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.
The Strategic Petroleum Reserve site at West Hackberry, Louisiana has historically experienced casing leaks. Numerous West Hackberry oil storage caverns have wells exhibiting communication between the interior 10 3/4 x 20-inch (oil) annulus and the ''outer cemented'' 20 x 26-inch annulus. Well 108 in Cavern 108 exhibits this behavior. It is thought that one, if not the primary, cause of this communication is casing thread leaks at the 20-inch casing joints combined with microannuli along the cement casing interfaces and other cracks/flaws in the cemented 20 x 26-inch annulus. An operation consisting of a series of nitrogen leak tests, similar to cavern integrity tests, was performed on Cavern 108 in an effort to determine the leak horizons and to see if these leak horizons coincided with those of casing joints. Certain leaky, threaded casing joints were identified between 400 and 1500 feet. A new leak detection procedure was developed as a result of this test, and this methodology for identifying and interpreting such casing joint leaks is presented in this report. Analysis of the test data showed that individual joint leaks could be successfully identified, but not without some degree of ambiguity. This ambiguity is attributed to changes in the fluid content of the leak path (nitrogen forcing out oil) and possibly to very plausible changes in characteristics of the flow path during the test. These changes dominated the test response and made the identification of individual leak horizons difficult. One consequence of concern from the testing was a progressive increase in the leak rate measured during testing due to nitrogen cleaning small amounts of oil out of the leak paths and very likely due to the changes of the leak path during the flow test. Therefore, careful consideration must be given before attempting similar tests. Although such leaks have caused no known environmental or economic problems to date, the leaks may be significant because of the potential for future problems. To mitigate future problems, some repair scenarios are discussed including injection of sealants.
A suite of laboratory triaxial compression and triaxial steady-state creep tests provide quasi-static elastic constants and damage criteria for bedded rock salt and dolomite extracted from Cavern Well No.1 of the Tioga field in northern Pennsylvania. The elastic constants, quasi-static damage criteria, and creep parameters of host rocks provides information for evaluating a proposed cavern field for gas storage near Tioga, Pennsylvania. The Young's modulus of the dolomite was determined to be 6.4 ({+-}1.0) x 10{sup 6} psi, with a Poisson's ratio of 0.26 ({+-}0.04). The elastic Young's modulus was obtained from the slope of the unloading-reloading portion of the stress-strain plots as 7.8 ({+-}0.9) x 10{sup 6} psi. The damage criterion of the dolomite based on the peak load was determined to be J{sub 2}{sup 0.5} (psi) = 3113 + 0.34 I{sub 1} (psi) where I{sub 1} and J{sub 2} are first and second invariants respectively. Using the dilation limit as a threshold level for damage, the damage criterion was conservatively estimated as J{sub 2}{sup 0.5} (psi) = 2614 + 0.30 I{sub 1} (psi). The Young's modulus of the rock salt, which will host the storage cavern, was determined to be 2.4 ({+-}0.65) x 10{sup 6} psi, with a Poisson's ratio of 0.24 ({+-}0.07). The elastic Young's modulus was determined to be 5.0 ({+-}0.46) x 10{sup 6} psi. Unlike the dolomite specimens under triaxial compression, rock salt specimens did not show shear failure with peak axial load. Instead, most specimens showed distinct dilatancy as an indication of internal damage. Based on dilation limit, the damage criterion for the rock salt was estimated as J{sub 2}{sup 0.5} (psi) = 704 + 0.17 I{sub 1} (psi). In order to determine the time dependent deformation of the rock salt, we conducted five triaxial creep tests. The creep deformation of the Tioga rock salt was modeled based on the following three-parameter power law as {var_epsilon}{sub s} = 1.2 x 10{sup -17} {sigma}{sup 4.75} exp(-6161/T), where {var_epsilon}{sub s} is the steady state strain rate in s{sup -1}, {sigma} is the applied axial stress difference in psi, and T is the temperature in Kelvin.
Three-dimensional finite element analyses simulate the mechanical response of enlarging existing caverns at the Strategic Petroleum Reserve (SPR). The caverns are located in Gulf Coast salt domes and are enlarged by leaching during oil drawdowns as fresh water is injected to displace the crude oil from the caverns. The current criteria adopted by the SPR limits cavern usage to 5 drawdowns (leaches). As a base case, 5 leaches were modeled over a 25 year period to roughly double the volume of a 19 cavern field. Thirteen additional leaches where then simulated until caverns approached coalescence. The cavern field approximated the geometries and geologic properties found at the West Hackberry site. This enabled comparisons are data collected over nearly 20 years to analysis predictions. The analyses closely predicted the measured surface subsidence and cavern closure rates as inferred from historic well head pressures. This provided the necessary assurance that the model displacements, strains, and stresses are accurate. However, the cavern field has not yet experienced the large scale drawdowns being simulated. Should they occur in the future, code predictions should be validated with actual field behavior at that time. The simulations were performed using JAS3D, a three dimensional finite element analysis code for nonlinear quasi-static solids. The results examine the impacts of leaching and cavern workovers, where internal cavern pressures are reduced, on surface subsidence, well integrity, and cavern stability. The results suggest that the current limit of 5 oil drawdowns may be extended with some mitigative action required on the wells and later on to surface structure due to subsidence strains. The predicted stress state in the salt shows damage to start occurring after 15 drawdowns with significant failure occurring at the 16th drawdown, well beyond the current limit of 5 drawdowns.
The U. S. Department of Energy Strategic Petroleum Reserve currently has approximately 500 million barrels of crude oil stored in 62 caverns solution-mined in salt domes along the Gulf Coast of Louisiana and Texas. One of the challenges of operating these caverns is ensuring that none of the fluids in the caverns are leaking into the environment. The current approach is to test the mechanical integrity of all the wells entering each cavern approximately once every five years. An alternative approach to detecting cavern leaks is to monitor the cavern pressure, since leaking fluid would act to reduce cavern pressure. Leak detection by pressure monitoring is complicated by other factors that influence cavern pressure, the most important of which are thermal expansion and contraction of the fluids in the cavern as they come into thermal equilibrium with the host salt, and cavern volume reduction due to salt creep. Cavern pressure is also influenced by cavern enlargement resulting from salt dissolution following introduction of raw water or unsaturated brine into the cavern. However, this effect only lasts for a month or two following a fluid injection. In order to implement a cavern pressure monitoring program, a software program called CaveMan has been developed. It includes thermal, creep and salt dissolution models and is able to predict the cavern pressurization rate based on the operational history of the cavern. Many of the numerous thermal and mechanical parameters in the model have been optimized to produce the best match between the historical data and the model predictions. Future measurements of cavern pressure are compared to the model predictions, and significant differences in cavern pressure set program flags that notify cavern operators of a potential problem. Measured cavern pressures that are significantly less than those predicted by the model may indicate the existence of a leak.