Contamination Control for Scientific Drilling Operations.

Drilling is an integral part of subsurface exploration. Because almost all drilling operations require the use of a drill fluid, contamination by infiltration of drill fluid into the recovered core material cannot be avoided. Because it is impossible to maintain sterile conditions during drilling the drill fluid will contain surface microbes and other contaminants. As contamination cannot be avoided, it has to be tracked to identify those parts of the drill core that were not infiltrated by the drill fluid. This is done by the addition of tracer compounds. A great variety of tracers is available, and the choice depends on many factors. This review will first explain the basic principles of drilling before presenting the most common tracers and discussing their strengths and weaknesses. The final part of this review presents a number of key questions that have to be addressed in order to find the right tracer for a particular drilling operation.

Suitability of virtual prototypes to support human factors/ergonomics evaluation during the design.

In recent years, the use of virtual prototyping has increased in product development processes, especially in the assessment of complex systems targeted at end-users. The purpose of this study was to evaluate the suitability of virtual prototyping to support human factors/ergonomics evaluation (HFE) during the design phase. Two different virtual prototypes were used: augmented reality (AR) and virtual environment (VE) prototypes of a maintenance platform of a rock crushing machine. Nineteen designers and other stakeholders were asked to assess the suitability of the prototype for HFE evaluation. Results indicate that the system model characteristics and user interface affect the experienced suitability. The VE system was valued as being more suitable to support the assessment of visibility, reach, and the use of tools than the AR system. The findings of this study can be used as a guidance for the implementing virtual prototypes in the product development process.

Structure design of and experimental research on a two-stage laval foam breaker for foam fluid recycling.

Environmental, economical and efficient antifoaming technology is the basis for achievement of foam drilling fluid recycling. The present study designed a novel two-stage laval mechanical foam breaker that primarily uses vacuum generated by Coanda effect and Laval principle to break foam. Numerical simulation results showed that the value and distribution of negative pressure of two-stage laval foam breaker were larger than that of the normal foam breaker. Experimental results showed that foam-breaking efficiency of two-stage laval foam breaker was higher than that of normal foam breaker, when gas-to-liquid ratio and liquid flow rate changed. The foam-breaking efficiency of normal foam breaker decreased rapidly with increasing foam stability, whereas the two-stage laval foam breaker remained unchanged. Foam base fluid would be recycled using two-stage laval foam breaker, which would reduce the foam drilling cost sharply and waste disposals that adverse by affect the environment.

Estimation of methane emission from California natural gas industry.

UNLABELLED: Energy generation and consumption are the main contributors to greenhouse gases emissions in California. Natural gas is one of the primary sources of energy in California. A study was recently conducted to develop current, reliable, and California-specific source emission factors (EFs) that could be used to establish a more accurate methane emission inventory for the California natural gas industry. Twenty-five natural gas facilities were surveyed; the surveyed equipment included wellheads (172), separators (131), dehydrators (17), piping segments (145), compressors (66), pneumatic devices (374), metering and regulating (M&R) stations (19), hatches (34), pumps (2), and customer meters (12). In total, 92,157 components were screened, including flanges (10,101), manual valves (10,765), open-ended lines (384), pressure relief valves (358), regulators (930), seals (146), threaded connections (57,061), and welded connections (12,274). Screening values (SVs) were measured using portable monitoring instruments, and Hi-Flow samplers were then used to quantify fugitive emission rates. For a given SV range, the measured leak rates might span several orders of magnitude. The correlation equations between the leak rates and SVs were derived. All the component leakage rate histograms appeared to have the same trend, with the majority of leakage rates<0.02 cubic feet per minute (cfm). Using the cumulative distribution function, the geometric mean was found to be a better indicator than the arithmetic mean, as the mean for each group of leakage rates found. For most component types, the pegged EFs for SVs of ≥10,000 ppmV and of ≥50,000 ppmV are relatively similar. The component-level average EFs derived in this study are often smaller than the corresponding ones in the 1996 U.S. Environmental Protection Agency/Gas Research Institute (EPA/GRI) study. IMPLICATIONS: Twenty-five natural gas facilities in California were surveyed to develop current, reliable, and California-specific source emission factors (EFs) for the natural gas industry. Screening values were measured by using portable monitoring instruments, and Hi-Flow samplers were then used to quantify fugitive emission rates. The component-level average EFs derived in this study are often smaller than the corresponding ones in the 1996 EPA/GRI study. The smaller EF values from this study might be partially attributable to the employment of the leak detection and repair program by most, if not all, of the facilities surveyed.

