Engineering topics

Barnes, John

Publications and source records attributed to Barnes, John.

10 records

DOE OSTI2022

Experimental Investigation of Polymer-Induced Fouling of Heater Tubes in the First-Ever Polymer Flood on Alaska North Slope Part II

A polymer flood pilot has been ongoing in the Schrader Bluff viscous oil reservoir at Milne Point on the Alaska North Slope. The results from the pilot are encouraging. However, a major concern of the operator is the influence of polymer on the production system after breakthrough, especially the fouling in heat exchangers. This work applies a multiexperimental approach to study the severity of polymer-induced fouling in both dynamic and static states of produced fluids to determine safe operating conditions. Dynamic scale loop (DSL) tests were conducted to study fouling due to polymer at different skin temperatures (165–350°F) in a dynamic state of fluid flow where the fluids’ flow mimics the residence time of fluids in the heat exchanger of the field pilot. Static deposit tests were also conducted at similar skin temperatures of 165–250°F using a novel experimental apparatus designed and built in-house. It was found that at higher skin temperatures of 250–350°F, tube blocking was observed in the DSL tests, whereas the tests at 165–200°F did not show any tube blocking, even in a more extended test period. The deposit test showed that the deposit rate generally increases with skin temperature, and the presence of polymer aggravates the fouling. The copper tube performs best when the skin temperatures are 165–200°F, while the stainless steel tube performs best at a skin temperature of 250°F. These experiments also manifested the influence of the cloudpoint of the solution as the deposit rate increased significantly when the skin temperature was higher than the solution cloudpoint. The study provides a source of practical guidance to the field operations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

History Matching and Performance Prediction of a Polymer Flood Pilot in Heavy Oil Reservoir on Alaska North Slope

The first-ever polymer flood pilot to enhance heavy oil recovery on Alaska North Slope (ANS) is ongoing. After more than 2.5 years of polymer injection, significant benefit has been observed from the decrease in water cut from 65% to less than 15% in the project producers. The primary objective of this study is to develop a robust history-matched reservoir simulation model capable of predicting future polymer flood performance. In this work, the reservoir simulation model has been developed based on the geological model and available reservoir and fluid data. In particular, four high transmissibility strips were introduced to connect the injector-producer well pairs, simulating short-circuiting flow behavior that can be explained by viscous fingering and reproducing the water cut history. The strip transmissibilities were manually tuned to improve the history matching results during the waterflooding and polymer flooding periods, respectively. It has been found that higher strip transmissibilities match the sharp water cut increase very well in the waterflooding period. Then the strip transmissibilities need to be reduced with time to match the significant water cut reduction. The viscous fingering effect in the reservoir during waterflooding and the restoration of injection conformance during polymer flooding have been effectively represented. Based on the validated simulation model, numerical simulation tests have been conducted to investigate the oil recovery performance under different development strategies, with consideration for sensitivity to polymer parameter uncertainties. The oil recovery factor with polymer flooding can reach about 39% in 30 years, twice as much as forecasted with continued waterflooding. Besides, the updated reservoir model has been successfully employed to forecast polymer utilization, a valuable parameter to evaluate the pilot test’s economic efficiency. All the investigated development strategies indicate polymer utilization lower than 3.5 lbs/bbl in 30 years, which is economically attractive.

Wang, Xindan↗

DOE OSTI2020

First Ever Polymer Flood Field Pilot to Enhance the Recovery of Heavy Oils on Alaska North Slope – Producer Responses and Operational Lessons Learned

The US Department of Energy and Hilcorp Alaska, LLC are jointly cosponsoring a field pilot project entitled “First Ever Field Pilot on Alaska’s North Slope to Validate the Use of Polymer Floods for Heavy Oil Enhanced Oil Recovery (EOR).” The objective of this pilot is to perform a field experiment to validate the use of an advanced polymer flooding technology to unlock the vast heavy oil resources on Alaska North Slope (ANS). Two pairs of horizontal injection and production wells have been deployed in an isolated fault block of the Schrader Bluff heavy oil reservoir at the Milne Point Field to conduct a polymer flood pilot which was designed to acquire field performance data to optimize polymer flood design in the Schrader Bluff heavy oil reservoirs on ANS. Hydrolyzed polyacrylamide (HPAM) polymer injection started on August 28, 2018 using a custom made polymer mixing and pumping unit. Polymer solution properties such as concentration, viscosity, and filter ratio, have been closely monitored and adjusted as necessary. Operational procedures have been improved to ensure adequate injectivity and polymer propagation through the formation. Oil and water production is tested frequently to monitor water cut performance, and produced water is sampled and analyzed for polymer content. Tracers were pumped pre and post polymer injection startup to compare polymer flood breakthrough timing and sweep efficiency. Polymer injectivity of the horizontal wells drilled in the Schrader Bluff NB sand is found to be sufficient to replace the reservoir production voidage although there were some declines as high viscosity polymer swept the near wellbore region. Production data show significant reduction in water cut and the oil production rate has stabilized. No polymer production has been confirmed from the two horizontal producers after 22 months of polymer injection into the two supporting horizontal injectors. Tracer data show very low sweep efficiencies with waterflood alone, whereas significant improvement has been achieved with polymer flood. Many operational lessons have been learned and improvements have been made regarding polymer mixing, pumping, and onsite quality control, particularly in a challenging Arctic environment. Adequate polymer injection rate can be achieved with diligent monitoring and quality assurance of the properties of the injected polymer solution.

