Lessons Learned: A Case Study in Successful Application of Natural Gas Fuel in High Horsepower Pressure Pumping Services

Transcription

1 take a closer look Lessons Learned: A Case Study in Successful Application of Natural Gas Fuel in High Horsepower Pressure Pumping Services Pat Osachuk Project Lead, Frac Team HHP Summit 2012, Houston September

2 Agenda Background of Project Research, Planning, Preparation Project Progress Equipment Overview Preliminary Results Cost Framework Other Ancillary Equipment Summary Future? Questions

3 Background of Project Mandate: What can we do with our Frac Equipment, to become more efficient and fit-for-purpose (FFP)? Started June 1, 2010 Concentrate in Horn River initially Two Island Lake (TIL) Kiwigana (KWG) After discussion with vendors, learned that needed to work on: quick hit short-term ideas (<1 yr) continue on long-term initiatives (>1 2 yrs) Decided to work on critical, high cost components initially: work with Schlumberger (SLB) maintenance and non-productive time engines proceed to research fuel options natural gas? tackle short-term ASAP, treat as pilot project look at other long-term FFP ideas concurrently

4 Background cont d Location Map of Horn River TIL, KWG Horn River Encana is active in: Horn River Montney Duvernay CBM Jonah Piceance Haynesville Collingwood Deep Panuke

5 Background cont d Typical Frac Spread Equipment Horn River need approx HHP pads typically 5 16 wells, with fracs per well potential for 300+ fracs per pad, 24 / 7 operations, 3 fracs / day, 5-6 hrs each most common engine CAT 3512C HD, but Cummins, MTU with other vendors typically 20 pumps, 2250 HP each ( HP) redundancy, pumps lower on curve, less load rate m3 / min ( bbl / min) pressure MPa ( psi) fuel usage will range litres ( USgal) per frac diesel FOB padsite ~$1.30 / litre ($4.95 / USgal) Horn River field gas 12% inert CO2, natural gas AECO $2.10 / mcf

6 Research, Planning, Preparation Reviewed engine technology, other industries, fuel options quick, minimal engine changes, flexible need same or more power : footprint ratio, power : weight ratio no CNG, no LNG, but existing fuel gas pipeline infrastructure within field Reviewed success of ALTRONIC / GTI with drilling rigs GTI Bi-fuel (vs Dual-fuel defn) normally aspirated through air intake not direct injection into cylinder (WESTPORT system) drilling success with approx 50 60% natural gas substitution Integrated Fuel Gas infrastructure planning work with TIL and KWG Development / Facilities Teams determine optimal fuel gas infrastructure plan, upgrades centralized vs local pad-site treating of natural gas, sweetening design, fabrication padsite fuel metering, distribution to pumps HARC (SLB), HAZOP (ECA), FIELD LOOKBACK reviews absolutely critical integrate ideas and support from field operations, all stakeholders

7 Project Progress Pilot Project Timeline: decision to proceed with SLB (October 2010) expected 50 60% natural gas substitution, approx 7 e3m3/d (0.25 mmcf/d) per pump GTI feedback, Bi-fuel drilling experience convert pump #1 initially at TIL b-76-k (March 2011) 19 fracs capture data, order more kits expand with pumps #1 - #4 at TIL d-1-d (July 2011) 55 fracs additional data, more statistics proceed with pumps #1 - #8 at KWG c-15-d (November 2011) pumps #1 - #4 253 fracs pumps #5 - #6 35 fracs, pumps #7 - #8 27 fracs more data, statistics continue with 8 pumps at KWG a-67-d (April 2012) total of 202 fracs, but only 117 fracs pumped on Bi-fuel NG unavailable

8 Project Progress cont d TIL b-76-k / d-1-d pads, KWG c-15-d / a-67-d pads Summary and feedback from operations: Pump #1 19 fracs pumped engine performed well issues with liquids in fuel gas line (condensate? methanol?) incorporate better system to ensure gas clean, dry winter operations need better individual natural gas metering and data capture Pumps #1 - #4 55 fracs pumped engines performed well still need better metering for natural gas vibration leaks on engine piping ideas for better ramps, quick-connect couplings, braided-hose length

9 Project Progress cont d TIL b-76-k / d-1-d pads, KWG c-15-d / a-67-d pads Pumps #1 - #8 253 fracs pumped more comfort from operations staff individual natural gas meter problems continue with fine-tuning of engines, and optimize load and substitution variability Pumps #1 - #8 117 fracs pumped more routine operations need to enhance conversion kit mounting, vibration need fine-tuning of safety system monitoring ongoing maintenance routine established General Engine performance each one has its own character performance, substitution fine-tuning of set points for all pumps prior to each pad is recommended, with new gas analysis for that campaign

