目前石油行业处于低迷时期，油气行业正致力于寻找能够提高生产率同时降低费用的操作方案。在长期低迷周期，提高防喷器利用率并扩展钻井作业可用时间对降低成本有很大影响。
来自 | GE
编译 | 赵金成
通过结合工业技术和数据分析，GE推出了为用户提供减少停钻时间的解决方案——SeaPrime I MUX海底防喷器控制系统。SeaPrime I采用新型设计，可以减少由于海底防喷器控制舱复杂性增加所导致的高达40%停机时间。SeaPrime I具有容错架构和海底液压功能易恢复的特点，采用冗余设计，提供高于系统可用性的性能的同时确保不需要回收防喷器，减少停机时间。
升级防喷器控制系统
目前约有250个浮式钻机依靠海底防喷器控制舱来进行防喷器控制，随着作业难度的不断增加，控制舱的复杂性逐渐增加，超过40%的防喷器停机时间归因于控制舱系统故障。由此造成的停机耗费每年为数十亿美元，业内亟需一款能够显著降低防喷器故障、减少停机时间的防喷器控制技术。
行业法规规定钻井时使用两个防喷器控制舱来提供系统冗余，如果一个控制舱失效，为保证操作安全，目前的行业做法是回收工具并进行系统检索和修复，这就会造成停机，加重作业成本。
GE集团的SeaPrime I海底防喷器控制系统正在改变这种常规处理海底防喷器控制系统的方式，它允许开发商利用ROV系统恢复液压关键功能，而不需要回收防喷器，大大减少停机时间。
这种新一代容错架构具有重新配置海底液压功能的能力，避免代价高昂的设备回收修复。液压功能通过海底控制系统的遥控潜水器隔离，对液压功能重新布线到同一个控制舱的指定冗余部分，同时保持充分的海底操作性。这种智能冗余单元使系统本身重新配置，提供3倍于双控制舱的系统可用性。
提高技术可靠性
SeaPrime I系统使用GE可靠性工艺和模型设计来驱动系统设计和体系结构，其性能在实际应用中已得到证明。先进的制造方法简化了部件的机械设计，同时GE全球研究中心采用先进的仿真功能驱动热效率并显著改善水力性能。
由内而外的独特设计
这种由内而外的控制系统设计是GE的最新成果，GE在2016年的SPE海洋石油技术会议上宣布了该技术的研发成功，它能简化了电力、液压功能的维护，降低维护成本。
此外，通过使用该技术无需拆卸控制舱即可访问关键功能，从而减少人为失误的几率。新型防喷器的设计还消除所有的管线接头，降低了40%的潜在泄漏点，该系统为八腔设计，为15,000psi和20,000psi系统提供了解决方法，拥有20%的冗余以适应未来作业难度增长需要。
满足数据和控制需求
GE集团的海底液压控制系统SeaONYX（既控制防喷器水力控制系统的电子控制中心）由Mark VIe控制平台供电，它的用户操作界面更加清晰，能够进行容易、可靠的诊断。
完整的防喷器控制系统，既包括SeaONYX地面控制和SeaPrime海底控制在内，还可以使用由Predix供电的SeaLytics防喷器系统，来提高操作可视性，使得预测更准确、基于操作现状。
Predix是世界上第一个，也是唯一的石油和天然气工业云平台，是GE工业互联网产品的基础。先进的工业技术和大量数据分析的结合为用户提供了解决方案和先进的技术产品，使之基于状况维修从而减小停钻时间。
特性优势
1.双控制舱设计，提供足够的冗余度；
2.单控制舱能够分别控制压力，确保在一个控制舱失效的情况下能够正常工作；
3.可以通过ROV操作进行远程控制舱修复；
4.整体无导油管对接设计，降低40%的泄漏风险；
5.具有8油腔设计，BOP操作更加灵活。
With the current downturn, the industry is focused on finding ways to improve productivity and efficiency while reducing cost. In this long-lasting downcycle, improving BOP availability and extending the available time to drill has a significant impact on customers’ bottom lines. By focusing on reliability-driven design innovations, GE Oil & Gas is addressing some of the industry’s most complex challenges while helping drilling contractors and operators reduce downtime and drive process changes across the industry.
Improving BOP control systems
About 250 floating rigs rely on subsea MUX pods for BOP control. Due to increased complexity in subsea pods, up to 40% of BOP downtime has been attributed to faults in these systems. Downtime costs the industry billions annually, making downtime reduction a critical priority.
Industry regulations dictate the use of two MUX control pods during drilling to provide system redundancy. Should a pod fail, current industry practice is to retrieve and repair the system, causing downtime. The GE Oil & Gas SeaPrime I Subsea BOP Control System is changing this industry practice for subsea MUX controls, allowing drilling contractors to recover critical hydraulic functions without the need for a costly stack pull.
This next generation fault-tolerant architecture has the ability to reconfigure hydraulic functions subsea, preventing costly stack pulls. Hydraulic functions are isolated using an ROV for the subsea control system to reroute hydraulic functions to specific redundant sections within the same pod, all while maintaining full operations subsea. This smart redundancy element enables the system to reconfigure itself, providing three times greater system availability with only two pods.
Reliability
The SeaPrime I system has been designed from the ground up using GE’s Design for Reliability process and Reliability Availability Maintainability models, proven in other businesses, to drive system design and architecture. Advanced manufacturing solutions simplified the mechanical design of the components, while GE’s Global Research Center used advanced simulation capabilities to drive thermal efficiency and significantly improve hydraulic performance.
Maintainable ‘inside-out’ design
This new design, which has been announced as an SPE Spotlight on Technology Award winner at the 2016 OTC, simplifies maintenance and reduces service costs by improving access to electric and hydraulic functions and serviceable parts. In addition, eliminating the need to disassemble the pod to access critical functions reduces the opportunity for human error. The design also reduces potential leak points by 40% by eliminating all pilot tubing and connectors. The system offers a solution for eight-cavity 15,000-psi and 20,000-psi systems, with 20% spare functions for future growth.
Where data and controls meet
GE Oil & Gas’ SeaONYX surface control system—or the “electronic brain” that drives the subsea hydraulic controls—is powered by Mark VIe controls technology to enable robust diagnostics easily managed through an enhanced user interface. The integrated suite of controls, including both the SeaONYX surface controls and SeaPrime subsea controls, also can be paired with the SeaLytics BOP Advisor system, powered by Predix, to improve operational visibility and enable predictive condition-based maintenance. Predix, the world’s first and only cloud platform built exclusively for the oil and gas industry, is the foundation for GE’s Industrial Internet offerings. This meshing of advanced industrial technology with big data analytics gives users solutions and advanced technical products that enable condition-based repairs to minimize rig downtime
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石油圈认证作者
- 毕业于中国石油大学（华东），油气井工程硕士，长期聚焦国内外石油行业前沿技术装备信息，具有数十万字技术文献翻译经验。
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