The oil and gas equipment represented by the 10,000-meter truck-mounted workover rig has been launched one after another, helping oil and gas exploration and development to march into deeper formations.
Recently, the newly developed XJ2750 10,000-meter truck-mounted workover rig of SOFE successfully completed several tests and was put into use in well 5-5H of Shunbei Oil and Gas field, successfully filling the gap in the field of ultra-deep workover operation equipment, marking the level of China's well workover project technology and equipment into the era of 10,000-meter deep wells.
In recent years, deep-formation, deep-water, unconventional oil and gas exploration and development has gradually become mainstream, which puts forward higher requirements for oil and gas equipment. Ultra-deep oil and gas wells more than 9,000 meters deep have high pressure and temperature at the bottom of the well, which makes exploitation difficult. Without excellent well workover equipment, oil and gas wells will not be able to resume production in a timely manner, and the overall economic benefits of oil and gas exploration and development will not be guaranteed. SOFE is doing what it needs to do, building up a solid foundation for realizing high-quality exploration and development by continuously making its strength in the field of well workover equipment.
Innovation
Improve and strengthen well workover equipment technology
Oil and gas wells may fail at any time during the production process, resulting in a reduction in production or even a shutdown. At this time, it is necessary to use workover equipment for tripping drilling tools in/out, cleaning well bore, repairing wellhead device, etc., to ensure the smooth progress of oil and gas extraction.
The C series workover rig developed by National Oilwell Varco (NOV) is represented by a self-propelled or trailer-mounted chassis structure, with a maximum hook load of 57~181 tons, and the whole structure is light, user-friendly and easy to operate and maintain, and can achieve fast transportation and installation, but at the same time, there is a long delivery time and high price Improving operation capacity can not meet the needs of deep well operation.
In the face of the bottleneck problem, domestic enterprises(SOFE, RG), after years of technological accumulation and innovative development, completed the transformation of the research and development of workover equipment from 0 to 1, from 1 to N, and the technical level has been continuously improved, and the product series has been continuously improved, and now it has realized the overall parallelism with multinational companies, and has reached the international leading level in grid electric storage energy electric drive workover rig, ultra-deep well workover rig, and wellhead pipe column handling equipment.
"Scientific and technological innovation should have a technical base and underlying logic, and can't fight alone and go about several tasks at a time. For SOFE, it is to focus and concentrate on the development of ultra-high-pressure structure technology, ultra-high-hard material technology, ultra-high-energy control technology, and ultra-high-precision manufacturing technology, to accelerate the development of the new quality productivity, and to make the characteristic advantages." Wang Junqiao(President of SOFE) said.
Over 40 years of deep cultivation, SOFE has gone through the introduction of technology, digestion, absorption and independent research and development, and has run out of "acceleration" on the workover equipment track. Especially since the "14th Five-Year Plan", under the support of the "Four-super" technology, SOFE has earnestly practiced the national digitalization strategy and greening strategy, set up a cross-disciplinary R&D and innovation team to maintain the advantageous structure of the well dressing machine as the goal, and overcome the integration of the workover rig for transportation, with the goal of maintaining the advantageous structure of the workover rig, SOFE has overcome the problems of the integration of the workover rig, the large offset of the crown block, the difficulty of the integration of the carrier, etc., and has developed the equipment that is fast for transportation and disassembling and efficient and economical for operation, so that the workover rig can develop to a bigger hook load and higher power, and has continuously expanded the new functions of the automated workover equipment from the traditional diesel drive to the hybrid oil-electric and full-electric-drive, from the conventional multi-people operation to the unmanned and automatic pipe handling at the wellhead, and from the configuration of the multi-functional module to the one-piece high-efficiency integration package, constantly expanding the new functions of automated well repair equipment and polishing the intention of "intelligent and low-carbon".
"In the deeper, more ancient layer system to find resources strategic succession area, is China's oil and gas industry to ensure energy security of the inevitable choice, ultra-deep extra-deep layer has become China's oil and gas major discovery of the main position. To better serve the 'deep earth project', well repair equipment development and manufacturing must keep up." SOFE well workover equipment R & D head Li Zhe said.
Adhering to such a belief, SOFE has sped up the pace of research and development, XJ900 full-electric-drive workover rig, XJ900 grid energy storage workover rig, XJ1350DB and XJ1600DB full-electric-drive workover rig, XJ2750 10,000 meters of truck-mounted workover rig, and so a number of the first in the country, the world's first workover rig have come out, to help improve the quality of workover operations and upgrade the development of oil and gas exploration and development to the deeper stratum.
