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Vol. 224 No. 12 |
Oil/water separation
The Enviro-Cell induced gas flotation machine from Enviro-Tech Systems is new technology for the separation of oil and water. The design combines an inlet skimming section for removal of large free oil droplets, followed by four active cells, each having multiple eductors for small particle removal, followed by a quiescent cell at the outlet for residual oil removal. The design incorporates a reduced recycle rate with an increased recycle discharge pressure, allowing for a full 5 minutes retention time (including recycle) at design capacity. Adjustable oil weirs are provided in each compartment to eliminate the need to rotate wiper system for oil skimmings removal. The cylindrical vessel design reduces corrosion and provides a 95 – 97% removal efficiency.
3D seismic processor
 Landmark Graphics Corp. released ProMAGIC Server, an integration software product that creates an interpretive 3D seismic processing environment. It connects the visualization speed and precision of the GeoProbe volume interpretation system with the processing power of the ProMAX 3D seismic processing system. Developed in collaboration with BP, ProMAGIC Server enables ProMAX 3D seismic processors to leverage the volume visualization environment of GeoProbe to achieve greater analysis speed, more accurate parameter selection, and more rapid quality control for large data sets than is possible with traditional processing methods.
Thermoplastic gauges
New industrial process thermoplastic pressure gauges from Swagelok monitor vacuum and positive pressures up to 15,000 psi in the petrochemical and oil and gas industries. With dial sizes of 115 and 160 mm (4-1/2 and 6 in.) in lower-back-mount and lower-mount configurations, the gauges can be ordered with male NPT or tube adapter end connections, which allows users to rotate the gauge for optimum viewing. Available unfilled or liquid-filled with glycerin or silicone, they feature a turret-style design and blowout back for severe service.
Drawworks
 The LeTourneau Ellis Williams Company added the LEWCO 3000 drawworks to its line of heavy-duty oilfield equipment and components. Designed for up to 3,000 input hp and drilling depths up to 30,000 ft, the drawworks features a two- or three-motor drive system that can be either variable-frequency AC or SCR-controlled DC. Both the low-drum and high-drum drive clutches use the same PO-336 plate-type clutch for interchangeability and reduced parts-stocking; and they’re mounted one shaft behind the main drum shaft for reduced weight and easy access and maintenance. The 3000 has a robust disc braking system featuring hydraulically applied service brake calipers as well as spring-actuated emergency/ parking brake calipers.
Production BOP
Double-E, a producer of oilfield tools for production and wireline operations, offers a versatile blowout preventer featuring two-piece rams that can shut down a well even if no rod is in the hole, or with rod sizes up to 1-1/2 in. in diameter. The LP-15’s ram system features a pin-and-socket design combining a rubberelement and a ductile iron plate. This arrangement resists upward pressurethrusts and avoids the separation failures that sometimes occur with bonded assemblies. O-ring sealed, the BOP promotes quick ram and rubber replacements and fulfills low-pressure control requirements for pulling rods or sealing polished rods. At 41 lb and 9-1/2 in. high, it is available in standard thread connections and combinations. Options include handles and special elastomer rams.
Composite Mat System
 The DURA-BASE Interlocking, high-density polyethylene (HDPE) mats from SOLOCO LLC improve production by increasing access to remote locations and wetlands. The 1,050-lb (477-kg) mats measure 8 ft x 14 ft (2.44 m x 4.27 m).
First deepwater subsea all-electric intelligent system
 After a five-year development project involving Baker Oil Tools (BOT), Baker Atlas, Petrobras and Quantx, a joint venture company between Expro International and Baker Hughes, BOT installed the world’s first deepwater subsea all-electric intelligent well completion system for Petrobras in the Marlim Sul field in Campos basin offshore Brazil. The system, trademarked InCharge, was installed from a DP drilling rig in 3,832 ft of water and is permanently tied back to the Petrobras’ P-40 floating production vessel via a 3.7-mi umbilical. The system can be monitored from any point within Petrobras’ internal network.
