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Noise, chemicals, and other workplace hazards
Abstract Acid gases are produced as part of normal operation of Ethane crackers. Raw ethane contains impurities in minor amount consisting of CO2, H2S, COS and CO which need to be removed and disposed safely. These acid gases are removed in feed pretreatment section of the cracker unit and subsequently burnt in acid gas flare for safe disposal. Due to low calorific value of these components, some amount of natural gas is mixed with the acid gas to enable complete combustion and H2S destruction. Due to this addition of natural gas to the acid gases, there is always some amount of potential product being lost to flare. These additional emissions are due to natural gas injection which can be avoided by alternate routing of acid gas safely.
- Energy > Oil & Gas > Upstream (1.00)
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (0.68)
- Reservoir Description and Dynamics > Improved and Enhanced Recovery (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
- Health, Safety, Environment & Sustainability > Environment > Air emissions (1.00)
Breaking Barriers: Downhole H2S Scavenger Automation Pilot Trial Intellisweet
Abd-Rahman, A-Sukaimy (Brunei Shell Petroleum Co) | Turner, Michael (Brunei Shell Petroleum Co) | Kulkarni, Rahul (Brunei Shell Petroleum Co) | McGregor, Stuart (Shell UK Ltd) | Ajibode, Sulaimon (Baker Hughes) | Leidensdorf, Jeremy (Baker Hughes) | Pukall, Alejandro (Baker Hughes) | Othman, Abdullah (Baker Hughes)
Abstract Seawater Injection has been used in Offshore field as a means of pressure maintenance for improving oil recovery. Since there is no Sulphate removal and Nitrate injection from Day 1, H2S generation from Sulphate Reducing Bacteria (SRBs) has led to reservoir souring. This has led to a serious attention to manage the H2S production risks in terms of health, safety and environment (HSE). A new technology with real time H2S Scavenger and Automation was trialled in an offshore oil production platform. INTELLISWEET automated H2S chemical management system is an intelligent chemical injection system that enables autonomous and controlled H2S scavenger injection rates based on well and topside production conditions. Mixed production fluid samples are continuously collected from wellhead, passed through temperature/pressure conditioning, and through a series of sample conditioning and analysis to allow for accurate measurement of the total H2S in the produced fluid. The field trial was conducted in an offshore facility platform in a well with a downhole capillary string chemical injection in an Electrical Submersible Pump (ESP) well. Based on the field trial outcome, a reduction in the H2S ppm (as low as 4ppm) and the % removal efficiency of up to 98% was observed. The system package has proven to be effective in maintaining H2S levels below target while allowing 24h online remote monitoring and the ability to make changes remotely as well. This first of its kind digital automation system continuously captures data that shows chemical pump performance, amounts of H2S being produced and scavenged, amounts of H2S scavenger being injected, well production data, alerts of system anomalies, and various other information that gives total visibility of the chemical injection treatment program. With INTELLISWEET, a reliable cost-effective automated removal of total H2S in the oilfield can be achieved. It allows for minimized HSE risk of employees โ less field exposure, unlocks access to high H2S well reserves, and gives remote access to monitor and control H2S chemical injection treatment programs with automated and optimized dosages.