Ning, Samson↗

DOE OSTI2020

Experimental Investigation of Polymer Induced Fouling of Heater Tubes in the First-ever Polymer Flood Pilot on Alaska North Slope

Polymer flooding has been validated in the lab and by successful applications in other countries, such as Canada and China, to be an effective EOR technique for heavy oil reservoirs. Currently, polymer flooding is being pilot tested for the first time in the Schrader Bluff viscous oil reservoir at Milne Point field on Alaska North Slope (ANS). One of the major concerns of the operator is the impact of polymer on the oil production system after polymer breakthrough, especially the polymer induced fouling issues in the heat exchanger. This study investigates the propensity of polymer fouling on the heater tubes as a function of different variables, with the ultimate goal of determining safe and efficient operating conditions. A unique experimental set-up was indigenously designed and developed to simulate the fouling process on the heating tube. The influence of heating tube skin temperature, tube material, and polymer concentration on fouling tendency was investigated. Under each test condition, the test was run five times with the same tube, and in each run, the freshly prepared synthetic brine and polymer solution were heated from 77°F to 122°F to mimic field operating conditions. The heating time and fouling amount were recorded for each run. The morphology and composition of the deposit samples were analyzed by environmental scanning electron microscopy (ESEM) and X-ray diffraction (XRD), respectively. It has been found that, in general, the presence of polymer in produced fluids would aggravate the fouling issues on both carbon steel and stainless steel surfaces at all tested skin temperatures (165°F, 250 °F and 350°F), but only higher skin temperatures of 250°F and 350°F could cause polymer induced fouling issues on the copper tube surface and the fouling tendency increased with polymer concentration. At the lower skin temperatures of 165°F, no polymer-induced fouling was identified on the copper tube. A critical temperature that is related to the cloud point of the polymer solution was believed to exist, below which polymer induced fouling would not occur and only mineral scale deposited, but above which the polymer would obviously aggravate the fouling issue. The heating efficiency of the tube would be reduced gradually as more fouling material accumulates on its surface. The ESEM results indicate that if polymer precipitated and deposited on the surface, it would bond to the mineral crystals to form a stronger three- dimensional network structure, and that is why the polymer induced fouling was tougher and more difficult to be removed from the tube surface. The XRD analysis results confirm that the presence of polymer in the fluids can enhance the mineral scale propensity. Overall, the study results have provided practical guidance to the field operator for the ongoing polymer flooding pilot test on ANS. This study may also prove to be valuable for other chemical EOR projects around the world.

Alaska North Slope↗

DOE OSTI2020

Experimental Investigation on Separation Behavior of Heavy-Oil Emulsion for Polymer Flooding on Alaska North Slope

The first-ever field pilot on Alaska North Slope (ANS) to validate using polymer floods for heavy-oil enhanced oil recovery is currently ongoing. One of the major concerns of the operator is the effect of polymer on oil/water-separation efficiency after polymer breakthrough. This work investigates the influence of polymer on the separation behavior of heavy-oil emulsions and evaluates the performance of emulsion breakers (EBs). In this study, two types of heavy-oil emulsions were prepared and tested at 20 and 50% water cut (WC), respectively. The bottle test method was used in the experiments, in which the separated water volume with time, the separated water quality, and the volume fraction of phases were recorded. Results showed that polymer accelerated the oil/water separation acting as an emulsion inhibitor at 20% WC but tended to impede the water separation at 50% WC. Regardless of WC, polymer resulted in poor water quality and the formation of a stable intermediate oil in water (o/w) emulsion, because of the increased viscosity of the water phase. The performance of EBs showed a complex dependency on the WC, the type of demulsifier and dosage, and the polymer concentration. Despite the varied conditions encountered in the heavy-oil/water/polymer/demulsifier system, a compound EB achieved satisfactory demulsification performance, showing the highest potential for deployment in the current ANS polymer flooding pilot. Here, we systematically studied the potential influence of polymer breakthrough on the separation behavior of heavy-oil emulsion on ANS for the first time. The findings of this study will provide practical guidance in advance for produced fluid treatment of the ongoing first-ever polymer flooding pilot on ANS.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

