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JET
Developm
Tr
and
ansportation,
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10, JET
ent,Manual
Acid
AcidStorage,
10,
EquWS
ipment,
Acid
Tr aining
Mixing,
Handling
& Spills
, Acid
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to identify the products and services described herein are either trademarks,
trade names or service marks of Schlumberger and its licensors, or are the
property of their respective owners. These marks may not be copied, imitated
or used, in whole or in part, without the express prior written permission of
Schlumberger. In addition, covers, page headers, custom graphics, icons, and
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of Schlumberger, and may not be copied, imitated, or used, in whole or in part,
without the express prior written permission of Schlumberger.
A complete list of Schlumberger marks may be viewed at the Schlumberger
Oilfield Services Marks page: http://markslist.slb.com
Marks of Schlumberger include but may not be limited to CemCADE*,
DeepSTIM*, i-District*, i-Handbook*.
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Document Control
Owner:
Author:
Reviewer:
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Contact Information
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1.0
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Regulatory Compliance
Waste management
IMPORTANT INFORMATION FOR CORRECT DISPOSAL OF THE EQUIPMENT
This symbol means that the equipment cannot be discarded in a rubbish-bin. At
its end of life, the equipment and/or its components must be treated, following
Schlumberger Environmental procedures, in compliance with Schlumberger QHSE
Policy and applicable laws and regulations on waste management.
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Foreword
New releases of this document supersede any other version. The most current
version of the document is in www.InTouchSupport.com.
If you have a printed copy, check the "Release Date" against the content in
InTouch to be sure you have the most current version.
This document is OBSOLETE when printed.
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vi
vi
Table of Contents
Regulatory Compliance
Foreword
__________________________________________
iv
_________________________________________________________
1
1.1
1.2
Introduction ____________________________________________________
Learning Objectives __________________________________________
Safety Warning ______________________________________________
1-1
1-2
1-2
2
2.1
2.2
2.3
2-1
2-1
2-2
2-2
3
3.1
3.2
3.3
3.4
3.5
3-1
3-1
3-2
3-3
3-5
3-8
4
4.1
4.2
4.3
4.4
4.5
5
5.1
5.2
5.3
5.4
5-1
5-1
5-3
5-3
5-4
6
6.1
6.2
6.3
6.4
6.5
6.6
6-1
6-11
6-18
6-24
6-27
6-28
6-30
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vii
6.7
6.8
6.9
6.10
6.11
vii
6-31
6-31
6-32
6-39
6-40
7
7.1
7.2
7-1
7-1
7-3
8
8.1
8.2
8.3
8.4
8-1
8-2
8-7
8-9
8-9
9
9.1
9.2
9.3
9.4
9.5
9.6
9-1
9-1
9-3
9-4
9-5
9-5
9-5
10
_____________________
10-1
11-1
11-2
11-3
11-4
11-4
11-5
12
_____________________
12-1
13
____________________________________
13-1
11
11.1
11.2
11.3
11.4
11.5
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viii
List of Figures
2-1
2-2
2-3
3-1
3-2
3-3
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
5-1
5-2
5-3
5-4
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
6-11
6-12
6-13
6-14
6-15
6-16
6-17
6-18
6-19
6-20
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viii
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ix
6-21
6-22
6-23
6-24
6-25
6-26
6-27
6-28
6-29
6-30
6-31
6-32
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-40
6-41
6-42
6-43
6-44
6-45
6-46
6-47
6-48
6-49
6-50
6-51
6-52
6-53
6-54
6-55
6-56
6-57
6-58
6-59
6-60
6-61
6-62
6-63
6-64
6-65
7-1
7-2
ix
6-6
6-6
6-6
6-6
6-7
6-7
6-7
6-7
6-7
6-8
6-8
6-9
6-9
6-10
6-10
6-10
6-11
6-12
6-13
6-13
6-14
6-15
6-17
6-17
6-19
6-20
6-21
6-21
6-24
6-25
6-26
6-27
6-29
6-30
6-31
6-33
6-34
6-35
6-36
6-37
6-38
6-39
6-41
6-42
6-42
7-1
7-2
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7-3
7-4
7-5
7-6
8-1
8-2
8-3
8-4
9-1
9-2
11-1
11-2
11-3
12-1
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7-4
7-4
7-5
7-6
8-3
8-6
8-8
8-8
9-6
9-6
11-1
11-1
11-3
12-2
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xi
xi
List of Tables
3-1
4-1
8-1
8-2
8-3
9-1
9-2
11-1
11-2
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3-5
