油气田废弃旧油管绿色再制造关键技术创新与工业化应用

Innovation and Industrial Application of Key Technologies for Green Remanufacturing of Used Tubulars in Oil and Gas Fields

近年来,陕北气田在试油、试气以及压裂作业后,产生了大量的废旧油管,亟需解决回收现场混放废旧油管钢级材质分选困难、经修复后的API(美国石油学会)螺纹粘扣及采用的特殊扣无法通用等再制造油管使用周期不长等问题。提出基于“化学成分+硬度”现场测试值判据的综合分析方法区分管材的钢级和材质,以N80及以上钢级抗拉强度高、抗粘扣性能优异的特殊螺纹油管代替加厚油管作为压裂管柱专用扣型,再生油管经全尺寸实物试验评价及示范应用,质量指标和服役性能满足气井压裂作业工况要求。项目试验及推广期间,完成安62井、子22-2等现场压裂83井次,使用再生油管30 896根(包括变扣和短节),节约管材投资总额2 798余万元。同时开展了再生油管多次压裂试验,其中开展二次压裂14井次,三次压裂2井次,最大作业深度达到3 854 m,作业压力52~54 MPa,取得较好成效。通过旧油管绿色再制造,将旧油管变为满足压裂作业使用要求的作业管柱,不仅能延长管材服役周期,也能大量挽回油气田的间接损失,经济效益和社会效益可观。

In recent years,the Northern Shaanxi gas field has generated a large amount of waste oil pipes after oil testing,gas testing,and fracturing operations.It is urgent to solve the problems of difficult sorting of steel grade materials for mixed waste oil pipes at the recycling site,inability to use repaired API(American Petroleum Institute)thread fasteners and special fasteners universally,and short service life of remanufactured oil pipes.A comprehensive analysis method based on the criterion of"chemical composition+hardness"on-site test values is proposed to distinguish the steel grade and material of pipes.Special threaded pipes with high tensile strength and excellent anti sticking performance of N80 and above steel grade are used instead of thickened pipes as the special buckle type for fracturing strings.Regenerated pipes are evaluated and demonstrated through full-scale physical tests,and their quality indicators and service performance meet the requirements of gas well fracturing operation conditions.During the project testing and promotion period,a total of 83 on-site fracturing operations were completed for wells An-62 and Zi-22-2,using a total of 30896 recycled used tubing(including variable couplings and short joints),saving a total investment of over 27.98 million yuan in tubular materials.At the same time,multiple fracturing tests were carried out on the regenerated tubing,including 14 second fracturing tests and 2 third fracturing tests,with a maximum operating depth of 3854 m and an operating pressure of 52~54 MPa,achieving good results.By green remanufacturing used tubing,they can be transformed into operational columns that meet the requirements of fracturing operations.This not only prolongs the service life of the tubing,but also significantly recovers the indirect losses of oil and gas fields,the economic and social benefits are considerable.