Methane emissions from natural gas compressor stations in the transmission and storage sector: measurements and comparisons with the EPA greenhouse gas reporting program protocol.

Equipment- and site-level methane emissions from 45 compressor stations in the transmission and storage (T&S) sector of the US natural gas system were measured, including 25 sites required to report under the EPA greenhouse gas reporting program (GHGRP). Direct measurements of fugitive and vented sources were combined with AP-42-based exhaust emission factors (for operating reciprocating engines and turbines) to produce a study onsite estimate. Site-level methane emissions were also concurrently measured with downwind-tracer-flux techniques. At most sites, these two independent estimates agreed within experimental uncertainty. Site-level methane emissions varied from 2-880 SCFM. Compressor vents, leaky isolation valves, reciprocating engine exhaust, and equipment leaks were major sources, and substantial emissions were observed at both operating and standby compressor stations. The site-level methane emission rates were highly skewed; the highest emitting 10% of sites (including two superemitters) contributed 50% of the aggregate methane emissions, while the lowest emitting 50% of sites contributed less than 10% of the aggregate emissions. Excluding the two superemitters, study-average methane emissions from compressor housings and noncompressor sources are comparable to or lower than the corresponding effective emission factors used in the EPA greenhouse gas inventory. If the two superemitters are included in the analysis, then the average emission factors based on this study could exceed the EPA greenhouse gas inventory emission factors, which highlights the potentially important contribution of superemitters to national emissions. However, quantification of their influence requires knowledge of the magnitude and frequency of superemitters across the entire T&S sector. Only 38% of the methane emissions measured by the comprehensive onsite measurements were reportable under the new EPA GHGRP because of a combination of inaccurate emission factors for leakers and exhaust methane, and various exclusions. The bias is even larger if one accounts for the superemitters, which were not captured by the onsite measurements. The magnitude of the bias varied from site to site by site type and operating state. Therefore, while the GHGRP is a valuable new source of emissions information, care must be taken when incorporating these data into emission inventories. The value of the GHGRP can be increased by requiring more direct measurements of emissions (as opposed to using counts and emission factors), eliminating exclusions such as rod-packing vents on pressurized reciprocating compressors in standby mode under Subpart-W, and using more appropriate emission factors for exhaust methane from reciprocating engines under Subpart-C.

Mechanical expansion of steel tubing as a solution to leaky wellbores.

Wellbore cement, a procedural component of wellbore completion operations, primarily provides zonal isolation and mechanical support of the metal pipe (casing), and protects metal components from corrosive fluids. These are essential for uncompromised wellbore integrity. Cements can undergo multiple forms of failure, such as debonding at the cement/rock and cement/metal interfaces, fracturing, and defects within the cement matrix. Failures and defects within the cement will ultimately lead to fluid migration, resulting in inter-zonal fluid migration and premature well abandonment. Currently, there are over 1.8 million operating wells worldwide and over one third of these wells have leak related problems defined as Sustained Casing Pressure (SCP). The focus of this research was to develop an experimental setup at bench-scale to explore the effect of mechanical manipulation of wellbore casing-cement composite samples as a potential technology for the remediation of gas leaks. The experimental methodology utilized in this study enabled formation of an impermeable seal at the pipe/cement interface in a simulated wellbore system. Successful nitrogen gas flow-through measurements demonstrated that an existing microannulus was sealed at laboratory experimental conditions and fluid flow prevented by mechanical manipulation of the metal/cement composite sample. Furthermore, this methodology can be applied not only for the remediation of leaky wellbores, but also in plugging and abandonment procedures as well as wellbore completions technology, and potentially preventing negative impacts of wellbores on subsurface and surface environments.

Design and development of turbodrill blade used in crystallized section.

Turbodrill is a type of hydraulic axial turbomachinery which has a multistage blade consisting of stators and rotors. In this paper, a turbodrill blade that can be applied in crystallized section under high temperature and pressure conditions is developed. On the basis of Euler equations, the law of energy transfer is analyzed and the output characteristics of turbodrill blade are proposed. Moreover, considering the properties of the layer and the bole-hole conditions, the radical size, the geometrical dimension, and the blade profile are optimized. A computational model of a single-stage blade is built on the ANSYS CFD into which the three-dimensional model of turbodrill is input. In light of the distribution law of the pressure and flow field, the functions of the turbodrill blade are improved and optimized. The turbodrill blade optimization model was verified based on laboratory experiments. The results show that the design meets the deep hard rock mineral exploration application and provides good references for further study.