4-3
8-10
8-11
8-12
9-3
9-7
11-4
11-5
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1-i
1
1.1
1.2
1-i
Introduction
Learning Objectives ____________________________________________
Safety Warning _________________________________________________
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1-2
1-2
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1-1
1-1
Introduction
JET 10,
Acid
Equipment,
Storage,
JETMixing,
Manual
Acid Handling,
Spills
10, WS
andAcid
Training
Disposal,
Trans
& portation,
Development,
Acid
Acid
This job execution training (JET) manual introduces the storage, handling,
mixing, and transportation of the acids used by Schlumberger Well Services (WS)
and Well Intervention Services (WIS) in matrix and acid-fracturing treatments
and other acid-pumping services provided to clients.
This manual discusses how acid mixing and storage systems work, describes
the major components used, reviews their proper operation, and addresses
important safety and maintenance issues.
Note
Hydrochloric acid (HCl) is by far the most common acid used by Schlumberger,
and unless otherwise stated, will be the acid of reference throughout this JET
manual.
Other acids used are hydrofluoric acid (HF), acetic acid (CH3CO2H), formic
acid (HCO2H), or mixtures of acids.
Because Schlumberger has locations all over the world, acid storage tanks and
related equipment, transfer pumps, and transport tankers are procured from a
variety of sources. For this reason, operating and maintenance procedures are
different depending on the location.
However, some basic facts do not change. It is important for the equipment
operator (EO) to understand and do the following:
Handle acid and acid materials with extreme caution. They are hazardous
products.
Ensure that the correct personal protective equipment (PPE) are available
and wear the correct PPE at all times.
Be up to date on the required safety training and certification in standards
and procedures. This applies to all personnel.
Review all material safety data sheets (MSDSs) for all materials before
handling.
Perform a risk assessment before any operation.
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1-2
1-2
Ensure that all equipment associated with the handling, storage, transport,
transfer, mixing, and pumping of any acid or acid materials are well
maintained and in good operating condition. In addition, ensure that the
Standard Equipment Maintenance (STEM) program is well documented and
followed.
Document all procedures for the operation of any equipment and processes
relating to the storage, handling, mixing, transportation, and pumping of
acids. All personnel must be competent.
Note
The EO has a significant impact both on the HSE performance and the
profitability of the operation through the application of best practices related to
the storage, handling, and transportation of acids.
1.1
Learning Objectives
Upon completion of this manual, you will be able to
describe the safe working practices required when working with acids
explain the principles of acid storage
identify the various types of bulk storage tanks, transfer pumps, fume
scrubbers and transport tanks.
describe the operational guidelines for district acid plants and acid plant
equipment on location
describe maintenance and procedures for acid storage and transport tanks.
1.2
Safety Warning
Proper supervision is required during hands-on training. Request assistance
from your supervisor if you are unfamiliar with or uncomfortable with the proper
operation of any equipment or chemical.
All personnel involved with the operation of acid equipment and transfer units
must understand the dangers involved when dealing with the materials and
equipment, along with all applicable Schlumberger, WS, and WIS safety
standards. Follow proper procedures before working with equipment, acids,
and acid additives, e.g., job safety analyses (JSAs) and Hazards Assessment
and Risk Controls (HARCs).
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2-i
2
2.1
2.2
2.3
2.3.1
2.3.2
2-i
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2-1
2-2
2-2
2-2
2-4
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2-1
2-1
2.1
Definition of an Acid
An acid is any chemical compound that, when dissolved in water, contributes
hydrogen ions (H+) to a solution, resulting in a pH of less than seven.