Pursuing
Forging a sharp weapon for ultra-deep oil and gas development
In recent years, the energy central enterprises represented by Sinopec and CNPC have made many major breakthroughs in the exploration and development of onshore ultra-deep oil and gas in China, and led China's ultra-deep oil and gas exploration and development to walk in the forefront of the world.
Sinopec Shunbei Oil and Gas Field is a rare ultra-deep oil and gas reservoir in the world. The average buried depth is more than 8,000 meters, and the deepest well is more than 9,300 meters. With the further development, many oil and gas Wells with a depth of 8,000 meters are faced with workover problems Under the condition that the maximum hook load capacity of traditional workover rig is insufficient, Northwest oilfield is forced to adopt the mode of module rig workover. Although it can meet the requirement of workover, it has long moving period and high operating cost and high safety risk.
SOFE aimed at the technical gaps in ultra-deep oil and gas well workover operation equipment, and set up a research and development team with 15 people as the core. Through adequate technical preparation and field practice, it continuously enhanced the function of well workover equipment to improve operational efficiency and safety.
The overall development plan of ultra-deep well workover rig is the key to the success of equipment research and development, and the top-level design must be done well.
Since July 2022, SOFE R&D personnel have been stationed at the workover operation site of Shunbei Oil and Gas Field, focusing on field research, determining the key input conditions and main technical parameters of equipment, and on this basis, developing 12 kinds of ultra-deep well workover overall plans, and organized cross-professional personnel to review several times within the company, selected 5 better plans, and then organized oilfield field experts and operator of the well site to review together and finally selected the solution that everyone agrees is the most suitable.
Although the final solution is theoretically optimal, it is not easy to realize. Not only to ensure that the load of the well workover rig is greatly increased, but also to realize the fast disassembling and transportation of the well workover rig, how can we "get both the fish and the bear's paw"? The SOFE R&D team has given the answer with actions.
After more than 11 consecutive months of scientific research, in July 2023, the world's first 10,000-meter truck-mounted workover rig was developed: the maximum carrying capacity of the eight-axle heavy-duty chassis reached 104 tons, which was 14.29% higher than the seven-axle chassis of the conventional workover rig, solving the integration and transportation problems; the first set truck-mounted drawworks with maximum fastline pull, to achieve a high-power drawworks capacity increased by 22%, weight increased by only 3.4%; the input torque of the high-torque power transfer case is 10626N.M, which is nearly 10% higher than that of the conventional device; The 41-meter large-load mast, with overall dimensions, weight and operational crown block displacement comparable to that of conventional equipment, can be moved and transported in an integrated manner with the workover rig; the modules of the 8-meter heavy-duty high-clearance substructure are limited to two, which makes disassembling and transportation convenient, and the disassembling and transportation time can be controlled in less than three hours.
In order to fully verify the design performance of the new workover rig, the R & D team also independently developed matched test fixtures to complete system verification before delivery to ensure the on-site reliability of the equipment.
In September 2023, the 10,000-meter truck-mounted well workover rig started industrial test in 5-5H well of Shunbei Oil and Gas Field, and was then formally put into production and application. Four modules of the complete set of equipment were transported to the well site, and the on-site installation and commissioning were completed in only six hours, and the 8,200-meter well depth sidetrack drilling and workover operation was completed within 10 days, with good results of use.
Following the actual demand, SOFE has sped up the application of research and development results, tailored to the characteristics of the workover equipment, can produce the maximum hook load of 60 ~ 275 tons, the workover depth of 500-10,000 meters of a full range of truck-mounted operating equipment, production and manufacturing of automated workover, 10,000 meters of ultra-deep wells workover rig, green energy workover rig, desert workover rig, offshore workover rig, no guyline and self-tightening guyline workover rig, double fastline workover rig and other characteristics of the equipment has been widely used in the domestic and foreign oilfield field site.
Equipment Highlights
l Advanced Core Technology
Applying advanced core technologies such as integrated high-efficiency transportation, eight-axle cross-country heavy-duty chassis, high-power lightweight drawworks, high-power power transfer case, heavy-load mast, crown block displacement control and heavy-duty high-clearance substructure.
l Features
Equipped with automated equipment such as power catwalks and BOP handling unit, it is characterized by fast disassembling and transportation, high equipment integration, low labor intensity, and economical and efficient operation.
l Maximum capacity
With a maximum hook load of 275 tons, an installed power of 1,320 hp, a heavy-duty chassis load of 103 tons, and a clear height of 41 meters mast is able to meet the demand for heavy-duty operation of 10,000-meter ultra-deep wells, the largest truck-mounted workover rig in China with maximum operating capacity.
