This report summarizes recent reviews, observations, and analyses believed to be imperative to our understanding of the recent two million cubic feet salt fall event in Big Hill Cavern 103, one of the caverns of the Strategic Petroleum Reserve (SPR). The fall was the result of one or more stress driven mechanical instabilities, the origins of which are discussed in the report. The work has lead to important conclusions concerning the engineering and operations of the caverns at Big Hill. Specifically, Big Hill, being the youngest SPR site, was subjected to state-of-the-art solutioning methods to develop nominally well-formed, right-circular cylindrical caverns. Examination of the pressure history records indicate that operationally all Big Hill SPR caverns have been treated similarly. Significantly, new three-dimensional (3-D) imaging methods, applied to old (original) and more recent sonar survey data, have provided much more detailed views of cavern walls, roofs, and floors. This has made possible documentation of the presence of localized deviations from ''smooth'' cylindrical cavern walls. These deviations are now recognized as isolated, linear and/or planar features in the original sonar data (circa early 1990s), which persist to the present time. These elements represent either sites of preferential leaching, localized spalling, or a combination of the two. Understanding the precise origin of these phenomena remains a challenge, especially considering, in a historical sense, the domal salt at Big Hill was believed to be well-characterized. However, significant inhomogeneities in the domal salt that may imply abnormalities in leaching were not noted. Indeed, any inhomogeneities were judged inconsequential to the solution-engineering methods at the time, and, by the same token, to the approaches to modeling the rock mass geomechanical response. The rock mass was treated as isotropic and homogeneous, which in retrospect, appears to have been an over simplification. This analysis shows there are possible new opportunities regarding completing an appropriate site characterization for existing operating cavern fields in the SPR, as well as expansion of current sites or development of new sites. Such characterization should first be consistent with needs identified by this report. Secondly, the characterization needs to satisfy the input requirements of the 3-D solutioning calculational methods being developed, together with 3-D geomechanical analyses techniques which address deformation of a salt rock mass that contains inhomogeneities. It seems apparent that focusing on these important areas could preclude occurrence of unexpected events that would adversely impact the operations of SPR.
Throughout the construction and operation of the caverns of the Strategic Petroleum Reserve (SPR), three types of cavern volume measurements have been maintained. These are: (1) the calculated solution volume determined during initial construction by solution mining and any subsequent solutioning during oil transfers, (2) the calculated sonar volume determined through sonar surveys of the cavern dimensions, and (3) the direct metering of oil to determine the volume of the cavern occupied by the oil. The objective of this study is to compare these measurements to each other and determine, if possible, the uncertainties associated with a given type of measurement. Over time, each type of measurement has acquired a customary, or an industry accepted, stated uncertainty. This uncertainty is not necessarily the result of a technical analysis. Ultimately there is one definitive quantity, the oil volume measure by the oil custody transfer meters, taken by all parties to the transfer as the correct ledger amount and for which the SPR Project is accountable. However, subsequent transfers within a site may not be with meters of the same accuracy. In this study, a very simple theory of the perfect relationship is used to evaluate the correlation (deviation) of the various measures. This theory permits separation of uncertainty and bias. Each of the four SPR sites are examined, first with comparisons between the calculated solution volumes and the sonar volumes determined during construction, then with comparisons of the oil inventories and the sonar volumes obtained either by surveying through brine prior to oil filling or through the oil directly.
Because of limited direct observation, understanding of the interior conditions of the massive storage caverns constructed in Gulf Coast salt domes is realizable only through predictions of salt response. Determination of the potential for formation of salt spalls, leading to eventual salt falls, is based on salt creep and fracture using the Multimechanism-Deformation Coupled Fracture (MCDF) model. This is a continuum model for creep, coupled to continuum damage evolution. The model has been successfully tested against underground results of damage around several test rooms at the Waste Isolation Pilot Plant (WIPP). Model simulations, here, evaluate observations made in the Strategic Petroleum Reserve (SPR), storage caverns, namely, the accumulation of material on cavern floors and evidence of salt falls. A simulation of a smooth cavern wall indicates damage is maximum at the surface but diminishes monotonically into the salt, which suggests the source of salt accumulation is surface sluffing. If a protuberance occurs on the wall, fracture damage can form beneath the protuberance, which will eventually cause fracture, and lead to a salt fall.