditions for more reliable log acquisition. The memory sub divides tasks into two different levels according to the level of intelligence needed. 


HSE WINNER

CRUSOE ENERGY SYSTEMS INC.
DIGITAL FLARE MITIGATION

The Digital Flare Mitigation (DFM) system by Crusoe Energy Systems Inc. deploys modular, mobile, energy-intensive data centers directly to well sites to consume natural gas that would otherwise be wasted through flaring. Scalable to millions of cubic feet per day at each location, the system provides a badly needed beneficial use for associated gas, facilitates regulatory compliance with gas capture requirements and achieves a 30% to 40% reduction in CO2-equivalent greenhouse-gas emissions, plus significant air quality and visual impact improvements versus open flaring. DFM systems are commissioned in a matter of days and can remobilize to new sites as gas volumes decline through well maturation. Relative to other flare mitigation technologies, Crusoe’s system represents a complete and scalable solution for the operator’s associated gas stream that is economically attractive. In many cases, the DFM system is delivered at low or no cost. For projects with sufficient scale, term and supply redundancy, Crusoe can provide gas revenue to operators where no revenue existed before, while simultaneously delivering critical regulatory and environmental compliance value.

Crusoe installed the first DFM system in the Powder River Basin of Wyoming in January 2019 and grew to 10 deployments over the following year. Each of Crusoe’s deployments helps an upstream operator reduce natural gas flaring in the field and simultaneously provides a low-cost energy source for compute processes running in Crusoe’s data centers.

(Source: Crusoe Energy Systems)
Crusoe operates 10 DFM systems across North Dakota, Montana, Wyoming and Colorado. (Source: Crusoe Energy Systems)

HSE WINNER

FRANK’S INTERNATIONAL
RACK BACK CONSOLE

Frank’s International
The Rack Back Console incorporates visual indicators to inform the control panel operator of the current sequential step of the console’s program. (Source: Frank’s International)

To reduce the risk of dropped joints or stands of pipe during rack back operations, Frank’s International has developed the Rack Back Console, a specialized control console designed to control pneumatic elevators and spiders building double, triple or quad stands for racking back in the derrick. Although these programmed functions can be controlled electronically, mechanical programming with pneumatic logic allows working on the rig floor without the need for costly hazardous area certifications. The Rack Back Console programming will allow only the correct tool (elevator or spider) control valve to be activated at each operational step of the tubular stand building process, thereby preventing the tool from being activated out of operational sequence. The Rack Back Console automatically resets each stand building cycle based on the number of steps required to complete a double, triple or quad tubular stand. It also includes both run and pull modes for building and laying out stands. This feature allows the operation sequence to be reversed in the event the tubular stand must be disassembled.

The Rack Back Console was first successfully deployed in January 2019 to rack back a variety of stands on a multiwell project for a major operator on a dual-activity drillship in the Gulf of Mexico. The Rack Back Console successfully ran more than 180 stands with several wells.


HYDRAULIC FRACTURING/PRESSURE PUMPING WINNER

BJ SERVICES
THINFRAC MP FRICTION REDUCER

(Source: BJ Services)
The molecular structure of ThinFrac MP allows a clean, efficient break with little to no formation or proppant pack damage. (Source: BJ Services)

BJ Services’ ThinFrac MP friction reducer is a fluid solution for the effective extraction of hydrocarbons from unconventional reservoirs. It is designed to provide pumping efficiency, complex fracture networks and precise breakability to increase production and improve operational efficiencies.

ThinFrac MP is a cost-effective polyacrylamide polymer friction reducer with superior proppant-carrying properties. This synthetic engineered polymer provides rapid hydration in 8 to 10 seconds, delivering instantaneous friction reduction. Due to its viscoelastic properties, it provides superior proppant transport capabilities in slickwater fracturing operations to deliver the proppant to the fractures. Because of its high molecular weight and rapid hydration, it delivers greater pipe friction reduction at lower loading.