First Ever Polymer Flood Field Pilot To Enhance The Recovery Of Heavy Oils On Alaska’s North Slope - Pushing Ahead One Year Later

In June 2018 the team embarked on an ambitious project to address the slow development pace of Alaska’s 20+ billion barrels heavy oil resource via the first ever polymer flood pilot. Following the successful commencement of the pilot in August 2018, the field demonstration, supporting laboratory experiments and numerical simulation have steadily progressed. A significant amount of valuable data and lessons learned have been collected, and are reported in this paper. The ongoing pilot and the research activities is making headway toward the primary objective of validating the use of polymer flooding for extracting heavy oil in Alaska’s challenging environment. The pilot is conducted in two pre-existing pairs of horizontal injectors and producers in an isolated fault block of the Schrader Bluff heavy oil reservoir at the Milne Point Field. A customized polymer blending and pumping unit injects HPAM polymer at a concentration of 1,750 ppm to achieve a target viscosity of 45 cP. Supporting coreflood laboratory experiments have focused on quantification of polymer retention in the rock, and effect of injection water salinity, polymer, and their combinations on oil recovery. The injection and production response of the pilot flood pattern is utilized to develop a history matched reservoir simulation model for forecasting oil recovery beyond the pilot. Finally, specially designed laboratory experiments address anticipated operating concerns regarding post-polymer breakthrough such as oil-water separation efficiency and polymer induced fouling of heater tubes. Polymer has been injected continuously since startup except for two short equipment modification shutdowns, and more recently a prolonged disruption due to polymer hydration issues at the J-pad field site. Cumulatively, over 600,000 lbs. of polymer has been injected, corresponding to ~7%PV. The two producers show significant decrease in the water cut, gradually increasing oil rate, and no polymer breakthrough. Two main observations from the coreflood are a significant uncertainty in polymer retention values, and positive oil recovery response to low salinity water (2,600 mg/liter TDS). The heterogeneity in the flood pattern presents some challenges in obtaining a robust history matched simulation model. Experimental results on produced fluids treatment indicate the formation of a dense polymer deposit, at certain conditions, on heating tubes that can negatively impact the heat transfer efficiency. The scientific knowledge, including the lessons learned during unanticipated shutdowns, quality control, logistics and field data that is being acquired from this effort has referential value for other planned EOR projects. Finally, by all indications, the polymer field pilot is steadily progressing toward achieving the ultimate goal of unlocking the massive heavy oil resources on Alaska North Slope (ANS).

Dandekar, Abhijit↗

DOE OSTI2019

First Ever Polymer Flood Field Pilot to Enhance the Recovery of Heavy Oils on Alaska’s North Slope – Polymer Injection Performance

Alaska North Slope (ANS) holds an estimated 20-30+ billion barrel heavy oil resources, yet the development pace has been very slow due to high development costs and low oil recovery using conventional waterflood and EOR methods. The objective of this pilot is to perform a field experiment to validate the use of an advanced polymer flooding technology to unlock the vast heavy oil resources on ANS. The advanced polymer flooding technology combines polymer flooding, low salinity water flooding, horizontal wells, and if necessary, injection conformance control treatments into one integrated process to significantly improve oil recovery from heavy oil reservoirs. Two pairs of horizontal injection and production wells have been deployed in an isolated fault block of the Schrader Bluff heavy oil reservoir at the Milne Point Field to conduct a polymer flood pilot. The pilot will acquire scientific knowledge and field performance data to optimize polymer flood design in the Schrader Bluff heavy oil reservoirs on ANS. Polymer injection started on August 28, 2018 using a custom made polymer blending and pumping unit. This paper focuses on the facility setup and polymer injection performance into the horizontal injectors drilled and completed in the Schrader Bluff heavy oil reservoir. Partially hydrolyzed polyacrylamide (HPAM) polymer was selected and the initial target viscosity was set at 45 centipoise. Polymer injection rate was set at 2200 bbl/day for one injector (J-23A) and 1200 bbl/day for the other (J-24A) based on production voidage. Injection pressure was controlled at below fracture pressure to prevent fracturing the reservoir and causing fast breakthroughs. Step rate and pressure falloff tests indicate that short term polymer injectivity is similar to water injectivity, which means that injectivity is mostly controlled by fluid mobility deep in the reservoir rather than that in the vicinity of the injection wellbore. Long term injection data indicate that polymer injectivity has been decreasing in both injectors as the reservoir is filled by polymer. No polymer has been observed in the production stream 7 months after the start of polymer injection compared with a 3-month breakthrough time with waterflood. This indicates that polymer significantly delays breakthrough time which will lead to increased sweep efficiency.

