This paper was prepared for presentation at the 2007 International Oil Conference and Exhibition in Mexico. Paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Paper does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members.
This paper was prepared for presentation at the 2007 International Oil Conference and Exhibition in Mexico. Paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Paper does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members.
This paper was prepared for presentation at the 2007 International Oil Conference and Exhibition in Mexico. Paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Paper does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members.
Environmentally Safe Waste Disposal: The Integration of Cuttings Collection,
Transport, and Reinjection A. Alba, F. Fragachan, A. Ovalle, and T. Shokanov, M-I Swaco Copyright 2007, Society of Petroleum Engineers
This paper was prepared for presentation at the 2007 International Oil Conference and Exhibition in Mexico held in Veracruz, Mexico, 2730 June 2007.
This paper was selected for presentation by an SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or members. Papers presented at SPE meetings are subject to publication review by Editorial Committees of the Society of Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, Texas 75083-3836 U.S.A., fax 01-972-952-9435.
Abstract The development of new oilfield technologies to explore such remote areas as deep waters and environmentally sensitive locations brings with it increased emphasis on protecting the natural resources of the drilling area. Accordingly, many regulatory agencies demanding zero discharge policies require all generated wastes to be disposed in a responsible manner. Such process requires the adequate management of wastes generated during drilling operations including cuttings, excess drilling fluid, contaminated rainwater, produced water, scale, produced sand, and even production and cleanup waste. Old practices involve temporary box storage and hauling of the waste products to a final disposal site. Often, these sites are several kilometers away from the generation source, creating not only liabilities for the operating company but also environmental risks such as accidental spills, gas emissions and eventually high operating costs. Over the years, waste management technologies have evolved to address environmental solutions in the most efficient and cost-effective processes. As such, Cutting Re- Injection (CRI) nowadays is considered top-of-the line technology for the final disposal of drilling wastes through sub-surface injection into an engineered-designated formation where wastes are permanently contained. Transporting the wastes to the final disposal well poses a challenge in large development fields, where the most cost-effective solution is often to drill a dedicated injector and convey all produced wastes to the site. This paper addresses the success of integrating methodologies for containing, handling, and transporting drill cuttings from several drill sites to a unique CRI well, where wastes are injected for final and responsible disposal. Case histories of several sites around the world are presented as they used different process configurations to achieve the common final objective: a cost-effective and environmentally friendly solution for waste management.
Introduction The three main drivers for the selection of a cuttings collection and transport system and re-injection package are regulations, logistics and cost. Depending on the country, region or marine area, the existing regulations may or may not allow discharge or transportation of the waste. In some areas where legislations are less stringent, transportation of generated waste to satellite disposal sites (in land or offshore) is allowed. In highly sensitive areas in which zero discharge policies are strictly enforced, all generated waste must be stored, treated and disposed in-situ. Because of such limitations, drilling operations were often limited by the collection capacity and ability of the CRI system to inject all waste concurrently. The new approach is to decouple the injection process from the drilling operation, providing a totally independent cost- effective process. For the logistics, the main limitations are determined by rig configuration, availability of space, types of materials, distance of the material transportation, and safety, which ultimately translate into costs. Therefore, each operation should be analyzed individually to determine compliance with local regulations, logistics and cost involved so proper collection, transport and re-injection packages are tailored to fulfill the specific needs of the project. The best approach to provide the most reliable solution for environmentally safe waste disposal has been identified as the integration of cuttings collection and pneumatic transport system as part of the CRI package.
Cuttings Re-Injection In general, CRI is a process wherein solids (cuttings) and liquids (waste fluids) are gathered and conveyed to a series of components that classify, degrade, mix, and condition them into an stable and pumpable slurry. This slurry is then hydraulically injected into a subsurface formation that is receptive and permanently isolated at a safe depth beneath a cap-rock to prevent propagation to the surface. The main advantages of CRI are: No release to surface environment, providing full compliance with zero discharge policies. Reducing the logistical burden. 2 SPE 108912 Limited risk of environmental discharge during transportation. Total control for the operator, who can oversee and manage the whole process in-situ. Cost effective. The versatility of CRI has made it an attractive fit-for- purpose solution that has been proven to work onshore and offshore, for tubular or annular injections, and in abandoned, currently used or dedicated wells. One of the most attractive configurations shown in Figure 1 is commonly used in the North Sea, where the slurry injection takes place into a producer annulus simultaneously with production in the same wellbore with cuttings coming from a drilling well within the same platform.
Figure 1. Simultaneous Drilling, Production and CRI
A successful CRI operation requires a system capable of delivering the required fluid volumes downhole at adequate pressures. Each CRI system should be configured to satisfy the disposal volume requirement and fit the space available in the rig. Typically, equipment is skidded to allow unitization in a close cluster, allowing the CRI package to be distributed throughout the available space when necessary. Overall, a Cuttings Re-Injection package is comprised of three principal components: 1. Cuttings Transport System 2. Slurrification System 3. Re-Injection System Figure 2 illustrates a basic CRI configuration with all equipment from all three systems.