Operators have seen as much as 85% reduction in pipe friction pressure, which has proven to lower hydraulic horsepower and surface equipment requirements. The polymer friction reducer is compatible with freshwater, brines and low-pH fluids.


HYDRAULIC FRACTURING/PRESSURE PUMPING WINNER

NINE ENERGY SERVICE
BREAKTHRU CASING FLOTATION DEVICE

Nine Energy Service
 (Source: Nine Energy Service)

Nine Energy Service’s BreakThru Casing Flotation Device is a technologically advanced barrier designed to float casing across long lateral runs to the toe of the wellbore.

BreakThru works by running casing to a predetermined depth based on wellbore modeling using two fewer connections and two fewer thread sets than conventional casing flotation devices. Then fluid is pumped into the casing above the barrier, creating the force necessary to push the casing all the way to target depth.

Once the casing is fully landed, additional fluid accumulates until it reaches the activation pressure needed to disintegrate the barrier into fine, sand-like particles.

These fine particles are easily circulated out through sleeves, toe valves and float equipment, eliminating the need for a debris trap, fluid flushes or extra trips to retrieve device pieces.

As a result, operators can begin pumping cement immediately, saving time and generating increased efficiencies. BreakThru’s durability provides a reliable seal under the extreme temperatures and axial loads encountered during run-in, yet reliably shatters once the casing is landed. 


INTELLIGENT COMPONENTS WINNER

HALLIBURTON
IMERSIV AUGMENTED AND VIRTUAL REALITY SOLUTIONS

Conventional offshore rig site surveys typically take weeks. With the new Imersiv Augmented and Virtual Reality Solutions from Halliburton, operators can save at least two days of rig time and improve the accuracy of rig surveys and audits for offshore solids control and fluid management. Using a Microsoft HoloLens, users can digitally overlay precise 1:1 scale 3D models of equipment onto existing physical rig spaces while concurrently performing high-resolution scans of the respective rig space and access routes. This combination delivered by Imersiv Augmented and Virtual Reality Solutions enables users to promptly identify obstacles that can impede installation and ensure the selected equipment conforms to the operator’s rig design and processing requirements in real time, increasing levels of confidence. Survey experts no longer have to travel across time zones to a rig, which could add days or weeks of nonproductive time (NPT) and significant cost overruns. Now these same specialists can provide remote survey assistance to multiple operations in different parts of the world, without ever having to leave their office. The end result is lower operating costs, reduced headcount, less NPT and lower risk.

(Source: Halliburton)
The scanned equipment is loaded into an application on the Hololens and can be accessed through voice or gesture commands. Users can then manipulate and place 3D holograms of separation equipment in real space, with all clearances virtually measured to help ensure optimal placement. (Source: Halliburton)

INTELLIGENT COMPONENTS WINNER

SIEMENS
ADDITIVE MANUFACTURING FOR FOSSIL-FREE COMBUSTION IN GAS TURBINES

Source: Siemens
AM enables the design of gas turbine components in support of the decarbonization of the oil, gas and power generation industries. (Source: Siemens)

As a fuel source, hydrogen is well positioned to meet the market demands for low-emission gas turbines with dry low emission (DLE) combustion systems. The turbines incorporate the latest generation of DLE burner, which efficiently burns hydrogen or hydrogen/fuel gas mixes to lower CO2 and NOx emissions. In recent years, the development effort has been accelerated by incorporating additive manufacturing (AM) techniques to enable rapid design, prototyping and manufacturing. Prototypes produced by AM are delivered faster than by conventional manufacturing, which makes testing of different components more efficient and reduces testing and development time by as much as 75%. AM also delivers 60% faster repairs of components like burner tips, 40% to 50% lower lead times for spare parts and complete burner sets, and an essentially limitless flexibility in the design of new parts.

Siemens’ medium-size gas turbines run on a wide range of fuel specs. The model SGT-800 gas turbine runs with up to 50 vol-% H2 in the fuel mix, the SGT-700 with up to 55 vol-% H2 and the SGT-600 with up to 60 vol-% H2. The ultimate goal of delivering a 100 vol-% H2 is closer to realization, thanks to promising test results of a single burner operating on 100 vol-% H2 in Siemens Clean Energy test center in Berlin.