For example: HCl in water ionizes to hydrogen and chloride ions:
HCl H+ + ClHence an aqueous solution of HCl is acidic.
The word acid comes from the Latin acidus meaning sour. Acids have the
following chemical and physical properties:
reactivity: Acids react with metals, oxides, hydroxides, or carbonates to form
salts and other products.
electrical conductivity: Acids are electrolytes.
touch: Acids produce a stinging feeling, particularly strong acids.
Acids are hazardous materials capable of doing harm. The handling, storage,
transportation, and mixing of all acids must be done with extreme care.
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2-2
2.2
2-2
Applications
The wide range of properties of acids makes them very useful in many different
industrial applications. Acids are used in the steel processing, water treatment,
paper, leather, brewing, cosmetics, pharmaceutical, chemical manufacturing
(production of inorganic salts, pesticides, catalysts, and plastics), metal
extraction and producing, and food-producing industries.
In the oilfield, hydrochloric acid (HCl), organic acids (e.g., acetic, formic, and citric
acid) and hydrofluoric acids are used for a variety of purposes. Their properties,
reactivity, and reactions with various compounds is controlled with additives.
The demand for acids in the oil and gas industry is increasing worldwide. In
1999, the demand for hydrochloric acid (also known as muriatic acid) in the US
exceeded 6,500,000 metric tons. One percent of this demand was for use in oil
well stimulation. According to the Chemical Economics Handbook (CEH), in
2009, 12% of all North American HCl demand was for use in oil well stimulation.
According to IHS, in 2012, US contribution to world consumption of HCl stands at
around 24% HCl, obtained from about 80 suppliers around the world.
2.3
Acid Properties
Acid has specific properties that are important to understand to be able to handle
it safely.
2.3.1
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2-3
2-3
For Quality Assurance/Quality Control (QA/QC), the following tests are required
for acid strength:
1. Specific gravity test by hydrometer (Specific Gravity Method)
2. Acid content test by titration with Sodium Hydroxide (Titration Method)
3. Chloride content test by titration with Silver Nitrate (Chloride Content)
These three laboratory tests are required to determine hydrochloric acid
concentration in acid concentrate. All three tests confirm the strength of the acid,
while the third test also verifies that the acid is HCl and only HCl.
The most common method of measuring the concentration of dissolved gas is
by determining the specific gravity of the acid solution. The lower the specific
gravity is, the lower the concentration of acid is. The specific gravity reading is
then converted into a percentage HCl by weight.
A hydrometer is used to measure the specific gravity (and thus the strength) of
HCl solutions. A sample of the HCl is placed in a graduated cylinder so that it
floats freely (refer to Figure 2-1). Any floating oil must be removed from the
surface of the acid and the hydrometer must be cleaned. The point on the
hydrometer scale at the surface of the liquid indicates the specific gravity.
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2-4
2-4
Acid strength is also measured using the Baume scale, where 1.0 Baume units =
1.0069 specific gravity.
The specific gravity is affected by temperature; therefore, it is also necessary
to measure the temperature of the acid at the same time. Corrections are then
made to convert the readings back to the reference temperature of 60 degF
(16 degC).
Refer to Section 3 of the Matrix Materials Manual (MMM), InTouch content ID#
4013354, for more information about hydrochloric acid. Refer to the Key Service
Quality Testing Requirements Matrix, InTouch content ID# 3051128, for more
information about the QA/QC tests to check acid strength.
2.3.2
pH Scale
The pH scale (Figure 2-2) is a measure of the relative acidity or alkalinity of a
solution. A change of one pH unit means a 10x change in the acidity or alkalinity
of the solution. For example, a change from pH 5 to pH 2 means an increase in
acidity of 1,000x.
