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工廠化作業(yè)提供了一個新方向。這種生產組織模式通過集成先進的技術、裝備和管理手段，實現(xiàn)鉆完井批量化和流水線施工，有效提高作業(yè)效率，降低作業(yè)成本。工廠化作業(yè)正孕育著油氣生產領域的深層變革。
成功開發(fā)致密油氣等低品位資源的關鍵何在？答案是規(guī)?；⒌统杀?。
長慶油田安83井區(qū)安平54井組，通過實施工廠化作業(yè)，獲得提速、降本的明顯優(yōu)勢。截至9月15日，這個井組部署的6口水平井平均單井日產油12.8噸。6口井鉆井總用時69天，壓裂試油總用時45天，而去年這一地區(qū)1口水平井的鉆井周期是31天，壓裂試油周期達79天。井場共建、集中供水等節(jié)省的費用，幾乎能再打1口新井。
儲量低品位化趨勢日漸明顯，是石油企業(yè)不得不正視的嚴峻現(xiàn)實。今年年初以來，中國石油積極探索工廠化作業(yè)，在油氣生產領域掀起一場全新變革。如同初升的旭日，工廠化作業(yè)正照亮低品位資源經濟有效開發(fā)的道路。
由分散到集約：“標準化”思路加速規(guī)模建產
長慶油田蘇東三區(qū)是中國石油設立的首批6個工廠化作業(yè)示范區(qū)之一。這個區(qū)塊G0-7井場共部署3口直井和6口水平井。正在這里施工的川慶鉆探50053鉆井隊隊長王步寬感慨：“以前從沒打過這么大規(guī)模的叢式水平井組?！?
叢式布井是工廠化作業(yè)的基礎理念。油氣井由“獨居”變?yōu)椤叭壕印?，在提高資源利用效率和作業(yè)效率等方面的好處顯而易見。以G0-7井場為例，節(jié)約征地18畝，井場施工周期縮短58天；井架底座配套滑軌，50DB鉆機搬家時間由3天下降至3個小時，極大減少等停時間。
“叢式布井只是第一步，標準化的技術系列和生產組織，對于工廠化實踐至關重要?！敝袊涂碧脚c生產分公司工程技術與監(jiān)督處副處長毛蘊才認為，工廠化作業(yè)就是在地質認識基本清楚、油藏條件基本相似的區(qū)域，采用大平臺布井方式，集中部署一批井身結構相似、完井方式相似的井，并且使用成熟的、標準化的技術系列和裝備組合，以流水線的方式進行鉆完井作業(yè)的模式。
中國工程院院士胡文瑞一言以蔽之：“標準化是工廠化作業(yè)的核心思想?！痹谒磥?，只有達到標準化，才能真正觸及工廠化的精髓，即實現(xiàn)批量化、流水線作業(yè)，從而最大限度地降本增效。
長慶油田蘇里格南作業(yè)分公司正是由于抓住標準化這個關鍵因素，工廠化實踐取得突出效果，做到1個井叢9口井上部表層批量施工一次完成，鉆井、壓裂交替作業(yè)，今年井叢建井周期同比縮短15%，壓裂作業(yè)周期由2011年的52天縮短至目前的32天，單井壓裂成本下降16%。
由正向到逆向：“全局視野”瞄準效益最大化
多名專家接受采訪時，都不約而同地用“由正向思維到逆向思維的轉變”，來闡釋工廠化作業(yè)背后開發(fā)思路的調整。長慶油田工程技術管理部負責人說，傳統(tǒng)油氣生產在地質確定井位后，按部就班實施鉆井、壓裂等工序。工廠化作業(yè)則是緊緊圍繞“開發(fā)效益最大化”的目標，反向系統(tǒng)優(yōu)化井位部署直至后期投產等各環(huán)節(jié)。
蘇東三區(qū)靖平06-6井組共部署2口水平井、1口直井和6口定向井。通過開挖蓄水池集中供水和使用大排量連續(xù)混配車等措施，9口井壓裂試氣周期由4個月減少至1個半月。川慶鉆探長慶井下作業(yè)公司靖邊項目部經理李富強介紹說，僅創(chuàng)造性地應用大尺寸連續(xù)油管進行通、洗井作業(yè)這一項措施，就節(jié)約24天時間。
“全局視野”下的系統(tǒng)優(yōu)化，使工廠化作業(yè)特別要求地質與工程、地面與井筒、鉆井與完井等多專業(yè)和工序的密切配合。中國石油勘探與生產分公司工程技術與監(jiān)督處高級工程師葉新群說，考慮到叢式布井是工廠化的前提，這種作業(yè)模式適用于分布相對穩(wěn)定的油氣藏。目前，工廠化探索對于工藝技術的考慮較多，今后要在油藏部署上進一步深化理念，真正實現(xiàn)地質與工程的一體化。
盡管每個項目優(yōu)化方案不盡相同，但都充分體現(xiàn)出工廠化作業(yè)的優(yōu)勢。首先，批量、流水化作業(yè)有效提高施工效率。其次，資源優(yōu)化配置實現(xiàn)經濟和環(huán)保效益雙贏。再次，充分發(fā)揮機器設備效用解放勞動力。最后，施工隊伍共享經驗整體提升技術水平。
今年年底，蘇東三區(qū)有望提前1年基本建成30億立方米產能。長慶油田采氣一廠副廠長、產能建設項目組經理王振嘉說：“成績的取得，工廠化作業(yè)功不可沒?！?
由粗放到精細：抓管理“靈魂”實現(xiàn)多方協(xié)作
精細化管理是工廠化作業(yè)的靈魂。正如經濟技術研究院高級工程師田洪亮所說，工廠化作業(yè)是利用管理學優(yōu)化方法對整個建井過程進行集成創(chuàng)新的結果。它的意義不僅是集成應用隨鉆測量等一系列先進技術和裝備，而且是利用科學的管理方法對油井建井各項因素進行最優(yōu)化處理，為推動整個油氣勘探開發(fā)工程的降本提效提供了思路和借鑒。
現(xiàn)階段，盡管我國的工廠化作業(yè)已經取得初步成效，但總體來說尚處于起步摸索階段。毛蘊才認為，今后要發(fā)展得更好，必須著力解決兩個問題。
首先，要深化理念上的認識，不能淺嘗輒止、隨意濫用工廠化標簽。他說：“工廠化本身很嚴謹、很科學，但如果把單一的批鉆或者泥漿重復利用都叫工廠化，就會影響對其內涵的準確把握，進而影響工廠化效用的充分發(fā)揮。”
第二，要做精做細管理。工廠化作業(yè)不同于傳統(tǒng)生產隊式的分散作業(yè)模式，根本上是一個集成性的管理平臺，覆蓋鉆井、壓裂等多個專業(yè)，同時也涉及油氣田公司、鉆井承包商及工程技術服務公司等多家單位。毛蘊才說，在這個過程中，公司要當“指揮家”，演奏好工廠化作業(yè)這部盛大的“交響曲”。一方面，在油氣田公司內部，要加強油藏地質、工程工藝、地面流程等多專業(yè)協(xié)作，不僅僅是現(xiàn)場生產方式的變化，也需要地質油藏研究等方面的轉變和調整。另一方面，要在加強油氣藏研究、優(yōu)化調整井位井場部署的基礎上，加強現(xiàn)場組織和甲乙方的團結協(xié)作。
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