TESTING; THE NEXT GENERATION TEST SYSTEM: DALLAS - FORT WORTH. - - PowerPoint PPT Presentation

ADVANCES IN PERFORATING TESTING; THE NEXT GENERATION TEST SYSTEM:

HOW TO DO IT “SAFELY” AT HPHT CONDITIONS

2019-NAPS-1.1

AUTHORS: David C Atwood PE, Quan Guo, Moises Enrique Smart, Diana Higuera, Michael Morrison; Schlumberger DALLAS - FORT WORTH. AUGUST 5-6, 2019.

SECTION IV TESTING REQUIREMENTS HAVE EVOLVED OVER THE PAST 30+ YEARS

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 API RP-43 Section IV testing goes back to API Project 36, started in 1986.  Core flow testing goes back even further, mid-1950’s.  API RP-43 with Section IV issued in 1987; first “official” procedure for a flow test.

• Pc = 4500 psi; Pp = 1500 psi; Pb = 750 psi; no temperature.
• Flow a fixed volume (5 ltr) at 1 differential pressure (50 psid).

 Section IV was last re-written from 2009-2012, with some minor modifications since then.

• Pc = 6500 psi; Pp = 3500 psi; Pb = 3000 psi; still no temperature.
• Flow OMS, brine, or gas; constant rate(s) or constant DP allowed.
• Radial Flow geometry or Axial Flow geometry allowed.

 The older systems designed and built by most of the service companies have reached their “functional limits.”  Operating companies and the Industry at large are finding oil and gas in places that are hotter and at higher pressure than ever before.

WHERE IS THE INDUSTRY HEADED?  Older designs are being pushed to “the limit.”

• Testing equipment is being used at very close to vessel design MWP in many cases, beyond where

they ought to be used.

• Many have been modified to add “some” temperature capability.

 Many (most?) older systems cannot match current field conditions “exactly.”

• Operating companies want this match of conditions.
• Compromises being made for some testing by shooting at an equivalent effective stress and UB/OB,

but not at actual conditions.

 New testing requirements will ALWAYS be heading to higher and higher conditions.  Graphics on the next slide present test conditions requested by Operators from 1999 – 2012 and 2017 -- current.

• Plotted as reservoir pressure vs. overburden stress and reservoir temperature vs. overburden stress.

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

TESTING CAPABILITIES & CONDITIONS? - FOR PRESENT AND FUTURE

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 SELECTED 1999 TO 2019 TESTING REQUESTS (AND/OR TESTS) AT SRC PERF LAB FACILITY  DATA SET SUGGESTED A SYSTEM WITH THE FOLLOWING DESIGN CONDITIONS:

• Vessel Confining Pressure of at least 40,000 PSIG [Overburden stress]
• Sample Pore Pressure of at least 30,000 psi [Reservoir pressure]
• SWB Pressure of at least 30,000 psi [Wellbore pressure]
• Temperature capability of at least 400º F

SELECTION: NEXT GENERATION SYSTEM CAPABILITITIES

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

FOR AMBIENT TEMPERATURE TESTS, BELOW 200º F

• Confining Pressure = 50,000 psi maximum
• Pore Pressure = 40,000 psi maximum
• SWB Pressure = 40,000 psi maximum

FOR HIGH TEMPERATURE TESTS, GREATER THAN 201º F

• System Temperature = 550º F maximum
• Confining Pressure = 40,000 psi maximum
• Pore Pressure = 30,000 psi maximum
• SWB Pressure = 30,000 psi maximum

Flow liquid or gas; liquid at maximum of 20 cc/second (1.2 lpm) and full line pressure in and out of vessel. Multiphase flow; currently with two different liquids. Fully automated operation. No human allowed inside the Test Bay once a test has started.

PV-550 TEST SYSTEM – THE NEXT GENERATION

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

Overall view with vessel rotated horizontal

PV-550 TEST SYSTEM – THE NEXT GENERATION

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

Overall view with vessel vertical Close in view

PV-550 TEST SYSTEM – THE NEXT GENERATION

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

Servo Intensifier Units Automated Valves

PV-550 TEST SYSTEM – THE NEXT GENERATION

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

Surge Accumulator Intensifiers (SWB to left, Pore to right) Close in view

PV-550 TEST SYSTEM – THE NEXT GENERATION

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

Control Cabinet (left is inside, right shows all cables in/out) TerraPERF Control Software Screenshot

SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (1/4)

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 Vessel and equipment designs must be fit for purpose. Look at designs per the following codes and methodologies and select the most conservative design.

• ASME Section 8, Division 3
• PED (from the EU)
• Traditional Thick Wall Cylinder Design; von Mises stress or Octahedral shear stress approach
• HPHT complicates material selections. Must use extreme caution and due diligence.

 Seal designs are critical. What may work at HPHT, may not work at HP or HT alone; and vice versa.  Tests must be carried out inside of a controlled access test bay that is designed for explosives and HPHT.  All valves that require opening/closing during a test MUST BE AUTOMATED.

SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (2/4)

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 NO OPERATOR INTERVENTION inside Test Bay once a test has started. All must be handled remotely.  Test system must be PLC and/or computer controlled. No manual operations while at HPHT.  Control and DAQ software must be “bullet proof.” No margin for error.

• Must be Fit For Purpose. “Off the shelf” solutions will not work.
• Must be able to handle upsets and to prevent “runaway situations” with heaters and pressure intensifiers, etc.

(Heart Beat, safety interlocks, etc.).

 Positive pressure control at all times. Important as you will be operating at above the boiling point of water and the flash point of OMS.

• Servo-controlled pressure intensifiers; uses lower pressure hydraulics (3000 psi) to create HP fluid sources (up

to 50000 psi).

SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (3/4)

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 KNOW YOUR FLUID PROPERTIES

• Is your gas really a gas at HP?
• Water can “freeze” at room temperature at HP.
• Liquid viscosities for oils at HP can get extremely high. Are you trying to pump grease?

 SURGE FLOW requirements need special consideration.

• Bladder accumulators typically used on older systems will not work at these conditions. MUST USE PISTON STYLE

accumulators.

• Further, you must use an intensifier style design to limit the pressure of gas on the driving side.
• You do not want large volumes (required) of HP gas on the driving side.
• How much surge do you need?
• How much will you actually get?

 Understand the perforating wellbore dynamics of your system at HPHT.

• How much surge flow is enough? How much is too much?
• SWB pressure at shot time. How low can it go? How to control?

SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (4/4)

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 Fluids must be heated prior to entering a “hot” rock core, and must be cooled below flash point prior to any venting to atmosphere.

• Do not want to cause a thermal stress issue with the core or vessel.
• Must ensure that flashing of liquids to gas does not happen.

IN SUMMARY…..

2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System

 Many aspects of testing at HPHT conditions are not completely understood and defined.  HPHT Testing will require development of new processes and new equipment, just as they had to be developed for the original Section IV testing 33 years ago.  Industry needs to learn to crawl, before it walks, and before it runs.  Further new equipment and modifications to existing equipment are a given for HPHT Perforation Flow Testing.

FACE IT AND EMBRACE IT!

2019-NAPS-1.1

AUTHORS: David C Atwood PE, Quan Guo, Moises Enrique Smart, Diana Higuera, Michael Morrison; Schlumberger DALLAS - FORT WORTH. AUGUST 5-6, 2019.

QUESTIONS? THANK YOU