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2-5
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3
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.4.6
3.4.7
3.5
3.5.1
3.5.2
3.5.3
3.5.4
3.5.5
3.5.6
3.5.7
3.5.8
3-i
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3-1
3-2
3-3
3-5
3-7
3-7
3-7
3-7
3-8
3-8
3-8
3-8
3-9
3-9
3-10
3-10
3-10
3-11
3-11
3-11
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3-1
3-1
3.1
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3-2
3.2
3-2
Historical Background
The use of acids in oil wells began over 100 years ago (Figure 3-1).
The following significant dates and events mark the development of well
stimulation.
1895: Ohio Oil Company used hydrochloric acid to acidize wells. It was reported
that oil wells increased production three times and gas wells four times.
March 1896: A patent for using hydrochloric acid (HCl) for acidizing limestone
was issued to Herman Frasch, a chief chemist with Standard Oil Company.
Unfortunately, the use of corrosion inhibitors was not considered and the acid
severely corroded the well casing. The technique declined in popularity and was
dormant for about 30 years.
1931: Dr. John Grebe of the Dow Chemical Company discovered that arsenic
inhibited the action of HCl on metal. The Gypsy Oil Company performed a
number of well treatments in sandstone formations, in which inhibited HCl was
used in an attempt to remove gyp deposits (calcium sulfate). The treatment
results were mostly unimpressive, and no patents were filed on the process.
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3-3
3-3
3.3
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3-4
3-4
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3-5
3.4
3-5
Form
SG at 60
degF
Flash
Point
(degF)
pH
H005
Colorless liquid
1.025
> 200
H075
Liquid
1.037
> 200
H010
Liquid
1.050
> 200
H015
Colorless-light
yellow liquid
1.075
> 200
H020
Liquid
1.100
> 200
H028
Colorless-light
yellow liquid
1.140
> 200
H036
Colorless-light
yellow liquid
1.18
> 200
H152
Colorless to
yellow liquid
1.20
> 200
H200
Colorless liquid
1.20
> 200
4.1
at
20%
(wt)
H700
Y001
Intensifier Y1 ammonium
bifluoride
White crystals
H948
Colorless liquid
1.50
> 200
2 at
0.5%
(wt)
> 200
Colorless liquid
1.10
> 200
Colorless liquid
1.10
> 200
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3-6
3-6
Form
SG at 60
degF
Flash
Point
(degF)
pH
Y006
White granular
powder
1.40
> 200
5.1
at
Intensifier Y6
1%
(wt)
H813
Colorless liquid
1.1
> 200
Colorless liquid
1.1
> 200
Colorless liquid
1.1
> 200
<2
Colorless liquid
1.1
> 200
0.1
H913
H914
L400
Colorless liquid
1.05
109
1.0
at
70%
(wt)
L401
Colorless liquid
1.00 to 1.05
90
1.0
L036
Formic acid
Colorless liquid
1.20
64 degC
(147
degF)
2.2
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3-7
3.4.1
3-7
Hydrochloric Acid
Hydrochloric acid (HCl) is a solution of hydrogen chloride gas in water. The
strength of the acid depends on how much hydrogen chloride gas is dissolved
in a given quantity of water. The maximum concentration of commercial grade
HCl is about 36% by weight. Concentrations of HCl up to 28% by weight are
generally used in oilfield treatments. In Well Services (WS) and Well Intervention
Services (WIS), the chemical code for hydrochloric acid includes H005, H015,
and H028, with the last three digits representing the concentration of HCl in
percent (for example, H028 is 28% hydrochloric acid).
3.4.2
Hydrofluoric Acid
Hydrofluoric acid (HF) is the second most frequently used acid in the oilfield and
is always used with another acid, usually HCl. The most common form of HF
is mud acid (refer to Section 3.4.3). HF reacts with and dissolves all materials
that are soluble in HCl. HF also reacts with, dissolves, or partially dissolves
bentonite, naturally occurring formation clays, and other siliceous materials.
