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Proprietary
Field Testing of Electrofrac ™ Process Elements at ExxonMobil’s Colony Mine
William A. Symington, James S. Burns, Wadood El-Rabaa, Glenn A. Otten,
Norman Pokutylowicz, P. Matthew Spiecker, Richard W. Williamson, Jesse D. Yeakel
29th Oil Shale SymposiumColorado School of Mines
October 20, 2009
Upstream Research
Electrofrac Process Schematic
ElectrofracOil Shale Conversion via Electrically Conductive Fr actures
• Electrofrac laboratory research focused on critical technical issues: Identification of conductant. Maintaining electrical continuity. Expulsion under in situ stress. Completion strategy for effective
heating.
• Planar Electrofracs should heat far more effectively than radial conduction from wellbores.
• Electrofrac field research focused on construction and operation. Pumping an electrically
continuous hydraulic fracture. Building power connections. Operating at low temperature for
several months.
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Location of ExxonMobil’s Colony Mine Upstream Research
Parachute
Battlement Mesa
I-70
Mine Bench
ColonyRoad
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
50 feet
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
South Drift
North Drift
Cro
sscu
t
DeclineIncline
Mine Drainage
Physical Layout of Colony Mine …
… An Ideal Electrofrac Field Laboratory
50 feet
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
• Geologic mapping of natural fractures.
• Fracture pretests to understand hydraulic fracturing in the mine.
• A thermal conductivity pretest to understand in situ thermal rock properties.
• Pumping two Electrofracs with calcined coke. Mapping and verification with observation coring.
• Pumping/squeezing of Electrofrac power connections at EF1 and EF3. Preceded by lab and field pretests.
• Instrumentation and heating of one of the two Electrofracs. And the winner is – EF3 at 51.7 Ohms .
8.5 ft9.5ft ’
1-1.5’
8.5 ft9.5ft ’
1-1.5’
8.5 ft9.5ft ’
1-1.5’
South drift
North
Cross-cut
5’
All holes 2” diameter
Plan View
4’
4’
Built and verified two Electrofracs :EF1 ~140 ftEF3 ~200 ft
Cored 28 observation holes: All intersections probed are electrically connected
EF1
EF3
Instrumentation Holes on EF1
99 ft
132 ft
North Drift
South Drift
Crosscut
Decline
Built and verified two Electrofracs :EF1 ~140 ftEF3 ~200 ft
Cored 28 observation holes: All intersections probed are electrically connected
EF1
EF3
Instrumentation Holes on EF1
99 ft
132 ft
North Drift
South Drift
Crosscut
Decline
Coke-filled Electrofrac
Mine Rib
Insulated Coating on Steel Pipes
Connection Treatments
Electric current
Coke-filled Electrofrac
Mine Rib
Insulated Coating on Steel Pipes
Connection Treatments
Electric current
Electrofrac Field Research at Colony has Progressed in Phases
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
• Natural fracture trend influences hydraulic fracture direction.
• Minimum principle stress is ~150 psi, parallel to cliff face (normal to natural fracture direction).
• Natural fractures exert stress on fracture fill.
Fracture Pretests Helped Determine the Electrofrac Fracture Design
Location A Location B
Location C
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Built and verified two Electrofracs :EF1 ~140 ftEF3 ~200 ft
Cored 28 observation holes: All intersections probed are electrically connected
EF1
EF3
Instrumentation Holes on EF1
99 ft
132 ft
North Drift
South Drift
Crosscut
Decline
Built and verified two Electrofracs :EF1 ~140 ftEF3 ~200 ft
Cored 28 observation holes: All intersections probed are electrically connected
EF1
EF3
Instrumentation Holes on EF1
99 ft
132 ft
North Drift
South Drift
Crosscut
Decline
Two Electrofracs Pumped, Mapped by Coring
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Halliburton’s batch mixer & HT400 pump truck Freshly prepared gel (400 bbls) for EF1 frac job
Mixing calcined coke and Portland cementPrejob safety meeting
EF1 Hydraulic Fracture Job
Note: worker is not directly beneath sack of calcined coke.
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Two HT400’s and a boost pump provided higher, more stable pressure and flow.
For EF3, coke and cement (39,000 lbs) were premixed and arrived on site in a “W” truck.
EF3 Pumped at Higher Pressure, Rate
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
EF1-OB7 Camera/Core EF1-OB2 Core/Electrical EF3 Coke at Crosscut Rib
Continuity Probe (7/18/08)
Electrofracs Observed in Core, on Camera, Electrically, and on the Mine Rib
Resistivity of coke recovered from core is 1-4 Ω-cm (similar to lab values)
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Graphite “Good Juice” Injection Prevents Electrofrac Hot Spots
Function of Graphite “Good Juice”• Provide higher conductivity at power connections.• Provide an electrical connection between steel casing in
the hole and the body of the Electrofrac fracture.
Good juice being mixed in the GJP2000
GJP2000 set up at Location A
Good juice flowing from crosscut mine rib
Modeled Fracture Plane Temperatures (90 days)
Current = 31.6 ampsHeating = 15.7 kWMax temp = 134ºF
With Good Juice
Current = 31.6 ampsHeating = 24.9 kWMax temp = 1678ºF
Without Good Juice
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Squeezing the Graphite “Good Juice”Completes the Electrofrac Circuit
Injecting
Squeezing
Coke-filled Electrofrac
Mine Rib
Insulated Coating on Steel Pipes
Connection Treatments
Electric current
Coke-filled Electrofrac
Mine Rib
Insulated Coating on Steel Pipes
Connection Treatments
Electric current
Electrofrac Heating Circuit Schematic Flexible Porous Piston Assembly
“Pencil” Electrical Connection
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
EF3 Instrumentation Captures Temperature, Voltage, Current, and Rock Movement Data
Roughly perpendicular holes for thermocouples
Roughly parallel holes for Fiber Optic Temperature Measurement
North Drift
Cro
sscu
t
Decline
OB4
OB9
Multi-point extensometers in holes across and adjacent to fracture
Eight open holes (not shown) admit probes for voltage and current measurement.
