Weir公司Seaboard组合式锁环(ULR)井口装置：工程始于对话
真正的创新不是在真空室中完成的。Weir公司工程师的设计流程包含了与每个人(包括客户，制造和供应链专家)的协作对话沟通。这种方法使我们可以在实施之前在纸面上解决客户痛点。在这个过程中，我们终设计出了客户真正满意的解决方案。
Seaboard™组合式锁环(ULR)井口装置是三部分网络系列的主题。在倾听客户意见时，我们了解到他们大的问题是安全性、时间和成本。因此我们从头开始建立一个井口装置，以直接解决这些问题。
在该井口装置到达现场之前，Weir在制造方面的协作和精简方法可以利用并行开发路径来优化效率。从设计到现场交货的时间通常约为12周，比传统井口装置快6个月。
在安装过程开始之前，我们团队仔细研究了传统井口装置的运行程序。首先，安装下一个之前需要拆卸防喷器(BOP)，然后必须重新连接，且每个法兰连接需要三到四个小时。另外，操作人员还必须等待水泥干涸，才能将BOP提升并移动到下一个井口设备，手动设置滑动和修整外壳以匹配下一个阀芯。单这个过程可能就需要长达18个小时。
这个过程不仅耗时，而且很危险，需要在一个不稳定的环境里进行火焰切割，焊接和研磨。时间越长，对人员和资产来说风险就越大。我们的目标是简化安装，减少这些耗时的过程以及随之而来的风险和成本，这是ULR能实现的操作性三重技术。
首先，ULR在单件式外壳内采用了嵌套式系统，缩短了整体堆叠高度，减轻了重量，使安装更容易，安装风险更小。技术人员可以使用心轴套管悬挂器，在不需要切割、焊接或研磨的情况下，通过旋转工作台和防喷器来运行、着陆、循环和粘接套管。内部锁定密封组件消除了传统井口设备上的多个泄漏路径。
另一个提高安全性的策略是，Weir在寻找方法减少工作人员暴露在危险环境中的时间。内部锁环组件和油管挂可为每套管柱节省6-8小时。通过快速连接的集线器，操作员可以比传统的法兰连接更快地将井口上的防喷器对准，着陆和固定，安装时间从2小时减少到30分钟以内。另外，在恢复操作之前不再需要等待水泥干燥。
显然，减少操作时间可以缩减相关的劳动力成本。钻井时间的一天可以为井口付出代价，另外，通过降低风险，还可以�；ぐㄈ嗽痹谀诘谋笞什馐侵刂兄�。
在ULR这个案例中，Weir充分听取了客户的意见，并提供了降低总体拥有成本的解决方案。接下来，我们将深入探讨这个更安全、创新、节省时间的井口设备的特点。
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注：该文章由鼎恒石油编译，转发须注明出处。
附英文原文：
The Unitized Lock-Ring Wellhead: Engineering Begins with Conversation
True innovations don’t happen in a vacuum chamber. At Weir, our engineers make it part of the design process to collaborate with everyone—customers, manufacturing, and supply chain experts included. This approach allows us to address pain points on paper before they become reality. In the process, we engineer real-world solutions customers really appreciate.
Take the Seaboard™ Unitized Lock-Ring (ULR) wellhead, the subject of this three-part web series. In listening to customers, we learned their biggest issues are safety, time, and cost. So we built a wellhead from the ground up to directly address those issues.
Before the wellhead even arrives on site, Weir’s collaborative and streamlined approach to manufacturing leverages parallel development paths to optimize efficiency. Time from design to field delivery is typically about 12 weeks—six months faster than what’s required for a traditional wellhead.
And that’s before the installation process even begins. As a team, we took a hard look at running procedures on traditional wellheads. For the BOP, removal is required to install the next stage. Then it must be reconnected, with each flange connection taking three to four hours. Operators also have to wait for cement to dry before lifting the BOP up and off the next wellhead, manually setting slips and trimming casing to match the next spool. This procedure alone can take up to 18 hours.
Not only is the process time-consuming. It’s dangerous, requiring flame cutting, welding, and grinding in a volatile environment. The longer it takes, the greater the risk to personnel and assets. Our goal was to simplify the installation, eliminating these time-consuming procedures, along with the attendant risks and costs—an operational trifecta achieved with the ULR.
First off, the ULR features a nested system within a single-piece housing, resulting in an overall shorter stack-up height and reduced weight—making access easier and installation less risky. With mandrel casing hangers, technicians can run, land, circulate, and cement the casing through the rotary table and BOP with no cutting, welding or grinding required. An internal lock-down seal assembly eliminates the multiple leak paths found on traditional wellheads.
As another strategy for improving safety, Weir looked for ways to limit the amount of time workers are exposed in this dangerous environment. The internal lock ring assembly and mandrel hangers can save 6-8 hours per casing string. And with a quick-connect hub, an operator can align, land, and secure the BOP on the wellhead much faster than with a conventional flange connection, reducing rig-up time from two hours to less than 30 minutes. Plus, there’s no longer a need to wait for cement to dry before resuming operations.
Obviously, reducing the amount of time involved reduces the associated labor costs. A day of rig time could conceivably pay for the wellhead, plus, by reducing risk, you’re also protecting valuable assets, which include your people—that’s the underscore beneath every bottom line.
With the ULR, Weir has listened to customers and delivered a solution that lowers total cost of ownership. Next time, we’ll dive deeper into some of the features of this safer, innovative, time-saving wellhead.