INTELLIGENT COMPONENTS WINNER

U.S. WELL SERVICES
POWER PATH

U.S. Well Services’ (USWS) PowerPath provides 13,800-volt electrical power to remote pads that can be several miles away from the turbine generator. This advancement in technology allows the turbine to rig into one location and feed the electricity to multiple pads using a micro-grid, therefore decreasing the mobilization time between pads. This micro-grid and centralized location for the turbine also eliminates the need for each pad from having existing field gas pipelines to it before the wells are stimulated or having to truck CNG or LNG to each location during the frac job. PowerPath is not limited to only frac operations. Operators can utilize PowerPath to power other oilfield equipment such as drilling rigs when developing acreage within a concentrated area. USWS first deployed the PowerPath technology in June 2019 to successfully provide power to a remote hydraulic fracturing operation 2.5 miles away. The technology allows power generation to be centrally located among five hydraulic fracturing pads and to transmit power miles away via overhead lines to onsite Clean Fleet pumping equipment. Utilizing high-voltage electricity allowed the power to be sent multiple miles without power losses that come from low- and medium-voltage systems. 

(Source: U.S. Well Services)
U.S. Well Services’ PowerPath system shortens the mobilization time between pads and eliminates the need to run gas lines to each pad prior to the fracturing job. (Source: U.S. Well Services)

INTELLIGENT SYSTEMS WINNER

BEDROCK AUTOMATION
BEDROCK OPEN SECURE AUTOMATION

Source: Bedrock Automation
The Bedrock OSA product family provides high-performance PLC, RTU, DCS and EFM capabilities augmented with the built-in cybersecurity and communications necessary to remain competitive in the digital age. (Source: Bedrock Automation)

Bedrock Open Secure Automation (OSA) is a high-capacity control system with built-in cybersecurity. The authentication and encryption capabilities that had previously been available only in military and aerospace electronics are embedded into Bedrock’s control system platform. To overpower this digital  efense-in-depth, rogue code would have to pass through numerous authentication and encryption steps occurring in real time on all parts of the system electronics. This is not a practical possibility. The modules are further protected against cyber intrusion by encasement in sealed anti-tamper metal and a pin-less backplane, which also delivers extreme electromagnetic and thermal hardening for real-world reliability. OSA encompasses PLC, RTU, DCS and EFM capabilities, but it augments them with the cybersecurity and higher performance necessary to remain competitive. By making security built-in, Bedrock OSA has removed the cost of cybersecurity as a barrier to deploying IIoT architectures.


INTELLIGENT SYSTEMS WINNER

DATA GUMBO CORP.
GUMBONET

Data Gumbo Corp.’s GumboNet blockchain-based network automates smart contracts and transactions for industry leaders by utilizing the combination of distributed ledger technology with contract terms confirmed with operating field data. In providing a single, industry-agnostic immutable record of truth across participants, GumboNet solves long-standing issues of trust and data inaccuracies to reduce barriers associated with doing business. By forging trust between stakeholders, automating transactions and mitigating contract leakage, GumboNet is significantly changing how businesses transact. Old World business methodologies often include processes modeled on paper trails, isolated corporate views, rigid IT infrastructure, siloed systems, enterprise resource planning and transactional friction. With Data Gumbo, this approach is replaced by operational transparency, contractual flexibility and frictionless transactions. As a simple, intuitive and subscription-based blockchain network, companies are freed from building and sustaining standalone, siloed blockchain technologies that require resources and continuous oversight.

Data Gumbo Corp.
GumboNet has been adopted for a water haulage pilot program by the Offshore Operators Committee Oil & Gas Blockchain Consortium. (Source: Data Gumbo Corp.)

