Comparison of stabilised/solidified mixes of model drill cuttings based on the North Sea and Red Sea Areas

Following the global stringent legislations regulating the wastes generated from the drilling process of oil exploration and production activities, the management of hazardous drill cuttings has become one of the pressing needs confronting the petroleum industry. Most of the prevalent treatment techniques adopted by oil companies are extremely expensive and/or the treated product has to be landfilled without any potential end-use; thereby rendering these solutions unsustainable. The technique of stabilisation/solidification is being investigated in this research to treat drill cuttings prior to landfilling or for potential re-use in construction products. Two case studies were explored namely North Sea and Red Sea. Given the known difficulties with stabilising/solidifying oils and chlorides, this research made use of model drill cutting mixes based on typical drill cutting from the two case studies, which contained 4.2% and 10.95% average concentrations of hydrocarbons; and 2.03% and 2.13% of chlorides, by weight respectively. A number of different binders, including a range of conventional viz. Portland cement (PC) as well as less-conventional viz. zeolite, or waste binders viz. cement kiln dust (CKD), fly ash and compost were tested to assess their ability to treat the North Sea and Red Sea model drill cuttings. The dry binder content by weight was 10%, 20% and 30%. In addition, raw drill cuttings from one of the North Sea offshore rigs were stabilised/solidified using 30% PC. The characteristics of the final stabilised/solidified product were finally compared to those of thermally treated cuttings. The effectiveness of the treatment using the different binder systems was compared in the light of the aforementioned two contaminants only. A set of physical tests (unconfined compressive strength (UCS)), chemical tests (NRA leachability) and micro-structural examinations (using scanning electron microscopy (SEM), and X-ray diffraction (XRD)) were used to evaluate the relative performance of the different binder mixes in treating the drill cuttings. The results showed that the observed UCS covered a wide range of values indicating various feasible end-use scenarios for the treated cuttings within the construction industry. The teachability results showed the reduction of the model drill cuttings to a stable non-reactive hazardous waste, compliant with the UK acceptance criteria for non-hazardous landfills: (a) by most of the 30% and 20% binders for chloride concentrations, and (b) by the 20% and 30% of compost-PC and CKD-PC binders for the Red Sea cuttings. The 20% and 30% compost-PC and CKD-PC binders successfully reduced the leached oil concentration of the North Sea cuttings to inert levels. Copyright 2007, Society of Petroleum Engineers.

Pipeline uplift response in thawed sandy backfills: Preliminary findings

Offshore and onshore buried pipelines under high operating temperature and pressures may lead to upheaval buckling (UHB) if sufficient soil cover is not present to prevent the upward movement of the pipeline. In regions where seasonal changes involve ground soil undergoing freezing-thawing cycles, the uplift resistance from soil cover may be minimum when the soil is undergoing thawing. This paper presents the results from 2 directly-comparable minidrum centrifuge tests conducted at the Schofield Centre, University of Cambridge, to investigate the difference in uplift resistance responses between fully-saturated and thawed sandy backfill conditions. Both tests were conducted drained at 30g using an 8.6 mm diameter aluminium model pipe, corresponding to a prototype pipe diameter of 258 mm. The soil cover/pipe diameter ratio, H/D, was kept at 1. Fraction E fine silica sand was used as the backfill. Preliminary experimental results indicated that the ultimate uplift resistance of a thawing sand backfill to be lower than that of a fully saturated sand backfill. This suggests that in regions where backfill soil undergoes freeze-thaw cycles, the thawing backfill may be more critical than fully saturated backfill for uplift resistance. The 2-dimensional displacement field during the experiment was accurately measured and analysed using the Particle Image Velocimetry technique. Copyright © 2011 by the International Society of Offshore and Polar Engineers (ISOPE).

Increasing the life of flare tips

Flare tips are essential for safety. Maintenance is difficult and costly. Flare tips are subjected to high combustion temperatures, thermal cycling, oxidation and marine corrosion. Following a number of flare tip failures an in depth study by Imperial College was carried out into the failure of a flare tip from a UK platform, looking for service life improvement. Materials selection and design solutions were considered. The study considered alternative materials and concluded that materials selection was the smaller part of the answer; design changes can double service life. This study used failure investigation, high temperature experimental and thermo-mechanical modelling analysis. The modelling process simulated two common flaring conditions and correctly predicted the observed failure of initiation and crack propagation from holes used to bolt on flame stabilizing plates to the top of the flare. The calculated thermal stress and strains enabled the low cycle fatigue life and minimum creep life to be predicted. It was concluded that service life could be improved by replacing Incoloy alloy 800HT (UNS N08800) with Inconel alloy 625 (UNS N06625), an alloy with attractive mechanical properties and improved high temperature corrosion resistance. Repositioning or eliminating bolt holes can double service life. Copyright 2008, Society of Petroleum Engineers.