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
Underbalance Coil Tubing Drilling in Depleted Tight Gas Reservoir with Closed Loop System - Contributed Towards Adnoc Sustainability Targets by Minimizing Hydrocarbon Flaring in High Sour Gas Well
Siddiqui, Muhammad Ali (ADNOC Onshore) | Al Hosani, Abdullah Alhaj (ADNOC Onshore) | Subaihi, Maad Hasan Qayed (ADNOC Onshore) | Al Janahi, Mohammed Ibrahim (ADNOC Onshore) | Zain, Fawad (ADNOC Onshore) | Baslaib, Mohamed Ahmed (ADNOC Onshore) | Al Zarouni, Abdulla Haidar Abdulla (ADNOC Onshore) | AlBlooshi, Maryam Omar (ADNOC Onshore) | Alhammadi, Reem Mohamed (ADNOC Onshore) | El-Meguid, Mohamed Osama Abd (ADNOC Onshore) | Ahmad, Mubashir (ADNOC Onshore) | Al Marzouqi, Abdulla Mohammed (ADNOC Onshore) | Al Mutawa, Ahmed (ADNOC Onshore) | Shahat, Ayman El (ADNOC Onshore) | Sumaida, Ali Sulaiman Bin (ADNOC Onshore)
Abstract With the depletion of reservoir pressure in low permeable formation, drilling (overbalance) always become challenging and thus the productivity due to high invasion. In order to opt the unconventional solution to maximize the recovery, it requires integrated approach such as underbalance coil tubing drilling with closed loop. The reason for opting the coiled tubing rather conventional underbalance drilling is due to high H2S in reservoir and closed loop system added to reduce emissions during projects. Since the world demands more energy with less emission, Under Balanced Drilling is one of the solutions to prevent formation damage while drilling alongside of production from well. The UBCTD (Underbalance Coil tubing Drilling) planning requires detailed feasibility study, well configuration design along with completion design. Extensive safety reviews of all the surface network and equipment was conducted to minimize the risk of operations. Live Real time data accusation, remote well control system, continuous Nitrogen purging for handling of highly volatile condensate & H2S & SO2 dispersion modeling were conducted and implemented for successful operation. ADNOC successfully conducted first trail of technology on one of the operating brown field. The well was freshly drilled, cased and cemented to the top of desired formation. The rig was released after running the completion and later coiled tubing brought to site to drill three lateral hole through specially designed BHAs (Bottom Hole Assembly) and maintaining continuous underbalance conditions. Selection of appropriate material from sub-surface to surface equipment's is the key consideration for success of project. The well was drilled under-balanced to allow wellbore cleaning and returns (drilling / formation fluids) were routed to closed loop separation system. The produced gas & condensate was routed towards plant via the production line through compression system. The drill cuttings dumped to the mud pits and the drilling fluid was re-circulated. Flaring of high H2S & CO2 gases impacting the environment were totally removed. Three laterals were drilled successfully with coil tubing underbalance drilling technology, the well was successfully tested with almost triple production from conventional lateral drilling. Further evaluation is in progress to develop the reservoir through technology. The trials proved a success in developing the depleted tight reservoirs with no Flaring thus saving environment and enhancing the productivity. This paper will elaborate the integrated approach for planning UBCTD (Underbalance Coil tubing Drilling) operation without flaring considering the operational, Safety and subsurface aspects. Furthermore, it will highlight, how the pilot technology can contribute towards ADNOC strategy towards net zero emission as one of the key pillars of sustainability.
- Energy > Oil & Gas > Upstream (1.00)
- Government > Regional Government > Asia Government > Middle East Government > UAE Government (0.93)
Abstract Sulphur is a vital and essential by-product of sour gas processing. Smooth operation of Sulphur production/ handling facilities is a key for business continuity in gas processing industry. Sulphur (Solid) is a challenging material to handle due to its brittle nature and prone to breakage due to abrasion during transport, storage, and handling. Excessive dust generation poses a serious safety risk due to explosive nature of Sulphur dust. Despite various measures to collect and suppress Sulphur dust, it remains a potential source of fire and explosion hazards, as well as maintenance issues Apart from other forms of Sulphur compound (H2S/SO2/SO3), elemental Sulphur itself in the form of yellow dust is also an environmental pollutant. Sulphur is transported mainly in solid form as liquid Sulphur transportation is a big hazard. This study is based on experience from a Sulphur granulation and handling facility in an organization which produces and handles the liquid /granulated Sulphur at a very large scale with around 22000 TPD. During transport / storage / handling, due to breakage of Sulphur granules, huge dust is generated. Being air-borne, this Sulphur dust has a great potential of fire/explosion and serious HSE concern for organization considering safety as its top priority. Considering above, strength of granulated Sulphur product is of utmost importance. This strength depends on polymeric content in Sulphur. Various old research used to recommend different operating parameters to increase and maintain the polymeric Sulphur content. One of the conventional approaches is to maintain high liquid Sulphur temperature during transportation and storage and cooling in Sulphur coolers just before solidification in granulation process through Granulators. Sulphur coolers and associated system are CAPEX intensive. This paper explores the possibility of eliminating the Sulphur coolers requirement to optimize the CAPEX.