3.4.3
Mud Acid
Mud acid is a mixture of inhibited HCl and HF. It is used primarily to restore
permeability to damaged sandstones. There are three main classifications:
dilute mud acid any solution containing up to and including 7.5% HCl
and 1.5% HF
regular mud acid any solution containing 7.6 to 12.0% HCl and 1.6 to
3.0% HF
super mud acid any solution containing 12.1 to 16% HCl and 3.1 to 6%
HF..
3.4.4
Clay Acid
Clay acid is a mixture of HCl, intensifier Y001 (ammonium bifluoride), and
intensifier Y006, which contains boron. Clay acids slowly release HF from the
hydrolysis of HBF. There are four clay acid formulations:
full strength clay acid, used for 130 to 300 degF [54 to 149 degC]
full strength clay acid LT, used for 100 to 130 degF [38 to 54 degC]
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3-8
3-8
3.4.5
Acetic Acid
Acetic acid (CH3CO2H) can be prepared using either glacial acetic acid (using
stabilizing agent L400, 100% acetic acid) or a low freezing point acetic acid
solution (using stabilizing agent L401). The big advantage of acetic acid is that
concentrations of up to 12% acetic acid can be adequately inhibited from causing
steel corrosion at temperatures up to 350 degF for extended periods of time. In
most cases, acetic acid is used in conjunction with HCl.
3.4.6
Formic Acid
Formic acid (HCO2H) is a mixture of 9% L036 and water. It is much stronger than
acetic acid, but it is also more difficult to inhibit. It can be used at temperatures
as high as 400 degF [204 degC].
3.4.7
3.5
Acid Additives
Acid solutions are mixed with one or more additives to allow them to be used
effectively in oilfield applications. Schlumberger stimulation acids always contain
water, concentrated acid, and a corrosion inhibitor.
Note
Clean, rust-free tanks must be used when preparing all acid mixtures.
Other additives commonly used include
a nonemulsifier
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3-9
3-9
Note
All the additives used in a specific acid solution must be compatible with the
carrier fluid, with each other, and with the formation and reaction products.
Compatibility tests must be performed in a laboratory.
3.5.1
Inhibitors and inhibitor aids are hazardous materials. Extreme care should be
taken when handling these products (refer to the MSDSs).
For more details, refer to the Corrosion Inhibitor Reference Page (InTouch
content ID# 3300767).
3.5.2
Surfactants
A surfactant is a chemical that alters liquid-liquid or gas-liquid interfacial
properties. Surfactants reduce the interfacial tension and change the contact
angle at the interface between liquid and solid. Surfactants are used to
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3-10
3-10
3.5.3
Foaming Agents
Foams are used in stimulation treatments as a diverter and to improve cleanup.
To ensure that the foam is stable (that is, that the gas is well dispersed in the
liquid), a foaming agent is added. Foaming agents are surfactants.
Antifoams and alcohol tend to neutralize the actions of these foaming agents.
Common foaming agents include F78, F100, F105, and F107.
3.5.4
Mutual Solvents
Mutual solvents are multifunctional, nonionic agents soluble in oil, water, acid,
and brines. The mutual solvents act as wetting agents, nonemulsifiers and
surface/interfacial tension reducers. They dissolve oil on the rock surface and off
fines generated during acidizing, leaving them water wet. Water-wet fines do
not tend to stabilize emulsions.
Mutual solvents are used in large quantities of 5% to 80% solutions. They tend
to penetrate deep into the formation, aid in the injection of the treating fluid into
the rock matrix, and help clean up the treatment quicker.
U66 and U100 are common mutual solvents.
3.5.5
Antisludge Agents
Acid sludges are precipitates comprising asphaltenes, resins, asphaltogenic
acids, and/or other high-molecular hydrocarbons. These sludges are formed
when acid contacts the crude oil.
Antisludge additives stabilize the colloidal asphaltic materials found in crudes
and prevent the formation of sludge.
W60 and W54 are common antisludge agents.
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3-11
3.5.6
3-11
Nonemulsifying Agents
Most crudes contain emulsifying agents capable of generating very stable
emulsions downhole, resulting in formation damage. When a treating fluid comes
in contact with crude oil, varying degrees of emulsion takes place.