Uplifting behavior of shallow buried pipe in liquefiable soil by dynamic centrifuge test.

Underground pipelines are widely applied in the so-called lifeline engineerings. It shows according to seismic surveys that the damage from soil liquefaction to underground pipelines was the most serious, whose failures were mainly in the form of pipeline uplifting. In the present study, dynamic centrifuge model tests were conducted to study the uplifting behaviors of shallow-buried pipeline subjected to seismic vibration in liquefied sites. The uplifting mechanism was discussed through the responses of the pore water pressure and earth pressure around the pipeline. Additionally, the analysis of force, which the pipeline was subjected to before and during vibration, was introduced and proved to be reasonable by the comparison of the measured and the calculated results. The uplifting behavior of pipe is the combination effects of multiple forces, and is highly dependent on the excess pore pressure.

Experimental study of the vortex-induced vibration of drilling risers under the shear flow with the same shear parameter at the different Reynolds numbers.

A considerable number of studies for VIV under the uniform flow have been performed. However, research on VIV under shear flow is scarce. An experiment for VIV under the shear flow with the same shear parameter at the two different Reynolds numbers was conducted in a deep-water offshore basin. Various measurements were obtained by the fiber bragg grating strain sensors. Experimental data were analyzed by modal analysis method. Results show several valuable features. First, the corresponding maximum order mode of the natural frequency for shedding frequency is the maximum dominant vibration mode and multi-modal phenomenon is appeared in VIV under the shear flow, and multi-modal phenomenon is more apparent at the same shear parameter with an increasing Reynolds number under the shear flow effect. Secondly, the riser vibrates at the natural frequency and the dominant vibration frequency increases for the effect of the real-time tension amplitude under the shear flow and the IL vibration frequency is the similar with the CF vibration frequency at the Reynolds number of 1105 in our experimental condition and the IL dominant frequency is twice the CF dominant frequency with an increasing Reynolds number. In addition, the displacement trajectories at the different locations of the riser appear the same shape and the shape is changed at the same shear parameter with an increasing Reynolds number under the shear flow. The diagonal displacement trajectories are observed at the low Reynolds number and the crescent-shaped displacement trajectories appear with an increasing Reynolds number under shear flow in the experiment.

Injury rates on new and old technology oil and gas rigs operated by the largest United States onshore drilling contractor.

BACKGROUND: Occupational fatality rates among oil and gas extraction industry and specifically among drilling contractor workers are high compared to the U.S. all-industry average. There is scant literature focused on non-fatal injuries among drilling contractors, some of which have introduced engineering controls to improve rig efficiency and reduce injury risk. METHODS: We compared injury rates on new and old technology rigs operated by the largest U.S. drilling contractor during 2003-2012, stratifying by job type and grouping outcomes by injury severity and body part affected. RESULTS: Six hundred seventy-one injuries were recorded over 77.4 million person-hours. The rate on new rigs was 66% of that on old rigs. Roughnecks had lower injury rates on new rigs, largely through reduced limb injury rates. New rigs had lower rates in each non-fatal injury severity category. CONCLUSIONS: For this company, new technology rigs appear to provide a safer environment for roughnecks. Future studies could include data from additional companies.

Ultrasonic oil recovery and salt removal from refinery tank bottom sludge.

The oil recovery and salt removal effects of ultrasonic irradiation on oil refinery tank bottom sludge were investigated, together with those of direct heating. Ultrasonic power, treatment duration, sludge-to-water ratio, and initial sludge-water slurry temperature were examined for their impacts on sludge treatment. It was found that the increased initial slurry temperature could enhance the ultrasonic irradiation performance, especially at lower ultrasonic power level (i.e., 21 W), but the application of higher-power ultrasound could rapidly increase the bulk temperature of slurry. Ultrasonic irradiation had a better oil recovery and salt removal performance than direct heating treatment. More than 60% of PHCs in the sludge was recovered at an ultrasonic power of 75 W, a treatment duration of 6 min, an initial slurry temperature of 25°C, and a sludge-to-water ratio of 1:4, while salt content in the recovered oil was reduced to <5 mg L(-1), thereby satisfying the salt requirement in refinery feedstock oil. In general, ultrasonic irradiation could be an effective method in terms of oil recovery and salt removal from refinery oily sludge, but the separated wastewater still contains relatively high concentrations of PHCs and salt which requires proper treatment.

