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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.

Abstract not provided.

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.

The occurrence of gas in salt mines and caverns has presented some serious problems to facility operators. Salt mines have long experienced sudden, usually unexpected expulsions of gas and salt from a production face, commonly known as outbursts. Outbursts can release over one million cubic feet of methane and fractured salt, and are responsible for the lives of numerous miners and explosions. Equipment, production time, and even entire mines have been lost due to outbursts. An outburst creates a cornucopian shaped hole that can reach heights of several hundred feet. The potential occurrence of outbursts must be factored into mine design and mining methods. In caverns, the occurrence of outbursts and steady infiltration of gas into stored product can effect the quality of the product, particularly over the long-term, and in some cases renders the product unusable as is or difficult to transport. Gas has also been known to collect in the roof traps of caverns resulting in safety and operational concerns. The intent of this paper is to summarize the existing knowledge on gas releases from salt. The compiled information can provide a better understanding of the phenomena and gain insight into the causative mechanisms that, once established, can help mitigate the variety of problems associated with gas releases from salt. Outbursts, as documented in mines, are discussed first. This is followed by a discussion of the relatively slow gas infiltration into stored crude oil, as observed and modeled in the caverns of the US Strategic Petroleum Reserve. A model that predicts outburst pressure kicks in caverns is also discussed.

It is inevitable that sealing and abandonment will someday occur in a SPR cavern or caverns. To gain insight into the long-term behavior of a typical SPR cavern following sealing and abandonment, a suite of mechanical finite-element calculations was performed. The initial analyses predict how quickly and to what extent a cavern pressurizes after it is plugged. The analyses also examine the stability of the cavern as it changes shape due to the excessive pressures generated as the salt creeps and the brine in the cavern thermally expands. These large-scale analyses do not include the details of the plug but assume a good seal is established in the cavern wells. In another series of analyses, the potential for forming a leak at the plug is evaluated. A cement plug, emplaced in the casing seat of a cavern well, is loaded using the predicted brine pressures from the cavern analyses. The plugged casing analyses examine the potential for forming a leak path in and along the interfaces of salt, casing, and cement plug. In the last set of analysis, the dimensional scale of the problem is further reduced to examine a preexisting crack along a casing/salt interface. The cracked interface is assumed to be fluid filled and fully pressurized by the cavern fluids. The analyses address the potential for the fluid path to extend upwards along a plugged casing should an open microannulus surround the casing after it is plugged.

The relatively thin web of salt that separates Bayou Choctaw Caverns 15 and 17 was evaluated using the finite-element method. The stability calculations provided insight as to whether or not any operationrestrictions or recommendations are necessary. Because of the uncertainty in the exact dimensions of the salt web, various web thicknesses were examined under different operating scenarios that included individual cavern workovers and drawdowns. Cavern workovers were defined by a sudden drop in the oil side pressure at the wellhead to atmospheric. Workovers represent periods of low cavern pressure. Cavern drawdowns were simulated by enlargening the cavern diameters, thus decreasing the thickness of the web. The calculations predict that Cavern 15 dominates the behavior of the web because of its larger diameter. Thus, giventhe choice of caverns, Cavern 17 should be used for oil withdrawal in order to minimize the adverse impacts on web resulting from pressure drops or cavern enlargement. From a stability point of view, maintaining normal pressures in Cavern 15 was found to be more important than operating the caverns as a gallery where both caverns are maintained at the same pressure. However, during a workover, it may be prudent to operate the caverns under similar pressures to avoid the possibility of a sudden pressure surge at the wellhead should the web fail.

Effective sealing of the Waste Isolation Pilot Plant (WIPP) shafts will be required to isolate defense-generated transuranic wastes from the accessible environment. Shafts penetrate water-bearing hard rock formations before entering a massive creeping-salt formation (Salado) where the WIPP is located. Short and long-term seals are planned for the shafts. Short-term seals, a composite of concrete and bentonite, will primarily be located in the hard rock formations separating the water-bearing zones from the Salado Formation. These seals will limit water flow to the underlying long-term seals in the Salado. The long-term seals will consist of lengthly segments of initially unsaturated crushed salt. Creep closure of the shaft will consolidate unsaturated crushed salt, thereby reducing its permeability. However, water passing through the upper short-term seals and brine inherent to the salt host rock itself will eventually saturate the crushed salt and consolidation could be inhibited. Before saturating, portions of the crushed salt in the shafts are expected to consolidate to a permeability equivalent to the salt host rock, thereby effectively isolating the waste from the overlying water-bearing formations. A phenomenological model is developed for the coupled mechanical/hydrologic behavior of sealed WIPP shafts. The model couples creep closure of the shaft, crushed salt consolidation, and the associated reduction in permeability with Darcy's law for saturated fluid flow to predict the overall permeability of the shaft seal system with time. 17 refs., 6 figs., 1 tab.

A variety of geomechanical analyses are presented that support the WIPP project. The scale of the analyses ranged through laboratory experiments, small-scale in-situ tests, large-scale in-situ tests, underground rooms, shafts and shaft keys, and multi-room panels. The structural behavior of underground rooms, shafts, and experiments was investigated using the finite element method. Both two and three dimensional analyses simulated the time-dependent behavior of the salt host rock. Two different constitutive models were used to represent the creeping motion of the salt. The investigations aided in experimental planning, code validation, and assessing excavation responses for safety and performance assessment. This report compiles ten different structural analyses which assess the performance of excavations and experiments located at the Waste Isolation Pilot Plant (WIPP) in Carlsbad, NM. Chapter 2 discusses the constitutive models used to represent the salt behavior. Each of Chapters 3 through 12 presents an analysis. Chapter 13 concludes the report. 36 refs., 48 figs., 17 tabs.