IOR/EOR/REMEDIATION WINNER

SAUDI ARAMCO
NANO-ENCAPSULATED RESERVOIR CHEMICAL TREATMENTS

(Source: Saudi Aramco)
Nano-surfactant is persistently stable in high salinty and temperature. (Source: Saudi Aramco)

More than 50% of hydrocarbon resources in subsurface reservoirs are unrecoverable by current operations. Chemical EOR is one of the most promising and widely studied methods to help recover remaining hydrocarbons. Successful EOR formulations need to be low cost and accessible
at large quantities.

Saudi Aramco has developed a nano-surfactant technology that offers a one-step highly economic process for stabilizing and target-delivering hot brine-incompatible surfactants. The developed nano-encapsulation technique extends the use of a large variety of reservoir chemical treatments that are otherwise inoperative in high salinity and temperature reservoirs. At the same time, it improves their performance and depth of penetration as well as reduces the amount of chemicals needed without affecting performance. The method was inspired by formulations widely used in nanotechnology for medicine and successfully translated into the oil field by a multidisciplinary team of scientists and engineers. Studies demonstrated that this method of nano-encapsulation of surfactants represents one of the industry’s first formulations that can be scaled up and synthesized in the field, can be used for various applications in reservoirs with various salinity and temperature brines, and provides high-efficiency mobilization of the remaining oil.


IOR/EOR/REMEDIATION WINNER

WELL-SENSE
FIBERLINE INTERVENTION SYSTEM

WELL-SENSE
The FLI technology can contain single-point sensors in its probe to deliver “active” real-time measurements that complement the distributed sensing. (Source: Well-SENSE)

Well-SENSE’s FiberLine Intervention (FLI) System is designed to deliver faster, smarter well intelligence. The technology has demonstrated efficiency gains and the rapid acquisition of high-quality, richer downhole data compared to conventional wireline methods. FLI is a self-contained, portable system using a pressure containing “launcher” connected to the wellhead. It deploys the probe into the well, which lays bare optical fiber to total depth. The fiber gathers instant, distributed data simultaneously across the entire length of the fiber-optic cable. Temperature and acoustic profiles can be captured, plus any changes over time, resulting in a rich picture of the complete well. As it does not rely on wireline, slickline or coiled tubing for deployment, results are obtained faster, more economically, using less personnel with reduced wellsite personnel on board, footprint and operational risk. FLI operations on average can take up to 3 hours of logging, compared to up to 24 hours for single-point wireline logging.

Just one Well-SENSE engineer is required to transport and operate FLI. Its lightweight, compact size means it is delivered to the well site in the back of a truck or via a small shipping box. This opens up new opportunities, allowing operators to acquire data from more challenging, less accessible wellsite locations, such as unmanned offshore satellite platforms with little or no deck space.

As a plug-and-play system, FLI is ready for rapid implementation. It takes just one person about 30 minutes to an hour to rig up, while rigging down is almost immediate. The probe is sacrificial or retrievable depending on the client’s preference. Compared with onshore data acquisition in the U.S., FLI could offer up to 50% to 75% cost savings, whereas this can potentially reach 90% in the offshore environment, depending on the application.


MARINE CONSTRUCTION & DECOMMISSIONING WINNER

SCHLUMBERGER
CEMFIT HEAL FLEXIBLE SELF-HEALING CEMENT SYSTEM

Schlumberger’s CemFIT Heal flexible self-healing cement system helps ensure well integrity from drilling to abandonment, providing a competent annular pressure seal and protecting against hydrocarbon leaks and sustained casing pressure (SCP). Using the CemFIT Heal system eliminates SCP at the construction phase and minimizes risks and operational challenges at decommissioning. Conventional cement systems expand after setting only in the presence of water coming from the formation; however, these systems cannot self-heal subsequently if the cement matrix is damaged. The CemFIT Heal system heals upon interaction with hydrocarbons, improving cement bonding and sealing
micro-annuli that can cause unwanted gas migration. A low Young’s modulus enables it to withstand cement sheath stresses from drilling, perforating, stimulation treatments, and temperature and pressure changes, which help prevent cement sheath failure.