Nonemulsifiers are added to the treating fluid. They help prevent the formation of
emulsions and also break existing emulsions.
W53 and W54 are common nonemulsifying agents.
3.5.7
Iron-Control Agents
When iron is dissolved during matrix treatments, iron precipitation and formation
damage may occur. Iron precipitation can be prevented by adding complexing
agents and reducing agents.
Common iron control agents include L1, L41, U42, and L58.
3.5.8
Specialty Additives
Specialty additives can be added to the acid or pre- and postflushes to help
improve the effectiveness of a stimulation treatment. These include
clay stabilizers
alcohols
antifoam agents
formation cleaners
emulsifiers
scale inhibitors
bactericides.
For more information about these and all of the other additives, refer to
the Matrix Materials Manual (MMM), InTouch content ID# 4013354 or the
Acidizing_Additives.htm TBT found in the Well Services SWBT IT Modules,
Matrix Acidizing, InTouch content ID# 4135038.
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4
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.4.1
4.4.2
4.4.3
4.5
4.5.1
4.5.2
Safety Considerations
Safety Standards _______________________________________________ 4-1
Responsibilities ________________________________________________ 4-2
Personal Protective Equipment _________________________________ 4-3
Eye and Face Protection _____________________________________ 4-4
Hand Protection _____________________________________________ 4-5
Skin and Body Protection _____________________________________ 4-5
Respiratory Protection ________________________________________ 4-6
Treating HF Acid Exposure ___________________________________ 4-7
Hazard Communication Documents ____________________________ 4-7
Material Safety Data Sheets __________________________________ 4-8
Chemical Labels _____________________________________________ 4-8
Dangerous Goods Warning ___________________________________ 4-9
Transportation ________________________________________________ 4-14
Hazardous Materials Transportation Placards _________________ 4-14
EU TREM Cards ____________________________________________ 4-14
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4-1
4-1
Safety Considerations
JET 10,
Acid
Equipment,
Storage,
JETMixing,
Manual
Acid Handling,
Spills
10, WS
andAcid
Training
Disposal,
Trans
& portation,
Development,
Acid
Acid
Acids and acid additives are hazardous materials, because they can cause
injury, a health hazard, or damage to property and equipment. To minimize
the risks while working with acids and acid additives, appropriate precautions
should be taken. For example, water should never be added to the concentrated
acid, because the solution could boil and splash into your face or on your body.
Always add acid to water.
4.1
Safety Standards
Personnel involved in handling and using any acid or acid additive must review
and be certified in the following standards:
Schlumberger QHSE Standard S008 (Environment), InTouch content ID#
3605373: details the requirements and procedures designed to protect the
environment, prevent pollution, minimize environmental impact, and comply
with environmental laws and regulatory requirements.
Schlumberger QHSE Standard S003 (Personal Protective Equipment),
InTouch content ID# 3260259.
Well Services (WS) QHSE Std 04: Equipment, InTouch content ID# 3313678.
WS QHSE Std 05: Wellsite Operations, InTouch content ID# 3313681, and
the technology-based training (TBT) at InTouch content ID# 3318425.
WS QHSE Std 12: Permit to Work, InTouch content ID# 3313688, because
the tanks used to store acids and acid chemicals are considered confined
spaces and personnel must meet all the confined space requirements before
entering them.
WS QHSE Std 17: Storage and Handling of Oxidizers, InTouch content ID#
3313693, and the TBT at InTouch content ID# 3334298.
WS QHSE Std 18: Chemical Product Management, InTouch content ID#
3313694, details specific rules and procedures that must be followed at all
locations at which hazardous materials are handled and used in operations;
also refer to the TBT at InTouch content ID# 3348663.
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4-2
4.2
4-2
Responsibilities
Management is responsible for
complying with these standards; supplying the necessary personal protective
equipment (PPE)
providing the training for personnel
applying for exemptions when compliance is not possible.