- Facilities Design, Construction and Operation > Processing Systems and Design > Gas processing (0.89)
- Facilities Design, Construction and Operation > Natural Gas Conversion and Storage > Liquified natural gas (LNG) (0.65)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (0.54)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (0.54)
ESP Deployment Cable Demonstrates Resilience in the Face of Corrosion Challenges in Harsh Downhole Environments
Al Munif, E. H. (Saudi Aramco, Dhahran, Saudi Arabia) | Banjar, H. M. (Saudi Aramco, Dhahran, Saudi Arabia) | Ejim, C. E. (Saudi Aramco, Dhahran, Saudi Arabia) | Xiao, J. (Saudi Aramco, Dhahran, Saudi Arabia)
Abstract Electric Submersible Pumps (ESPs) face significant corrosion challenges in downhole environments due to high temperatures, pressures, and presence of corrosive fluids. These conditions can cause material degradation and severe damage, reducing equipment lifespan and impairing its performance. A Cable Deployed ESP (CDESP) is an alternative ESP deployment method, where the ESP is deployed by a specially designed cable with hydrogen sulfide (H2S)-resistant properties. This paper shares lessons learnt from three different CDESP installations. It discusses the findings and results of dismantling, inspection, and testing of the encapsulated cable, as well as various CDESP components, including the pump, motor, connector assembly, seal, and sensor. The encapsulated cable was specifically designed for utilization in production environments with high H2S. The paper aims to provide valuable information on the performance and durability of CDESP components in downhole environments with corrosive fluids, high temperatures, and pressures. The metal encapsulated power cable played a pivotal role in the CDESP system by offering outstanding shielding against H2S attacks and enabling a smooth outer diameter that could be easily grasped and sealed around. Furthermore, the cable was able to withstand harsh H2S environments with concentrations of up to 15mol% and chloride levels exceeding 150,000 ppm, proven from the lab and from the fields. While the developed cable proved to be robust and effective in harsh downhole conditions with high H2S concentration over a long period of time, the study findings indicate that other equipment components need to be improved to withstand corrosion. In all installations, signs of corrosion were observed on other system components such as thrust bearings and runners. Corrosion can cause blockages, increase friction, reduce system efficiency, and result in electrical or mechanical failures. Electrical failures include insulation failure on the cable, connectors and motor windings, while mechanical failures include bearings failure, broken shafts, pinholes and impellers damages. As a preventive measure to mitigate this corrosion from occurring in the seal and motor sections, an H2S scavenger (copper tube) can be installed to all seal chambers. In addition, pressure testing procedures during installation should be developed to enhance reliability. Overall, this paper highlights the effectiveness of the developed cable and the need for further improvements in other components to ensure long-term reliability and performance of downhole equipment.
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
Corrosion Study of a Trunk Line of Western Offshore of India
Talukdar, Maushumi Kakoti (Institute of Engineering and Ocean Technology Oil and Natural Gas Corporation Ltd. Phase II Panvel, Raigad, Maharashtra) | Bareja, Simran (Institute of Engineering and Ocean Technology Oil and Natural Gas Corporation Ltd. Phase II Panvel, Raigad, Maharashtra) | Saini, Arzoo (Institute of Engineering and Ocean Technology Oil and Natural Gas Corporation Ltd. Phase II Panvel, Raigad, Maharashtra)
ABSTRACT The Oil & Gas produced in one of the western offshore fields are carried through long distance pipelines to the onshore units, where they are processed for marketing. A number of leakages were reported in the Oil pipeline at different locations. It was commissioned in 2005 and the first leakage was observed in 2016 near the platform from where it is originating, and there after subsequent leakages were observed in 2018, 2022 and 2023. On analyzing the internal environment of the pipeline, the probable contributing factors were deduced. The water cut in the pipeline was reported as 1.5%, which shows the internal system remains oil wetted. The software study revealed the flow regime as transient. The microbial data shows the presence of SRB in the range of 10 per ml. As given in the leakage history, the leak location is primarily the butt weld in majority incidences with initial 26 kms of the pipeline. The bathymetry shows that there is sag and undulations in the segment of frequent leakage zone. As per thickness reduction data, there is severe metal loss in the nearby region of the leakages. The temperature profile shows that the temperature is in the range of 40-50ยฐC in the leaked portions of the pipeline. This temperature range works best for bacteria to flourish and enhance their activity substantially4. It is also observed that, the H2S concentration is approximately 1500 ppm at the onshore end of the pipeline. However, the concentration of H2S at the platform ends of lines that are connected to this main pipeline was reported to be within 400 ppm. In another study carried out at our institute in 2009 it was observed that at that time period the H2S concentration of this pipeline was around 300 ppm at the onshore end. These facts also support the proliferation of SRBs at the sag bends of the pipeline, whose presence has resulted in substantial increase in H2S in the pipeline. However, in the segment where there are no significant undulations, no leakage is reported till date. MTM survey also shows the thickness reduction in this segment is mostly in less severe zone. As the pipeline samples were not available for analysis but with all the supporting data it may be concluded that the leakages were mainly due to microbial induced corrosion (MIC). Adequate recommendations are deliberated in the technical paper. In the Gas line, the CO2 is present in range of 2.65 - 2.81 mole % while H2S concentration remains in range of 97 - 105 ppm. It is CO2 dominated system. The SRB count in the line is 10 which is very high. The high content of Iron in the Gas line shows that the corrosion is taking place and the line is susceptible to leakages. This study will help in deciding the future strategy of the lines.