Fish assemblages associated with oil industry structures on the continental shelf of north-western Australia.

This study provides the first assessment of fish associations with oil and gas structures located in deep water (85-175 m) on Australia's north-west continental shelf, using rare oil industry video footage obtained from remotely operated vehicles. A diverse range of taxa were observed associating with the structures, including reef-dependent species and transient pelagic species. Ten commercially fished species were observed, the most abundant of which was Lutjanus argentimaculatus, with an estimated biomass for the two deepest structures (Goodwyn and Echo) of 109 kg.

Chemical and biological assessment of two offshore drilling sites in the Alaskan Arctic.

A retrospective chemical and biological study was carried out in Camden Bay, Alaskan Beaufort Sea, where single exploratory oil wells were drilled at two sites more than two decades ago. Barium from discharged drilling mud was present in sediments at concentrations as high as 14%, ~200 times above background, with significantly higher concentrations of Ba, but not other metals, within 250 m of the drilling site versus reference stations. Elevated concentrations of Cr, Cu, Hg and Pb were found only at two stations within 25 m of one drilling site. Concentrations of total polycyclic aromatic hydrocarbons (TPAH) were not significantly different at reference versus drilling-site stations; however, TPAH were elevated in Ba-rich layers from naturally occurring perylene in ancient formation cuttings. Infaunal biomass and species abundance were not significantly different at reference versus drilling-site stations; infauna were less diverse at drilling-site stations. Our assessment showed that discharges from single wells within large areas caused minimal long-term, adverse impacts to the benthic ecosystem.

Different roles in the quest for system resilience.

Into dangerous and complex systems with high degree of interactivity between its components, the variability is present at all time, demanding a high degree of control of its operation. Maintaining or recovering the normality, when the system is under some stress (instability) is a function of Resilience. To cope with prevention, forecast, recovery and with memory of experiences from learned lessons requires some features from the companies. This paper purposes a structure that enables the Total Resilience of a system production that defines the assignments for Workers, Designers and Management Team, according to its features and possibilities. During one year and a half developing studies on ergonomics area of a Brazilian Oil Refinery, several situations were observed and studied using Work Ergonomic Analysis. These situations show actions and strategies that workers use to maintain the system stability. Furthermore, they revealed the importance that these actions are stored in a database of learned lessons from the Company. The research resulted in a broad scheme. It places each of these groups in the process of Total Resilience. It also shows the human like a center of actions that ensure the continuity of the system, main element at Resilience (Anthropocentric View).

Characterization of corrosive bacterial consortia isolated from petroleum-product-transporting pipelines.

Microbiologically influenced corrosion is a problem commonly encountered in facilities in the oil and gas industries. The present study describes bacterial enumeration and identification in diesel and naphtha pipelines located in the northwest and southwest region in India, using traditional cultivation technique and 16S rDNA gene sequencing. Phylogenetic analysis of 16S rRNA sequences of the isolates was carried out, and the samples obtained from the diesel and naphtha-transporting pipelines showed the occurrence of 11 bacterial species namely Serratia marcescens ACE2, Bacillus subtilis AR12, Bacillus cereus ACE4, Pseudomonas aeruginosa AI1, Klebsiella oxytoca ACP, Pseudomonas stutzeri AP2, Bacillus litoralis AN1, Bacillus sp., Bacillus pumilus AR2, Bacillus carboniphilus AR3, and Bacillus megaterium AR4. Sulfate-reducing bacteria were not detected in samples from both pipelines. The dominant bacterial species identified in the petroleum pipeline samples were B. cereus and S. marcescens in the diesel and naphtha pipelines, respectively. Therefore, several types of bacteria may be involved in biocorrosion arising from natural biofilms that develop in industrial facilities. In addition, localized (pitting) corrosion of the pipeline steel in the presence of the consortia was observed by scanning electron microscopy analysis. The potential role of each species in biofilm formation and steel corrosion is discussed.