N
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
EF3 Instrumentation Captures Temperature, Voltage, Current, and Rock Movement Data
OK, 21 down -just 315 to go
Did he say miles?
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Electrofrac EF3 Operates Under Thermostatic Control
Thermocouples and electrical data
Fiber optic temperatures
Mine(acquisition & control)
Field Office(recording)
Over temperature
Alarms
If on: any temperature >135ºF - turn offIf off: TC temperatures below 110ºF after TC
thermostatic shutoff – turn back on
Control Logic
Fiber optictemperatures
Fiber optictemperatures
Data Acquisition Software
USBto fiber
USBto fiber
PC network
Voltage, current, power
Voltage, current, power
Thermocouple temperatures
Thermocouple temperatures(12 min freq) (12 min freq)(1 min freq)
TransducerSignals
To OB4and OB9
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Electrofrac EF3 Temperatures Viewed in 3D
North Drift
Cro
sscu
tDecline
OB4
OB9
After 8 Weeks of Operation (9/21/09) at 8.5 kW (ave rage)
Total Energy Input = 11.4 MW-hrs
OB6
I5a
I5b
I5c
I5d
I5e
I5f
OB17OB2
OB15OB1OB4
I6aI7a
OB3
OB16
I6b I6c
I6d
I6e
OB13
I7b
I7c I7d
I7e
I7f
OB12OB7 OB9
OB10
EF3OB6
I5a
I5b
I5c
I5d
I5e
I5f
OB17OB2
OB15OB1OB4
I6aI7a
OB3
OB16
I6b I6c
I6d
I6e
OB13
I7b
I7c I7d
I7e
I7f
OB12OB7 OB9
OB10
EF3
0.90.80.7 0.0
-0.4-0.8
1.000 0.893
0.664-0.019
0.039
-1.000-0.783
0.8950.325
0.667
0.007
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Electrofrac EF3 Voltage and Temperature
OB6
I5a
I5b
I5c
I5d
I5e
I5f
OB17OB2
OB15OB1OB4
I6aI7a
OB3
OB16
I6b I6c
I6d
I6e
OB13
I7b
I7c I7d
I7e
I7f
OB12OB7 OB9
OB10
EF3
1.4
23.2
11.6
24.5 26.6
6.3
3.2 6.8
6.6
2.7
7.9
503070
2010
59.439.4
12.8
35.3
86.2OB6
I5a
I5b
I5c
I5d
I5e
I5f
OB17OB2
OB15OB1OB4
I6aI7a
OB3
OB16
I6b I6c
I6d
I6e
OB13
I7b
I7c I7d
I7e
I7f
OB12OB7 OB9
OB10
EF3OB6
I5a
I5b
I5c
I5d
I5e
I5f
OB17OB2
OB15OB1OB4
I6aI7a
OB3
OB16
I6b I6c
I6d
I6e
OB13
I7b
I7c I7d
I7e
I7f
OB12OB7 OB9
OB10
EF3
1.4
23.2
11.6
24.5 26.6
6.3
3.2 6.8
6.6
2.7
7.9
503070
2010
59.439.4
12.8
35.3
86.2
Operating Resistance = 21-46 Ω
Normalized Voltage – Surveyed on 9/19/09x.xxx Normalized Voltage
Voltage ContourIdealized Graphite
Known “finger” of injected graphite
Suspected “finger”of injected graphite
Fracture Plane Temperature Rise – 9/21/09
xx.x Temperature RiseTemperature ContourIdealized Graphite
After 8 Weeks Operation at 8.5 kW (average)
Total Energy Input = 11.4 MW-hrs
Electrofrac field testing at ExxonMobil’s Colony Mi ne has followed phased approach, with learning opportunities in eac h phase. Thefield program has firmly established that:
• Electrically continuous hydraulic fractures (Electrofracs) can be created by pumping a mixture of calcined coke and cement, at pressure sufficient to break the rock.
• Power connections can be created by pumping mixtures of graphiteand cement into pre-existing calcined-coke-filled Electrofracs. Squeezing and de-watering the graphite can connect the fracture to steel pipe.
• Electrofracs can be heated with electric power for a period of months without developing hot spots that damage the connections.
Upstream Research
Colorado School of Mines Colorado Energy Research Institute
29th Oil Shale SymposiumOctober 19-23, 2009
Field Testing of Electrofrac™ Process Elements at ExxonMobil’s Colony Mine
Colony Field Research Contributors
Ade Adenekan, Jim Burns, Wadood El-Rabaa, Chen Fang, Mike Gay,Ganesh Ghurye, Larry Harrison, Steve Heiney, Nazish Hoda, Kiera Howell,
Sean Huang,Marvin Johnson, Jerry Kendall, Steve Kerr, Michael Lin,Robert Longoria, Timm Madden, Larry Manak, Nasser Mansoor, Bill Meurer,
Alex Morelos, Tom Murray, Mike Nicholis, Mike Norris, Glenn Otten,Tom Phillips, Norm Pokutylowicz, Jennifer Rainey, J. D. Rice, Kevin Robinson,Matt Spiecker, Bill Symington, Michele Thomas, Jana Van Alstine, Mat Walsh,
Ian Warren, Richard Williamson, Jesse Yeakel, URC Machine Shop,Friendswood Fabrication Facility, SEM/Newpark