Ning, Samson↗

DOE OSTI2019

First Ever Polymer Flood Field Pilot - A Game Changer to Enhance the Recovery of Heavy Oils on Alaska’s North Slope

The development pace of Alaska’s vast, 20-25 billion barrels, heavy oil resources has been very slow due to high development costs and low oil recovery using conventional waterflood, and the impracticality of deploying thermal methods due to the presence of continuous permafrost. Although, polymer flooding has attracted attention and has become a promising EOR technique in heavy oil reservoirs due to the extensive application of horizontal wells and advancement of polymer flooding technology, no field tests have been performed to date in Alaska’s underdeveloped heavy oil reservoirs. The overall objective of this research is to perform a field experiment to validate the use of polymer flooding for extracting heavy oil in Alaska’s challenging environment. Two pre-existing pairs of horizontal injection and production wells in an isolated fault block of the Schrader Bluff heavy oil reservoir at the Milne Point Field are currently being used for the field experiment. Hydrolyzed polyacrylamide (HPAM) polymer injection started on August 28, 2018 at 600 ppm (4 cP viscosity) concentration ramping up to 1,800 ppm (45 cP viscosity) over a three week time period, and has been maintained at an average concentration of ~1,800 ppm. Current injection rates in the two horizontal injectors are ~2,200 and 600 bwpd. Laboratory experiments to determine the polymer retention, optimum water salinity, synergistic effects of water salinity and polymer, and handling of produced fluids, in support of the field experiment, are currently ongoing. Similarly, reservoir simulation of coreflood behavior and history match of previous waterfloods to predict polymer flood performance in the project area are also conducted in parallel. The field data and scientific knowledge that have been collected since the start of the injection indicates that the field pilot is performing as predicted. To date, no unexpected injectivity issues or polymer breakthrough have been encountered, and the two horizontal producers are showing positive response to the polymer injection, resulting in incremental increase in oil production rate. Since the research is still in its early stages, selected field, laboratory and simulation results are presented and discussed to highlight the integrative approach adopted in this first ever polymer flood field pilot in Alaska.

02 PETROLEUM↗

NASA NTRS2016

Results of a Longer Term NDACC Measurements Comparison Campaign at Mauna Loa Observatory

Between November, 2015 and January, 2015, the Goddard Space Flight Center (GSFC) operated a pair of lidar instruments at the NOAA (National Oceanic and Atmospheric Administration) facility at Mauna Loa on the Big Island of Hawaii (Latitude 19.5 degrees North, Longitude 155.5 degrees West, altitude 3.397 kilometers). Measurements were made during six different four week periods during this time period by both the NASA GSFC Stratospheric Ozone Lidar (STROZ) and the Aerosol and Temperature (ATL) lidar. Also making measurements were the JPL Stratospheric Ozone Lidar and the NOAA Aerosol and Water Vapor Lidar. All instruments participate and archive data with the Network for the Detection of Atmospheric Composition Change (NDACC). Measurement comparisons were made among various instruments in accordance with the standard intercomparison protocols of the NDACC.

McGee, Thomas J.↗

NASA NTRS1991

SSSFD manipulator engineering using statistical experiment design techniques

The Satellite Servicer System Flight Demonstration (SSSFD) program is a series of Shuttle flights designed to verify major on-orbit satellite servicing capabilities, such as rendezvous and docking of free flyers, Orbital Replacement Unit (ORU) exchange, and fluid transfer. A major part of this system is the manipulator system that will perform the ORU exchange. The manipulator must possess adequate toolplate dexterity to maneuver a variety of EVA-type tools into position to interface with ORU fasteners, connectors, latches, and handles on the satellite, and to move workpieces and ORUs through 6 degree of freedom (dof) space from the Target Vehicle (TV) to the Support Module (SM) and back. Two cost efficient tools were combined to perform a study of robot manipulator design parameters. These tools are graphical computer simulations and Taguchi Design of Experiment methods. Using a graphics platform, an off-the-shelf robot simulation software package, and an experiment designed with Taguchi's approach, the sensitivities of various manipulator kinematic design parameters to performance characteristics are determined with minimal cost.

Barnes, John↗