Cuttings Transport System The main purpose of this system is to convey cuttings from point A to point B as necessary. The simplest configuration is to transport cuttings from the shakers to the slurrification system by gravity, but more complex configurations are necessary depending on the rig space availability and how equipment is spread out along the rig floor. In addition, in many cases cuttings or slurries need to be transported from the source location to the CRI injector well.
Figure 2. CRI Basic Equipment
To suit all different options, four transport systems are available: 1. Gravity Collection System 2. Augers or Belt Conveyors System 3. Vacuum Transport System 4. Pneumatic Bulk Transfer and Storage System All systems have been proven to work with certain limitations, but they can be implemented in conjunction with each other to provide improved results.
Gravity Collecting System In the Gravity Collection System, the force of gravity allows liquids and solids to flow from a higher elevation to a lower elevation as illustrated in Figure 3. This system is the simplest of all, and it is often the preferred option, but its use is not always possible due to space limitation on the rig floor.
Figure 3. Cuttings Discharge into Barge
Augers or Belt Conveyor System Augers shown in Figure 4 and Belt Conveyors Systems transport solids and solid/liquids blend by mechanical means in an effective manner, but is limited by high liquid content, short distances, elevation, direction change; the longer the auger the more degradation to materials. This option is simple and inexpensive if all equipment is on a vertical plane or at SPE 108912 3 lower elevations as it is virtually impossible to move high liquid content upwards; or else, rig modifications to fit this requirement will be major and costly. One important aspect is that cuttings are exposed during this type of transport, and foreign materials can easily plug or jam the system. Also, it is very common that cuttings do not always fit containers with 100% efficiency.
Figure 4. Auger used for Transport
Vacuum Transport System With the Vacuum Transport System, solids and liquids are transported by vacuum-drawn air in fixed lines using a vacuum blower unit. This system transports dry materials as well as wet materials from deck and pit cleaning. Vacuum Transport Systems provide a good option if the CRI equipment layout is more widespread or if the deck is higher than the cuttings ditch. However, the transportation distance is often limited and will depend on the combined vertical and horizontal distance, the material properties, as well as the expected rate of drilling, which will also determine with amount and type of units to be selected. Figure 5 shows a dual vacuum system
Figure 5. Dual Vacuum Transport System
Pneumatic Bulk Transfer and Storage System Bulk Transfer and Storage System allow de-coupling of the CRI injection process from the drilling operation providing better control over the slurry quality rather than being under command of the ROP. Solids and liquids can be transferred by a pneumatic system using positive air pressure and stored in tanks as shown in Figure 6. This system has a few limitations and allows transportation for longer distances and different heights, and adds an excellent contingency to temporary handling during downtimes without affecting the drilling program. By being a closed system, it can transport wet or dry materials in a safer and efficient manner.
Figure 6. Pneumatic Bulk Transfer and Storage System
Pneumatic Bulk Transfer and Storage technology was developed in 1998 as a response to logistics, safety and environmental concerns encountered while transporting cuttings with conventional mechanical systems and cutting boxes. Operational issues included dependency on cranes, ability to maintain boxes, reliability of the equipment, potential injuries to personnel, and risks of potential spillage. It has been proven effective on semi-submersible and jack- up mobile drilling rigs, platforms, supply boats, barges, and land rigs, with over 500,000 m of well drilled over 50,000 hours of running time, and total recorded availability or uptime of the system of 99.7%. It has been successful transporting water base cuttings as well as oil base cuttings even in hostile environments. The system comprises a blower, specially designed tanks, and a diverting valve. The blower is the prime mover of the system, it is a pressurized vessel equipped with an inlet valve, and outlet valve, and a feeder hopper mounted on top as shown in Figure 7.
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Figure 7. Blower for Pneumatic Bulk Transfer
The specially designed tanks are a combination of storage vessel and conveying device that can be transported fully lade with cuttings by road or rail to a discharge location. As each pump is an independent unit, these tanks provide extra storage allowing uninterrupted drilling totally decoupled from the CRI operation. These tanks are built within a standard ISO container frame (20-ft) with high structural strength, and which only moving part is the outlet valve as illustrated in Figure 8.
