ADVANCES IN PERFORATING TESTING; THE NEXT GENERATION TEST SYSTEM: DALLAS - FORT WORTH. AUGUST 5-6, 2019. 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
SECTION IV TESTING REQUIREMENTS HAVE EVOLVED OVER THE PAST 30+ YEARS 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. o Pc = 4500 psi; Pp = 1500 psi; Pb = 750 psi; no temperature. o 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 . o Pc = 6500 psi; Pp = 3500 psi; Pb = 3000 psi; still no temperature. o Flow OMS, brine, or gas; constant rate(s) or constant DP allowed. o 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. 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
WHERE IS THE INDUSTRY HEADED? Older designs are being pushed to “the limit.” o Testing equipment is being used at very close to vessel design MWP in many cases, beyond where they ought to be used. o Many have been modified to add “some” temperature capability. Many (most?) older systems cannot match current field conditions “exactly.” o Operating companies want this match of conditions. o 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. o 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 SELECTED 1999 TO 2019 TESTING REQUESTS (AND/OR TESTS) AT SRC PERF LAB FACILITY DATA SET SUGGESTED A SYSTEM WITH THE FOLLOWING DESIGN CONDITIONS: o Vessel Confining Pressure of at least 40,000 PSIG [Overburden stress] o Sample Pore Pressure of at least 30,000 psi [Reservoir pressure] o SWB Pressure of at least 30,000 psi [Wellbore pressure] o Temperature capability of at least 400 º F 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
SELECTION: NEXT GENERATION SYSTEM CAPABILITITIES FOR AMBIENT TEMPERATURE TESTS, BELOW 200 º F o Confining Pressure = 50,000 psi maximum o Pore Pressure = 40,000 psi maximum o SWB Pressure = 40,000 psi maximum FOR HIGH TEMPERATURE TESTS, GREATER THAN 201 º F o System Temperature = 550 º F maximum o Confining Pressure = 40,000 psi maximum o Pore Pressure = 30,000 psi maximum o 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. 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
PV-550 TEST SYSTEM – THE NEXT GENERATION Overall view with vessel rotated horizontal 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
PV-550 TEST SYSTEM – THE NEXT GENERATION Overall view with vessel vertical Close in view 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
PV-550 TEST SYSTEM – THE NEXT GENERATION Automated Valves Servo Intensifier Units 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
PV-550 TEST SYSTEM – THE NEXT GENERATION Close in view Surge Accumulator Intensifiers (SWB to left, Pore to right) 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
PV-550 TEST SYSTEM – THE NEXT GENERATION TerraPERF Control Software Screenshot Control Cabinet (left is inside, right shows all cables in/out) 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (1/4) Vessel and equipment designs must be fit for purpose . Look at designs per the following codes and methodologies and select the most conservative design. o ASME Section 8, Division 3 o PED (from the EU) o Traditional Thick Wall Cylinder Design; von Mises stress or Octahedral shear stress approach o 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 . 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (2/4) 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. o Must be Fit For Purpose. “Off the shelf” solutions will not work. o 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). 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (3/4) 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 . o Bladder accumulators typically used on older systems will not work at these conditions. MUST USE PISTON STYLE accumulators. o 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. o How much surge flow is enough? How much is too much? o SWB pressure at shot time. How low can it go? How to control? 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
SAFETY REQUIREMENTS TO PERFORM HPHT SECTION IV (and II) TESTS (4/4) Fluids must be heated prior to entering a “hot” rock core, and must be cooled below flash point prior to any venting to atmosphere . o Do not want to cause a thermal stress issue with the core or vessel. o Must ensure that flashing of liquids to gas does not happen. 2019-NAPS-1.1 Advances in Perforation Testing; The Next Generation Test System
IN SUMMARY….. 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 Advances in Perforation Testing; The Next Generation Test System
QUESTIONS? DALLAS - FORT WORTH. AUGUST 5-6, 2019. THANK YOU 2019-NAPS-1.1 AUTHORS: David C Atwood PE, Quan Guo, Moises Enrique Smart, Diana Higuera, Michael Morrison; Schlumberger
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