Job supervisors are responsible for
ensuring that all Schlumberger employees and contractors at the work site
comply with these standards
recognizing the risks associated with the operation and reducing these risks
to the greatest extent possible
ensuring that all Schlumberger personnel on site are competent to drive
and/or operate their assigned equipment
taking the appropriate action, up to and including terminating the job, if
unacceptable risks exist.
All employees are responsible for complying with these standards and
recognizing and reducing (to the extent possible), the risks associated with the
operation.
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4-3
4.3
4-3
acids (HCl)
Respirator
Protection
Acid
Hydrochloric
Butyl
Neoprene
Nitrile
Hydrofluoric
acids (HF)
PVC
Protection
Viton
X
Tightly-fitting
NIOSH-approved
Chemical-resistant
safety
respirator with
suit, boots.
goggles.
organic vapor/acid
Face shield.
gas protection
(color-coded
Acetic acid
yellow).
(L400, L401)
Formic acid
(L036)
Mud acids
(HCl + HF)
Clay acids
(HBF4 + HF +
HCl)
Y001 intensifier
NIOSH-approved
respirator with
Y006 intensifier
protection (3M
8210).
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4-4
4.3.1
4-4
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4-5
4.3.2
4-5
Hand Protection
Impervious gloves (Butyl, Neoprene, Nitrile, PVC, or Viton) must be worn (refer
to Table 4-1).
4.3.3
Note
A safety shower and eyewash station should be located in the immediate work
area.
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4-6
4.3.4
4-6
Respiratory Protection
When exposure levels could exceed 5 ppm, a NIOSH-approved air-purifying
respirator with an acid-gas cartridge (color-coded yellow) in combination with a
high-efficiency particulate air filter (HEPA) is recommended (refer to Figure 4-4).
When exposure levels could exceed 50 ppm, a self-contained breathing
apparatus with a full face piece is recommended (refer to Figure 4-5).
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4-7
4.3.5
4-7
4.4
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4-8
4.4.1
4-8
4.4.2
Chemical Labels
All chemical materials that cause a physical, health, or environmental hazard
must comply with the WS and WIS policy for labels. This includes chemicals
supplied by WS and WIS, repackaged chemicals, laboratory chemicals, raw
materials, and common chemicals such as solvents, coolants, and fuels.
Each material package or container must be clearly marked with the following
information:
chemical name or code of the chemical. This identity must show the
alphanumeric WS or WIS code and the trade name, and must be the same
as the description of the material in the MSDS (e.g., H015 hydrochloric acid
15%).
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4-9
4-9
hazard warnings
name and address of the manufacturer, the company packaging the product,
distributor, and so on.
Other requirements include the following:
Replace missing or worn labels immediately.
Do NOT remove or damage labels on purchased products.
Old labels may be replaced with new labels that meet WS and WIS
requirements.
4.4.3
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4-10
JET Manual 10 / Safety Considerations
Private
4-10
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4-11
JET Manual 10 / Safety Considerations
Private
4-11
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4-12
JET Manual 10 / Safety Considerations
Private
4-12
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4-13
4-13
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4-14
4.5
4-14
Transportation
Transporting acid presents several issues and concerns. This section describes
the different types of transportation cards used when transporting acids.
4.5.1
4.5.2
EU TREM Cards
In Europe, the ADR (Laccord europen relatif au transport international des
marchandises dangereuses par route, or the European agreement for the
international transport of dangerous goods by road) controls the road transport of
hazardous materials, such as acids. In addition to driver training and certification,
TREM (transport emergency) cards must accompany the driver and truck.
The TREM cards (refer to Figure 4-11) detail the hazardous material being
transported and safety information and instructions.