SCHLUMBERGER
Conventional offshore well cement barriers (left) can develop cracks and micro-annuli after pressure changes and other stresses. The CemFIT Heal system (right) responds to any contact with oil or gas by automatically repairing and sealing itself, eliminating SCP and adding options to simplify plug and abandonment. (Source: Schlumberger)

SUBSEA SYSTEMS WINNER

SCHLUMBERGER
CASING RECONNECT METAL-TO-METAL, GAS-TIGHT CASING REPAIR SYSTEM

SCHLUMBERGER
The Casing Reconnect system eliminates sidetracking and fishing operations, keeping drilling programs on schedule. (Source: Schlumberger)

Schlumberger’s Casing Reconnect Metal-to-Metal, Gas-Tight Casing Repair System is a cost-effective remediation system for well operations. The system seamlessly replaces stuck or damaged casing and provides a robust seal for the life of the well, keeping drilling programs on schedule and securing well integrity for plugging and abandonment operations. The Casing Reconnect system enables cutting and pulling casing anywhere between the wellhead and the stuck point. Replacement casing is then run with a Casing Reconnect system to the receptacle on the bottom—correctly spaced out with the casing hanger. The casing stump is then morphed into the Casing Reconnect system receptacle to rejoin the two strings with a high axial-load-bearing, metal-to-metal seal. The system accommodates excess swallow at the connection, simplifying space out for correctly landing the hanger. The system is ISO 14310 VO-rated and contains no moving parts. The full-axial-load-bearing reconnection tool uses Metalmorphology metal-to-metal sealing and anchoring technology.


SUBSURFACE COMPLETIONS WINNER

DEEP IMAGING
DEEP IMAGING REAL-TIME FLUID TRACKING

E&Ps were successful at developing highly productive well designs and then inadvertently spaced them too closely together. Despite technological advancements, teams can’t precisely evaluate how much rock was treated during a frac, nor can they effectively identify completions issues and whether they were successful in mitigating them. Deep Imaging offers a real-time system for tracking fluid as it’s pumped through the wellbore and out to the fracture tips during a completion job. While seeing stages form in real time, operators are validating models and successful stages while identifying, fixing or avoiding problem stages as they occur. By spotting issues at inception, companies are reducing waste and boosting well productivity. Lookback efforts to improve well models are important, but well inventories are too valuable to make adjustments solely on the next well. In one example, a customer discovered how to save up to $1 million on future wells by reducing the number of frac stages per well without impacting performance.

DEEP IMAGING
With the fluid tracking system, deployment does not require access to the well pad. A current is transmitted that creates an electromagnetic (EM) field in the subsurface. During a frac stage, the injected fluid alters the EM field, which is measured at the surface. (Source: Deep Imaging)

WATER MANAGEMENT WINNER

SAUDI ARAMCO
ACOUSTIC OIL-WATER-FINES SEPARATION

SAUDI ARAMCO
The Acoustic Oil-Water-Fines Separation concept separates oil and fines simultaneously with no flow intervention or pressure drop. (Source: Saudi Aramco)

Saudi Aramco’s Acoustic Oil-Water-Fines Separation system separates minute amounts of small oil droplets and solid particles from flowing fluid streams without intervention. The three-phase separation technology can be used to reduce the volumes of water produced from mature oil and gas reservoirs and pumped to the processing plants by several orders of magnitude. It reduces the costs for pumping and treating massive volumes of produced water as well as the health and environmental hazards associated with handling large volumes of produced water. Because of its ability to separate minute volumes of oil and particles, the technology can be utilized in treating produced water prior to injection into the disposal wells, reducing the risk of contaminating groundwater aquifers. The acoustic separation tool increases the oil-to-water ratios in producing wells and also reduces the risk of pore clogging and formation contamination should water be reinjected back in the formation. The tool also can be utilized as a surface separation system to reduce the volume of produced water prior to reaching the gas-oil separation plant (GOSP), thus costs of reconfiguring the GOSP to accommodate increased water cuts.


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