Effect of particle concentration on erosion rate of mild steel bends in a pneumatic conveyor

Particle concentration is known as a main factor that affects erosion rate of pipe bends in pneumatic conveyors. With consideration of different bend radii, the effect of particle concentration on weight loss of mild steel bends has been investigated in an industrial scale test rig. Experimental results show that there was a significant reduction of the specific erosion rate for high particle concentrations. This reduction was considered to be as a result of the shielding effect during the particle impacts. An empirical model is given. Also a theoretical study of scaling on the shielding effect, and comparisons with some existing models, are presented. It is found that the reduction in specific erosion rate (relative to particle concentration) has a stronger relationship in conveying pipelines than has been found in the erosion tester. © 2004 Elsevier B.V. All rights reserved.

Faecal pellets in deep marine soft clay crusts: Implications for hot-oil pipeline design

In recent years, the presence of crusts within near surface sediments found in deep water locations off the west coast of Angola has been of interest to hot-oil pipeline designers. The origin for these crusts is considered to be of biological origin, based on the observation of thousands of faecal pellets in natural crust core samples. This paper presents the results of laboratory tests undertaken on natural and faecal pellet-only samples. These tests investigate the role faecal pellets play in modifying the gemechanical behaviour of clayey sediments. It is found that faecal pellets are able to significantly alter both the strength and the average grain-size of natural sediments, and therefore, influence the permeability and stiffness. Hot-oil pipelines self-embed into and subsequent shear on crusts containing faecal pellets. Being able to predict the time required for installed pipelines to consolidate the underlying sediment and thus, how soon after pipe-laying, the interface strength will develop is of great interest to pipeline designers. It is concluded from wet-sieving samples before and after oedometer tests, that the process of pipe laying is unlikely to destroy pellets. They will therefore, be a major constituent of the sediment subject to soil-pipeline shearing behaviour during axial pipe-walking and lateral buckling. Based on the presented results, a discussion highlighting the key implications for pipeline design is therefore provided. Copyright © 2011 by ASME.

Upheaval Buckling Assessment Based on Pipeline Features

Upheaval buckling (UHB) is a common design issue for high temperature buried pipelines. This paper highlights some of thekey issues affecting out-of-straightness (OOS) assessment of pipelines. The following factors are discussed; uplift resistancesoil models, uplift resistance in cohesive soils, uplift mobilisation, ratcheting, uplift resistance at low H/D ratios and thecorrect methodology for load factor selection. A framework for determining ratcheting mobilisation is proposed. Furtherresearch is required to verify and validate this proposed framework. UHB assessment of three different diameter pipelineswere carried out using finite element SAGE PROFILE package incorporating pipeline mobilisation and the results arecompared with semi-analytical formulation proposed by Palmer et al. 1990. The paper also presents a summary of as-laidpipeline features based on projects over the past 10 years.

New evidence for the origin and behaviour of deep ocean 'crusts'

In situ tests in deep waterWest African clays show crust-like shear strengths within the top few metres of sediment. Typical strength profiles show su rising from mud-line to 10 kPa to 15 kPa before dropping back to normally consolidated strengths of 3 kPa to 4 kPa by 1.5m to 2m depth. A Cam-shear device is used to better understand the mechanical behaviour of undisturbed crust samples under pipelines. Extremely variable peak and residual shear strengths are observed for a range of pipeline consolidation stresses and test shear rates, with residual strengths approximating zero. ESEM of undisturbed samples and wet-sieved samples from various core depths show the presence of numerous randomly-located groups of invertebrate faecal pellets. It is therefore proposed that the cause of strength variability during shear testing and, indeed, of the crust's origin, is the presence of random groups of faecal pellets within the sediment. © 2011 Taylor & Francis Group, London.

PH-dependent leaching behaviour and other performance properties of cement-treated mixed contaminated soil

Portland cement has been widely used for stabilisation/solidification (S/S) treatment of contaminated soils. However, there is a dearth of literature on pH-dependent leaching of contaminants from cement-treated soils. This study investigates the leachability of Cu, Pb, Ni, Zn and total petroleum hydrocarbons (TPH) from a mixed contaminated soil. A sandy soil was spiked with 3000 mg/kg each of Cd, Cu, Pb, Ni and Zn, and 10,000 mg/kg of diesel, and treated with ordinary Portland cement (CEM I). Four different binder dosages, 5%, 10%, 15% and 20% (m/m) and different water contents ranging from 13%-19% dry weight were used in order to find a safe operating envelope for the treatment process. The pH-dependent leaching behaviour of the treated soil was monitored over an 84-day period using a 3-point acid neutralisation capacity (ANC) test. The monolithic leaching test was also conducted. Geotechnical properties such as unconfined compressive strength (UCS), hydraulic conductivity and porosity were assessed over time. The treated soils recorded lower leachate concentrations of Ni and Zn compared to the untreated soil at the same pH depending on binder dosage. The binder had problems with Pb stabilisation and TPH leachability was independent of pH and binder dosage. The hydraulic conductivity of the mixes was generally of the order, 10-8 m/sec, while the porosity ranged from 26%-44%. The results of selected performance properties are compared with regulatory limits and the range of operating variables that lead to acceptable performance described. © 2012 The Research Centre for Eco-Environmental Sciences, Chinese Academy of Sciences.