Application of the Advanced Methods to Investigate Incidents and Drilling Engineering Principles to Prevent Critical Wear-Out of Downhole Equipment When Drilling Wells in Chayandinskoye Field

The pressing challenge is the abnormally rapid wear of well logging equipment and drilling tools when drilling wells in pay zone of Chayandinskoye field. Wear-out of BHA stabilizers within one run makes directional drilling inefficient and results in additional trips to replace equipment. Wear-out of drill pipes results in emergencies risk increase. To prevent such incidents the necessity arises to conduct an unscheduled inspection, reject and replace drilling tools. All these conditions entail increase in drilling time and decline in profitability. Problem analysis and expert review was made by drilling optimization specialists from DD Contractor jointly with the experts from R&D Center and Operator Company. This paper discusses how cooperation of the engineers from three companies as well as a particular approach to incident investigation and drilling engineering made it possible to identify the most critical factors, which contribute to a standard BHA wear, to work out measures to prevent similar situations in future and select an alternative BHA. The gained experience has been successfully disseminated to the other wells in Chayandinskoye field and other fields in Eastern Siberia; and the incident investigation methods and drilling engineering procedures are effectively applied under the other projects.

ASSESSMENT OF THE CORROSION RATE OF PROCESS PIPELINES USING AUTOMATED REAL-TIME MONITORING

The article discusses a conceptual approach to ensuring the reliability of technological pipelines using automated corrosion monitoring tools in combination with predictive Analytics systems. The tasks are implemented using portable wireless ultrasonic sensors for monitoring the wall thickness of technological equipment and pipelines, which support the process of monitoring and evaluating the technical condition of the equipment. Installation of sensors is carried out without violating the integrity of the pipeline or changing the design of the equipment, which provides convenience and short terms of putting them into operation. The direct measurement method allows you to reliably monitor both the current state of the system and the rate of corrosion changes in the equipment. High accuracy and repeatability of measurements allows you to track changes in the thickness of the metal of the order of 10 microns, which significantly exceeds the sensitivity of the system compared to analogues. The standard period between measurements is 12 hours, which allows you to quickly identify episodes of corrosion activity and quickly compensate for them. All changed data is accumulated, processed and stored on the server, displayed on any number of working stations connected and automated in the network. Thanks to continuous monitoring, the user can carry out operational corrective actions. The sensitivity of the sensors to thinning of the walls of the equipment makes it possible to quickly respond to changes and make timely adjustments to the chemical and technological process aimed at protecting the process equipment from corrosion. With an increase in the inter-repair mileage, there are risks associated with equipment wear, i.e. the greater the inter-repair mileage, the greater the risk of unscheduled downtime increases. This corrosion monitoring system will reduce both direct operating costs for maintenance and repair, and indirect – this is an additional product output that can be implemented. The end result is the formation of an optimal maintenance and repair program with an emphasis on maintaining critical system assets in working condition during the inter-repair period.

The problem statement of an information system creation for evaluating and forecasting the states of the power boiler.

When operating a thermal power plant (TPP), it is of great importance to ensure the reliability and safety of the enterprise while minimizing the cost of maintenance and repair of equipment. The currently used strategy for preventive maintenance is to carry out periodic work at predetermined times, regardless of the technical condition of the equipment. At the same time, the operating timefeatures, heterogeneous loads and, consequently, various equipment wear are not taken into account. Almost always there is an episodic deviation of the operating parameters of a particular equipment from the nominal values, which leads to an intensification of the wear processes and thereby a decrease in the residual life of this equipment. Therefore, the urgent task is to create tools for information and analytical support for planning repair and maintenance work based on the assessment and prediction of the condition of equipment using data from operational monitoring and computer modeling. In this paper, we pose the problem of creating an information system for assessing and predicting the states of an energy boiler as one of the key nodes of a TPP.

Improvement of Abrasion Resistance of Production Equipment Wear Parts by Hardfacing with Flux-Cored Wires Containing Boron Carbide/Metal Powder Reaction Mixtures

In this work was established that serial traditional hardfacing materials based on the Fe-Cr-C system are not effective for improvement of abrasion resistance of elements of equipment for production of bricks, solid fuel briquettes and for restoration of augers, due to the fact that this equipment works at significant specific and cyclic loads. Features of the coarse-grained structure of Fe-Cr-C based coatings leads to intensive abrasive wear. The aim of this study was to increase a durability of that equipment by using of flux cored electrodes with reaction components of Ti, Cr, Mo, B4C and their combinations to provide synthesis, which leads to fine-grained structure of refractory borides and carbides and their solid solutions with increased hardness. Structure of the hardfacing coatings were investigated by method of metallography, scanning electron microscopy (SEM), electron backscatter diffraction (BSD) mode and energy dispersive X-ray spectroscopy (EDS). Temperature dependences of equilibrium phase amount of the hardfacing materials were calculated by the CALPHAD technique, using JMatPro software. It was investigated that the offered materials are characterized by higher wear resistance at high specific and cyclic loads in comparison with serial production high-chromium hardfacing materials (Lastek, ESAB, Paton IEW). It was established that the abrasion wear resistance at high specific and cyclic loads depends mostly of formation of the structure of hardfacing material, and not the hardness. Also, using of powders of pure metals and their combination as reaction mixture for FCAW leads to fine structure which contains of refractory borides and carbides and their solid solutions.