The InCharge system monitors real-time measurements of downhole pressure, temperature and flow in both the tubing and annulus. Petrobras is using the system to remotely monitor injection of 15,000 to 20,000 bpd of water into the 8-MLS-67HA-RJS well and its distribution between two discrete intervals. The system as deployed includes a cable by-pass expansion joint, retrievable feed-through packer, two flow measurement units, dry-mateable connectors, a single TEC line for power and communication, supervisory surface control system, and two Intelligent Production Regulators.
Petrobras is using Baker Oil Tools’ InCode software to monitor and control the system’s downhole devices, which include eight QuantX quartz pressure sensors for monitoring tubing and annulus pressure at the IPR valves and internal pressure at the flow measurement units.
Following rigorous tests in Houston, the system was deployed and commissioned in 2001 in a land-based injection well, then remotely controlled and monitored through a satellite link from a Baker Oil Tools surface control system computer located at Petrobras’ operational base in the city of Natal, 165 miles from the well site. After 11 months of operation, the system was retrieved from the land well, then installed in August 2003 in the Marlim Sul well.
Dopeless liner string run for the first time offshore
 TenarisConnections completed the successful running of the 5-in., 32 ppf, Q125 TenarisBlue Dopeless liner string on ConocoPhillips’ Ekofisk X50 well in Norway. The string was made of multiple connections, with two sections of TenarisBlueDopeless. This is the first time that a Dopeless connection has ever been run at an offshore location. The goal was to carry out a reliable and efficient operation with minimum impact on the environment, and the liner was well suited with its performance characteristics and the opportunity to eliminate pipe dope from the tubular column and from the drill floor, reducing operational, environmental and safety risks.
Why do casing and tubing need thread compound? With multiple connections, greases seal the voids between the threads, preventing leaks, and protect the thread from corrosion during shipping and storage. They also lubricate the metal surfaces in contact during make-up and breakout. Eliminating thread compound requires solutions for these three functions. Premium connections rely on metal-to-metal seals and thread compound to seal liquid and gases, both inside and outside the connection. TenarisBlue was designed with a metal-to-metal seal that is gas-tight in every possible load case without requiring thread compound as a secondary seal. The connection has been tested in several sizes according to ISO 13679 CAL IV, which requires that the dope be degraded by heating the connection to 180°C for at least 12 hr, ensuring that the only remaining seal is metal-to-metal.
Casing and tubing often remain in stock for months before use, so operators request a storage dope on the field end (pin and coupling) to prevent corrosion. Not applying dope means that the threads are exposed for months to corroding agents like water or oxygen. Then, during connection make-up and breakout, thread and seal surfaces slide while being subjected to high contact pressure, requiring an effective lubricant to prevent galling. With TenarisBlue Dopeless, a dry lubricant is applied at the mill. No storage dope is used, improving cleaning, inspection and eliminating thread compound disposal.
Ekofisk – pre-job preparation. Tenaris trained the crews assigned to cleaning, inspection and running activities as well as the drilling contractors on the TenarisBlue Dopeless concept. As a rehearsal for the final installation, Tenaris performed a “make-and-brake” test at the Weatherford facility in Tananger with pipes from the stock in two different conditions: as shipped, and after cleaning and inspecting. After five make-and-brake operations, with a maximum torque of 33,400 ft-lb, the connections were in excellent shape. Also, this allowed the cleaning, inspecting and running crews to have hands-on experience prior to rig operations.
All equipment was set up at Weatherford’s base, where a simulation was performed, to test the new gear and communication between offshore and onshore. Running crews were also trained in the use of a new tong with automatic stabbing guides.
Offshore operation. The first joint was run July 26. The crew became comfortable with the connection and running procedures after only a few make-ups, and a running speed of up to 12 joints per hour was achieved on this particular rig with automatic handling equipment. The make-up torque was taken from 18,000 ft-lb (standard for this connection) to 25,000 ft-lb, based on expected maximum rotation torque, by ConocoPhillips.
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