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
Sour Service Fracture Toughness from Lab-Scale to Full-Scale: An Overview of the Impact of Test Parameters and How They Link with the Cracking Mechanism
Thรฉbault, F. (Vallourec OneR&D, Aulnoye-Aymeries, France) | Mizukami, A. (ADNOC, Abu Dhabi, Abu Dhabi, United Arab Emirates) | Andres, B. (ADNOC, Abu Dhabi, Abu Dhabi, United Arab Emirates) | Garcia, D. (Vallourec OneR&D, Aulnoye-Aymeries, France) | Gomes, C. (Vallourec OneR&D, Aulnoye-Aymeries, France) | Barsoum, I. (Khalifa University of Science and Technology, Abu Dhabi, Abu Dhabi, United Arab Emirates)
Unconventional wells are well known to be cost driven and require cost-effective material due to the shorter production cycle after hydraulic fracking than conventional developments. As many of ADNOC gas discoveries are deep carbonate reservoirs and inherently sour, Sulfide Stress Cracking (SSC) risk must be considered during completion design. The integration of fracture mechanics into that process requires the determination of an accurate measure of the fracture toughness against SSC, e.g. KISSC, such that the risk of burst can be predicted and avoided more accurately in the field. This paper reminds the learnings from previous attempts for correlating burst pressure obtained in full-scale tests with fracture mechanics outputs from small-scale sour tests. The most used and relevant fracture mechanics tests employed on high strength OCTG steels in sour environments are described in a second part. A third part is dedicated to the review of the most important parameters affecting the measurement of the SSC fracture toughness. Followed a discussion on the reason why a crack arrest test like NACE TM0177 DCB test provides higher KISSC than a crack start test like a constant load SENT test.
- North America > United States (1.00)
- Asia > Middle East > UAE (0.67)
- Well Completion > Hydraulic Fracturing (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
Underbalanced Coiled Tubing Drilling: Delivering Well Production Safely in High H2S and Tight Gas Reservoirs, UAE
Khan, Rao Shafin Ali (SLB (Corresponding author)) | Molero, Nestor (SLB) | Alam, Shah Sameer (SLB) | Mishael, Mohammad Basim (SLB) | Basha, Maged (SLB) | Zia, Arslan (SLB) | Zhylkaidarova, Sholpan (SLB) | Abd El-Meguid, Mohamed Osama (ADNOC Onshore) | Hasan Al Ali, Abdulrahman (ADNOC Onshore) | Saleh, Abdalla (ADNOC Onshore) | Almazrouei, Saeed Mohamed (ADNOC Onshore) | El Shahat, Ayman (ADNOC Onshore) | Bin Sumaida, Ali Sulaiman (ADNOC Onshore) | Abdulla Al Mutawa, Ahmed (ADNOC Onshore) | Zain Yousfi, Fawad (ADNOC Onshore) | Ali Almteiri, Nama (ADNOC Onshore) | Baslaib, Mohamed Ahmed (ADNOC Onshore) | Mantilla, Alfonso (ADNOC Upstream) | Ladmia, Abdelhak (ADNOC Upstream)
Summary United Arab Emirates (UAE) is seeking to become self-sufficient in gas supply by 2030. This has led the country to initiate several exploratory and appraisal projects to achieve this goal. This study covers one such pilot project targeting production from tight gas reservoirs in three wells through a coiled-tubing (CT) underbalanced drilling (UBD) project in ADNOC Onshore. CT pressure control equipment (PCE) was rigged up on top of production trees with wells already completed and cemented. A CT tower was used to accommodate the drilling bottomhole assembly (BHA) and eliminate risks related to its deployment. CT strings were designed to reach target intervals with sufficient weight on bit (WOB), suitable for sour environments, and able to withstand high pumping rates with mild circulating pressures. To address the hazards of H2S handling at the surface, a custom-fit closed-loop system was deployed. The recovered water was treated on the surface and reused for drilling to decrease the water consumption throughout the operations. The plan was to drill 3 3/4-in. horizontal laterals in all candidate wells. Each well was completed with a combination of a 4 1/2-in. and a 5 1/2-in. tubing and a 7-in. liner. Five laterals were drilled across the three candidate wells targeting carbonate reservoirs with each lateral having an average length of ~4,000 ft. The achieved rates of penetration varied significantly from 15 ft/min to 30 ft/min while drilling through the various formations. Over the course of the pilot project, several challenges had to be addressed, such as material accretion on the CT string during wiper trips, treatment of return fluids having high H2S content and rock cuttings, and ensuring the integrity of the CT pipe while operating in severe downhole