Figure 8. Specially Designed Tanks for Pneumatic Bulk Transfer and Storage Cuttings feed into the blower unit can be controlled by a timer or hopper-level probes. When the unit is filled, it is automatically sealed and pressurized, then compressed air conveys the material and discharges it as a batch. Once a tank is full, the valve is used to divert the cuttings to the next available tank. Some of the advantages are: Environmentally sound design. Once cuttings enter the blower unit, they are contained into a close system avoiding foreign materials and isolated from personnel for safety. System flexibility. Blower units can be used to convey cuttings in a large variety of applications not limited to tanks, skips, but also including dryers, CRI units, thermal treatment units, barges, dumper trucks, disposal sites, among others. Efficiency. Cuttings can be transported for considerable distances, and it can also achieve significant vertical lifts. Reliability. Few moving parts that make units more robust, resulting in automatic operations that could be run on a variable timer if required. Smaller foot print. Compact design that saves valuable rig-floor space. Pneumatic Bulk Transfer and Storage technology has been awarded the U.S. National Ocean Industries Association (NOIA) Safety in Seas Award in 2006, becoming the leading technology for waste collection and transport.
Slurrification System Once the cuttings have been transported from the source location, the CRI slurrification system provides a means of degradation to acceptable levels and homogenizing the cuttings into a quality-slurry acceptable for down-hole injection operations. The process could require separate grinding applications when coarse materials are present or during periods of heavy sands, but in general a typical slurrification system includes: 1. Coarse Tank 2. Classification Shaker and Grinder 3. Fines Tank
Coarse Tank Once cuttings enter the slurry unit, they are mixed and blended with water by circulating the cuttings in the Coarse Tank using centrifugal degradation pumps. These pumps are modified centrifugal pumps equipped with special shortened, hard-faced impeller blades that increase the attrition in the pumping chamber, accelerating the degradation of the solids to quickly form slurry. The housing on the pumps also is equipped with hardened steel to minimize erosion from the sands. When the Coarse Tank is almost full, the modified Centrifugal Pumps transfer the slurry to a classification shaker.
SPE 108912 5 Classification Shaker and Grinder The classification shaker performs at least three important functions: Ensures proper particle size for the injection slurry Removes fines that would otherwise take up valuable mill volume, thus slowing the grinding process Eliminate fines before they are ground too fine, thus consuming extra time and energy Material not reduced to specified size by the centrifugal pumps will be further reduced by a grinder. Particles that do not meet the size specifications are transferred through the grinder then pumped back over the classification shaker. This process is a complete close loop system with the sand, which greatly helps to minimize the extreme wear on the centrifugal degradation pumps. The capability of a grinding system to perform its task effectively depends on the size reduction of the coarse material, and the removal fines from the circuit
Fines Tank Particles that meet the required specifications fall through the screen and enter the Fines Tank where the quality control and quality assurance process is verified. Conditioned slurry is prepared by mixing the correct ratio of solids to liquids, and proper chemical treatment to assure homogeneity and stability. Once the CRI operator is satisfied that the slurry meets the required criteria for re-injection the slurry is transferred to the Holding Tank, which is part of the Re-Injection package.
Re-Injection Package Each Re-Injection Package is designed to fit the project needs and limitations, while tailoring slurry parameters, injection well, and required hardware for monitoring. Overall, the three main components of this package include: 1. Holding Tank 2. Injection Pump 3. Data Acquisition and Monitoring System
Holding Tank Holding Tanks receive slurry only from the Fines Tank via the classification shaker. The classification shaker ensures all oversized material is discharged from the end of the shaker and returned for further processing. An agitator in each tank ensures the cuttings are kept dispersed and in suspension until the CRI operator determines the time for injection. At that stage, the slurry is transferred using the centrifugal pump on the CRI skid, to the HP Injection Pump low-pressure manifold to the selected HP re-injection pump, then down hole and into the chosen host formation. Holding tanks have a dual function, one is to store slurry batch for injection, and also in many cases these are used as a second quality control and quality assurance point. In the event slurry is found out of specifications, it is possible to re- condition the slurry thanks to its design. The tank is partitioned to include a higher volume of quality slurry and smaller volume for pill mix tank. The pill mix tank has a jet hopper located above it where a high viscous pill can be pre- made and introduced into the slurry as required to meet the required slurry characteristics.
I njection Pump The high pressure pump is designed to fit the characteristics of each job based on volumes, rates and pressures. It is important to specify proper injection pump to be able to handle and keep up with drilling operations when performed simultaneously.
Data Acquisition and Monitoring System One of the key elements for ensuring safe and seamless CRI operations is continuously monitoring injection parameters with regular in-depth injection pressure analysis. Historical injection data from other CRI projects proves that even the most detailed and comprehensive geo-mechanical model created during the initial design stage has to be validated and updated as injections progress. Monitoring of injection parameters provide the best risk mitigation and management tool. This process starts with detailed assessment of all of the injection parameters and events recorded during injection on a daily basis. These parameters include Injection rate, Injection Pressure, Injection time, Shut-in time, and Fluid rheology.