10 Sample Photo GTI after-market bolt-on

11 Sample Lease Photo TIL b-76-k pad

12 Sample Photo Prototype on-site at b-76-k

13 Sample Lease Photo TIL d-1-d pad

14 Sample Lease Photo KWG c-15-d pad

15 Sample Lease Photo KWG c-15-d pad

16 Pad Layout KWG c-15-d

17 Equipment Overview cont d Revised Designs, Lease Piping More complicated with 8 pumps fuel header system, fuel lines, ramps, control philosophy Continue to resolve HARC, HAZOP and FIELD LOOKBACK concerns Need to maintain safety, minimize secondary hazards place metering skid at corner of lease fuel line leaks, vibration, rupture congestion, tripping hazards Will ensure: maintain modular, portable maintain gas quality, integrity short-term vs long-term designs future expansion cost effective

18 Equipment Overview cont d Revised Designs, Lease Piping Example changes, optimization revised ramp designs quick disconnect couplings, proper braided hose lengths mechanical crew / gas fitter on-site for installation of fuel system piping GTI technician on site for fine-tuning of engines at start of each pad option to add dehy (desiccant) skid for winter operations, if gas not dry enough threaded fittings on engine conversion kits need modification

19 Sample Photo Original Concept Ramp

20 Sample Photo - Old Ramp design, Lease Piping

21 Sample Photo Gas Line

22 Sample Photo Things to Improve

23 New Ramp design Lease Piping

24 Quick-disconnect Couplings

25 Quick-disconnect Couplings cont d

26 Transportation Ramps, Piping

27 Treating skid Inlet Separator / Meter, Tank

28 Drawing Treating / Meter Skid

29 Preliminary Results Results initially qualitative, but now more quantitative continuing to capture data more confidence on metering on last pad Achieving 40 55% NG substitution approx average of 5 e3m3/d (0.175 mmcf/d) natural gas per pump GTI expected %, 7 e3m3/d (0.250 mmcf/d) per pump metering needs ongoing attention to ensure accuracy (calibration, maintenance, vibration?) fine tune engines, optimize operation window set-points (run Bi-fuel over longer periods of pumping) look at loading and substitution variability per engine look at variable / active blending valve look at other vendors other than GTI?

30 Cost Framework Cost per engine conversion kit, after-market bolt-on purchase various vendors range $ $ / kit installation, commissioning extra commercial terms will vary with frac vendor creative ideas Fuel savings total volume displaced at end of third pad litres ( USgal) Infrastructure planning centralized plant vs lease treating pipeline vs lease skid, dehydration what else needs natural gas? drilling rigs production operations if sour, sweet fuel gas as instrument air? costs can be substantial, but potential to share with other users at pad Continue with long-term Fuel Gas infrastructure planning with Development Team

31 Other Ancillary Equipment What else on the lease can run on natural gas? Rationalization of light towers, gensets example multi-well pad 22 light stands / towers, 6 generators minimize and optimize larger light towers, reduce number of gensets, centralize? run gensets on natural gas vs diesel Winter operations running boilers on natural gas vs propane frac water pre-heat with natural gas vs propane Alternate engines / drivers MTT / HUB CITY / GREENFIELD ENERGY SERVICES small HP mini-turbines can run on multiple fuels natural gas ideal Other future HP driver options?

32 Summary Bi-fuel is viable, no Red Flags yet R&D, Innovation, Pilot testing patience, perseverance look over the fence at other industries need management commitment, dedicated staff to focus on initiative collaboration across company (CAN, USA) multiple pilots, sharing takes longer than you realize (2 5 years depending on technology) teamwork with vendors and stakeholders improvements, optimization Communication, Education is critical Proceed to expand Bi-fuel initiative on future pads, but need to maintain: design integrity safety concerns fuel infrastructure expansion strategy for future vendor service and support Integrate any other feasible FFP Equipment in future

33 Other fuel delivery CNG, LNG Future? Work with more frac vendors? some progress by others? FRACTECH USA SANJEL CANADA BAYOU USA Investigate more Bi-fuel vendors? ALTRONIC / GTI enhancements AMERICAN POWER GROUP HYTHANE COMAP OEM engine manufacturers progress? home-grown systems coming CATERPILLAR, CUMMINS new builds aftermarket bolt-ons on existing engines new engine designs larger HP systems normal aspiration vs direct injection designs (WESTPORT concept) Other fuel or HP options?

34 Questions?

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