An Adaptive Control Scheme for Variable Speed Wind Turbines Providing Frequency Regulation in Isolated Power Systems with Thermal Generation

The lack of synchronous inertia, associated with the relevant penetration of variable speed wind turbines (VSWTs) into isolated power systems, has increased their vulnerability to strong frequency deviations. In fact, the activation of load shedding schemes is a common practice when an incident occurs, i.e., the outage of a conventional unit. Under this framework, wind power plants should actively contribute to frequency stability and grid reliability. However, the contribution of VSWTs to frequency regulation involves several drawbacks related to their efficiency and equipment wear due to electrical power requirements, rotational speed changes, and subsequently, shaft torque oscillations. As a result, wind energy producers are not usually willing to offer such frequency regulation. In this paper, a new control technique is proposed to optimize the frequency response of wind power plants after a power imbalanced situation. The proposed frequency controller depends on different power system parameters through a linear regression to determine the contribution of wind power plants for each imbalance condition. As a consequence, VSWTs frequency contribution is estimated to minimize their mechanical and electrical efforts, thus reducing their equipment wear. A group of sixty supply-side and imbalance scenarios are simulated and analyzed. Results of the case study are compared to previous proposals. The proposed adaptive control reduces the maximum torque and rotational speed variations while at the same time maintaining similar values of the load shedding program. Extensive results and discussion are included in the paper.

Study on the nature of impurities in the circulating glycol solution at the installation of gas purification from acidic components

Natural gas contains a large amount of moisture, which causes a lot of problems in its transportation and processing. In order to extract this moisture, natural gas gets subjected to the dewatering process, thereby reducing the moisture content and preventing further formation of hydrates. This is achieved by cleaning the gas from hydrogen sulfide and mercaptans and cooling in heat exchangers with the participation of a solution of monoethylene glycol. Together with gas, impurities come in the form of hydrocarbons, brine water, mechanical impurities, corrosion inhibitors, various SASs, resinous substances, etc. As a result of deposition of unwanted impurities on the internal surfaces of devices, the efficiency of mass exchange and heat exchange processes is reduced, equipment wear is increased, so is the laborious process of cleaning equipment during planned repairs, the temperature of the glycol block is disrupted and, as a result, the reagent consumption increases in order to maintain the necessary dewatering temperature of natural gas, and the waste of the glycol from the regeneration apparatus increases. The object of the study was the regeneration block of the saturated solution of monoethylene glycol. During the planned repairs of the plant, there was revealed significant contamination of the devices and heat exchange equipment of the glycol regeneration unit with a large number of unwanted impurities and sediments, as well as significant corrosion of pipe beams of heat exchangers and internal cavity of devices. We found that the most effective ways to prevent sediment formation in the monoethylene glycol regeneration unit are to better control the level of amine in the 374 B09 devices, to control the consumption of the amount of monoethylene glycol injected into heat exchangers, and to reduce the amount of impurities in the circulating solution of monoethylene glycol. Also, to reduce sediments in the heat exchange apparatus of the gas dewatering section, we recommend increasing the separation rate by installing jack elements in the 374 B09 separator and installing an additional filter in accordance with the proposed scheme, with a cartridge of polyphenylsulfide or fiberglass.

ТЕХНИКО-ЭКОНОМИЧЕСКОЕ ОБОСНОВАНИЕ ЭФФЕКТИВНОСТИ ПРИМЕНЕНИЯ ПЛАНЕТАРНЫХ ШЛИФОВАЛЬНЫХ ГОЛОВОК

The development of aviation technology is based on the introduction of new progressive technologies, the use of new materials, the improvement of technological equipment and tools. Improving aircraft engines often leads to greater use of wear-resistant, heat-resistant, heat-resistant materials based on nickel and titanium, which are characterized by low machinability. Blade processing of such alloys faces many difficulties: increased equipment wear, increased machine setup time for the operation, high cutting forces, increased wear of the cutting tool, increased processing time, etc. All this harms productivity, an increase in production time and a decrease in economic efficiency. The use of the operation of creep feed grinding instead of blade milling operations, pulling, planning and abrasive operations (pre-grinding, final grinding) reduces the time to manufacture parts while maintaining its quality and accuracy. The study of the technical and economic aspect of the proposed technology of creep feed grinding instead of preliminary and final grinding operations is of interest. The paper compares two methods of abrasive machining: traditional grinding and creep feed grinding on the SPD-30B surface grinder from Jotes (Poland) with a planetary grinding head (PGH) installed on its spindle. The study was conducted when grinding the castle part of turbine blades. The removable allowance was 3.8 mm. The processing according to the traditional grinding scheme took place in 10 passes, while the processing time was about three and a half minutes. The processing under the scheme of creep feed grinding with the use of PGH for 4 passes took about a minute of machine time. It should be noted a significant increase in productivity at the first transition when removing an allowance of 3.5 mm in the mode of deep grinding compared to traditional grinding 2.1 times. On the second and third transitions, the performance of both methods is virtually the same.