CRI Configurations Endless possibilities for cuttings collection and transport during CRI are available. Some of the most popular will be described below. Figure 9 and Figure 10 show some of the simplest configurations using augers, one connected directly to the CRI slurrification system, and the other filling cuttings boxes to be transported to a different location. Figure 11, illustrates a combination of auger and vacuum transport systems, while Figure 12 shows a typical vacuum system for CRI operations. When regulations permit, transport to shore or inter-field can be achieved by using vacuum systems for skip and ship transport as shown in Figure 13. Figure 14 shows Pneumatic Bulk Transfer and Storage System used for CRI operations. Notice that the number of tanks required, will de different depending on the type of job, storage capacity required, and availability of rig space.
Case 1 Case 1 represents one of the few CRI dedicated platforms in the world. In two and a half years of operation, nearly 1.3 million Bbls of waste have been injected into this platform. For this massive job, cuttings are collected in boxes and transported by boat from dozen of neighbor offshore wells. Once cuttings arrive to the dedicated CRI platform, cuttings are emptied by a hydraulic tipper that fills blower units for easier transport within the platform as shown in Figure 15. In addition, 12 specially designed tanks are used for additional storage and improved transport capacity in the platform. Although hydraulic tippers have improved the overall process, delays and equipment failure are often encountered due to foreign material and trash dumped into the cutting boxes as illustrated in Figure 16 and Figure 17.
6 SPE 108912 Case 2 Case 2 is an example for an area with strict zero discharge policies, by which no cuttings disposal overboard for water base mud is allowed. Cuttings are collected in boxes through a lifting crane to the supply vessel as shown in Figure 18. Even though regulations are fulfilled, the risks for spillage and personnel injuries are imminent. Lifting-related incidents involve about 20% of all accidents reported in offshore drilling operations according to the UK HSE OSD research report 183, 2004. For example, Norway had 8 fatalities related to lifting 1994-2004 according to the Norwegian PSA 33.790.007, June 2005.
Case 3 Case 3 illustrates the safest collection and transport system for CRI operations when injection is not feasible in the same location in which cuttings were generated. For this case, cuttings are stored on the rig illustrated in Figure 19, and their subsequently transferred to a supply boat by a 5 inch hose as shown in Figure 20 and Figure 21.
Conclusions The safest and most environmentally acceptable option for waste disposal is achieved by the integration of Pneumatic Bulk Transfer and Storage and CRI technologies. They both have been proven in different locations under a variety of conditions, fulfilling all the requirements of the most stringent regulations such as the zero discharge policy. The initial investment to implement these two technologies is high at the beginning of the project, but the return of investment is favorable in the long run. Different collection and transport systems are available, one or a combination of several can be used for a particular project. The main drivers for selection are logistics, safety and cost. Decoupling CRI from drilling operation provides huge benefits for the operator, especially while drilling top hole intervals, in which large volumes of waste are generated at fairly high rates. Savings in time while drilling is highly appreciated by operators, who are allowed to reach target times for production on-time or even earlier than anticipated.
Acknowledgments The authors wish to thank for their unconditional help and support: Gary Woolsey: CRI Operations Manager Technical Support, M-I SWACO. Jan Thore Eia: Cuttings Handling and Transportation Business Development Manager, M-I SWACO. Slava Anokhin, Julio Ronderos, and Said Benelkadi: GeoMechanics Engineers, CRI Sub-Surface, M-I SWACO.
References J.T. Eia, E. Hernandez: Environmental Advances in Drilling Fluids and Waste Operations Applying Novel Technology for Fluid Recovery and Recycling, SPE 102737 paper presented at the 2006 SPE Russian Oil and Gas Technical Conference and Exhibition held in Moscow, Russia, 3-6 October. Q. Guo, T. Geehan, A. Ovalle: Increase Assurance of Drill Cuttings Re-Injection Challenges, Recent Advances and Case Studies, SPE 87972 paper presented at the 2004 IADC/SPE Kuala Lumpur, Malaysia, 13-15 September. R C. Minton: The pneumatic collection, handling and transportation of oily cuttings Two years of field experience, SPE 83727, paper presented at the 2003 E&P Environmental Conference, San Antonio, Texas, March 2003.
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Figure 9. Auger Transport to Slurrification Unit
Figure 10. Auger Transport to Cuttings Boxes
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Figure 11. Auger-Vacuum Transport
Figure 12. Vacuum Collection System SPE 108912 9
Figure 13. Vacuum System for Skip and Ship
Figure 14. Pneumatic Transfer and Storage System 10 SPE 108912
Figure 15. CRI Dedicated Platform
Figure 16. Cuttings Boxes with Trash Figure 17. Equipment Failure due to Trash
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Figure 18. Lifting Crane for Cuttings Boxes Transport Figure 19. Specially Designed Tanks Installed on the Rig
Figure 20. Pneumatic Bulk Transfer from Rig to Boat Figure 21. Specially Designed Tanks in Boat