Final Report Title: Resin Compared to Cement as a Sealant for OCS Wells Contract No: E17PC00004 Date: October 12th, 2018 Version: 1.4 PREPARED FOR: PREPARED BY: Bureau of Safety and Environmental Paul Sonnier Enforcement Altan Aydin R&D Manager Petroleum Engineer, COR [email protected] CSI TECHNOLOGIES • 2202 Oil Center Court • Houston, Texas 77073 • 281.784.7990 • www.csi-tech.net TM-PM-03(3.0) TABLE OF CONTENTS acronyms and abbreviations ......................................................................................................................................... 0 List of Tables .................................................................................................................................................................. 2 List of Figures ................................................................................................................................................................. 3 List of Equations ............................................................................................................................................................ 7 1.0 Executive Summary ................................................................................................................................................. 8 2.0 Introduction ........................................................................................................................................................... 12 2.1 Objective ............................................................................................................................................................ 12 2.2 Conclusions and Recommendations .................................................................................................................. 12 2.2.1 Task 1.0 Conclusions - Formation of Industry Advisory Group ................................................................... 14 2.2.2 Task 2.0 Conclusions - Review of Previous Work ........................................................................................ 15 2.2.3 Task 3.0 Conclusions - Gathering Area Conditions in the OCS for Resin Application ................................. 15 2.2.4 Task 4.0 Conclusions - Fundamental Chemical Evaluation of Resins .......................................................... 16 2.2.5 Task 5.0 Conclusions - Laboratory Evaluation of Resin Performance Properties ....................................... 16 2.2.6 Task 6.0 Conclusions - Seal Integrity and Numerical Evaluation of Resin Performance ............................. 16 2.2.7 Task 7.0 Conclusions - Develop Operational Guidelines ............................................................................. 17 2.2.8 Task 8.0 Conclusions - Performance Assessment of Resin Compared to Cement ...................................... 17 2.2.9 Task 9.0 Conclusions - Cost-Benefit Analysis .............................................................................................. 18 2.2.10 Task 10.0 Conclusions - Regulatory Analysis of Resin as Well Sealant ..................................................... 18 2.3 Recommendation .............................................................................................................................................. 19 3.0 BACKGROUND and Report Structure ..................................................................................................................... 20 4.0 Task 1.0 - Formation of Industry Advisory Group .................................................................................................. 22 5.0 Task 2.0 - Review of Previous Work - Literature Review ....................................................................................... 22 6.0 Task 3.0 - Gathering Area Conditions in the OCS for Resin Application ................................................................ 23 7.0 Task 4.0 - Fundamental Chemical Evaluation of Resins ......................................................................................... 27 7.1 Thermal Gravimetric Analysis ............................................................................................................................ 29 7.2 Isothermal Treatment of Resins at 150˚C in Air ................................................................................................ 36 7.2 Differential Scanning Calorimetry ...................................................................................................................... 42 7.3 Immersion of Resins in Brine and Deionized Water at 150˚C ............................................................................ 47 7.4 Interaction of Cement with Brines .................................................................................................................... 48 7.4.1 Acidity Changes During Immersion ............................................................................................................. 48 7.4.2 XRF Microscope Measurements ................................................................................................................. 48 7.4.3 XRD Diffraction of Brine-Impacted Cements .............................................................................................. 50 8.0 Task 5.0 - Laboratory Evaluation of Resin Performance Properties—Small Scale ................................................. 52 8.1 Objective ............................................................................................................................................................ 52 8.1.1 Subtask 5.1-5.10 - Test Procedures ............................................................................................................ 52 8.1.2 Results......................................................................................................................................................... 59 8.1.3 FTIR Analysis of Cements Aged in Fluids ................................................................................................... 112 8.1.4 FTIR Analysis of Resins Aged in Fluids ....................................................................................................... 115 8.1.5 Small Scale Pressure Annular Seal ............................................................................................................ 134 8.1.6 Large Scale Pressure Annular Seal ............................................................................................................ 135 8.1.7 Cohesiveness of Resin ............................................................................................................................... 137 9.0 Task 6.0 - Seal Integrity and Numerical Evaluation of Resin Performance .......................................................... 138 9.1 Summary .......................................................................................................................................................... 138 9.2 Technical Approach ......................................................................................................................................... 138 9.3 Subtask 6.1-6.4 - Finite Element Model of Scale Systems ............................................................................... 139 9.3.1 Boundary and Initial Conditions ............................................................................................................... 142 9.3.2 Contact Interactions ................................................................................................................................. 143 9.3.3 Damage Modeling ..................................................................................................................................... 144 9.3.4 Pressure Loading ....................................................................................................................................... 144 CSI TECHNOLOGIES • 2202 Oil Center Court • Houston, Texas 77073 • 281.784.7990 • www.csi-tech.net TM-PM-03(3.0) 1 | P a g e 9.4 Results ............................................................................................................................................................. 146 9.4.1 Small Scale Results .................................................................................................................................... 146 9.4.1 Large Scale Results .................................................................................................................................... 149 10.0 Task 7.0 - Develop Operational Guidelines ........................................................................................................ 152 10.1.1 Subtask 7.1 - Resin Applications ............................................................................................................. 152 10.1.2 Subtask 7.2 - Operations ......................................................................................................................... 153 10.1.3 Subtask 7.3 – Resin supply for the Gulf of Mexico ................................................................................. 154 10.1.4 Subtask 7.4 – Field Application Limits of Resin Placement Identified by Industry Advisory Group ....... 154 10.1.5– Subtask 7.5 - HSE Concerns .................................................................................................................. 155 11.0 Task 8 - Performance Assessment or Resin Compared to Cement .................................................................... 156 11.1 Objective .......................................................................................................................................................