environments. Solutions and lessons learned from each well were implemented subsequently in the campaign, such as the use of increased concentrations of H2S inhibitor to coat the CT string, the use of nitrified fluids based on changing well parameters to maintain underbalance, thorough pipe management through real-time CT inspection, and adding a fixed quantity of fresh water to the drilling system every day to avoid chemical reactions between the drilling fluid additives and hydrocarbons. The wells completed with this method exceeded production expectations by 35โ50% across the project while reconfirming the value of the technology. The use of CT for UBD is still considered a challenging intervention worldwide. Such cases in high H2S environments are rare. This study outlines best practices for a CT UBD and a setup that can be replicated in other locations to implement this methodology with high H2S and when rig sourcing is a concern.
Reservoir Souring Assessment and Application of Design and Engineering Practice to Successfully Predict and Mitigate H2S Release in a Produced Water Well Intervention
Aniekan, Obot A. (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Basil, Ogbunude C. (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Imaobong, Bassey P. (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Eelah, Muzan (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Ihuoma, Green (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Conrad, Ibekwe (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Jonathan, Mude (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Onajite, Taro (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria) | Gogo, Oforiokuma (Shell petroleum Development Company, Port Harcourt, Rivers State, Nigeria)
Abstract In-depth understanding of subsurface risk is critical to the safe execution of well intervention operations. One of such high potential subsurface risk is the uncontrolled release of hydrogen sulphide (H2S) which is considered a critical hazard in the oil and gas industry that can put lives and asset at risk. H2S is often generated in anaerobic environments by the activities of Sulphur reducing bacteria which may be introduced by injection of sea or produced water into a reservoir. In addition, H2S can be released during well stimulation interventions in produced water disposal wells. These two possibilities for the release of H2S were considered in the recent assessment, planning and execution of BZ071 acid stimulation intervention. BZ071 is a produced water disposal (PWD) well injecting into the S1000 sand in the BZ NAG facility, with initial injection capacity of about 6kbwpd and cumulative of >2MMbbl disposed into the target reservoir. The initial reservoir souring prediction assessment carried out at the commissioning of the PWD facility showed a high potential of H2S proliferation in the reservoir, although with no chance of H2S release to surface since there was no producer on the S1000 sand. The planning and integrated risk assessment of the BZ071 acid stimulation intervention involved extensive integrated review of the initial souring assessment to keep any potential H2S gas release to As Low as Reasonably Practicable (ALARP). This paper presents the success story of the 1st experience of H2S Release in BZ well intervention operation, which was carefully managed without any HSSE exposure, achieving goal zero. It outlines the reservoir souring prediction assessment, collaborative roll-up of controls and the learnings which led to a successful execution and mitigation of H2S gas release.
- Water & Waste Management > Water Management > Lifecycle > Disposal/Injection (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Health, Safety, Environment & Sustainability > Health > Noise, chemicals, and other workplace hazards (1.00)
- Health, Safety, Environment & Sustainability > Environment > Water use, produced water discharge and disposal (1.00)
People who are passionate about running businesses often talk about money or people--but not both. Imagine, a chief operating officer at an oil company who doesn't listen to any ideas that won't result in more barrels or more money, right now. Many of us in the oil and gas industry know what it feels like to work in that organization. Or the human resources leader that puts together an offsite meeting with personality tests, teambuilding exercises, and some "feel-good" work that has nothing to do with the actual work of the company. Both examples have their place and their value, but they never work well together.