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4-15
JET Manual 10 / Safety Considerations
Private
4-15
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5
5.1
5.2
5.3
5.4
5-i
Acid Supply
Acid Supply Packaging _________________________________________
Material Specifications _________________________________________
Procedure to Receive Acid at the District _______________________
Inventory Control ______________________________________________
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5-1
5-3
5-3
5-4
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5-1
5-1
Acid Supply
JET 10,
Acid
Equipment,
Storage,
JETMixing,
Manual
Acid Handling,
Spills
10, WS
andAcid
Training
Disposal,
Trans
& portation,
Development,
Acid
Acid
Schlumberger uses approximately 80 acid suppliers around the world, with 60%
of the supply coming from five suppliers. The locations in which the largest use
of acid occur are US land, Canada, and the Arabian Gulf.
5.1
bulk acid in rail cars: Large volumes of bulk acid can be supplied in
rubber-lined, 22,000 to 23,500 gallon acid railcars (Figure 5-2) if the district
is close to a rail system. In technologically-advanced countries, most acid
cars are fitted with loading and unloading devices on a single nozzle, thus
protecting workers and the environment. In other locations, it is necessary to
unload the acid with an acid transfer pump and hoses.
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5-2
5-2
polyethylene drums (220 L): the drums are blow molded in one operation
together with the top and bottom out of high molecular weight - high density
polyethylene (HMW-HDPE), and have an integrated L-ring on the top (Figure
5-4). The drums are optimally drainable and can be stacked three to four
high on pallets. Refer to WS QHSE Std 18: Chemical Product Management,
InTouch content ID# 3313694, for stacking requirements.
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5-3
5.2
5-3
Material Specifications
Each product that Schlumberger buys must meet purchasing specifications. All
shipments must comply with these specifications.
Note
Product specifications are confidential.
The specifications list the following:
product code and name, e.g., H036, HCl 36% uninhibited H36
nominal composition information (chemical composition)
quality control test criteria (type of test, acceptable limits, and test method)
acknowledgements.
Acid delivered by suppliers generally contains <180 ppm iron content.
Note
Do NOT transfer acid to dirty storage tanks.
5.3
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5-4
5-4
3. Ensure that transport units equipped with air compressors from third-party
companies must use their air supply equipment to unload products.
4. Make sure that acid is transferred to a storage tank containing the same
material or to a clean, empty tank. If acid is received in drums or tote tanks,
then they should be stored in a safe area.
5. Before transferring acid into Schlumberger storage tanks, check the specific
gravity of the acid using a hydrometer and determine the acid concentration.
Note
Ensure that the verification of acid type and acid strength is consistent with
WS QHSE Std 18: Chemical Product Management (InTouch content ID#
3313694) and KSQR testing methods.
6. Confirm that the volume of acid ordered matches the volume received.
Note
If the acid received does not match the strength and volume ordered, inform
your supervisor immediately.
7. Complete a material reception form, stating the supplier, receipt date,
quantity, and description. Be sure to note any differences.
8. Enter the acid description, concentration, volume received, and storage
locations in the inventory system.
9. Follow safe procedures to flush all lines with water before the equipment
is disconnected.
Note
When flushing acid out of lines, valves, and pumps with fresh water, make
sure that you use a flush rate high enough to ensure all the acid is flushed out.
5.4
Inventory Control
The stock levels of acid and acid additives must be controlled and monitored.
This is very important for the profitability of the company. Effective inventory
control reduces waste and costs, ensuring resources are optimized.
In some parts of the world, it is also a legal requirement to keep acid in a secure
facility and maintain legal records of acid stocks.
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6-i
6
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.3
6.3.1
6.4
6.5
6.6
6.7
6.8
6.9
6.9.1
6.9.2
6.9.2.1
6.9.2.2
6.9.2.3
6.9.3
6.10
6.11
6.11.1
6.11.2
6-i
Acid Storage
Safety Equipment _____________________________________________
Acid Bulk Plant Area ________________________________________
Lining for Acid Storage Area _________________________________
Loading Slab _______________________________________________
Signage ____________________________________________________
Safety Shower and Eye Wash Stations _______________________
Spill Kit _____________________________________________________
Fire Extinguisher ____________________________________________
Acid Storage Tanks ___________________________________________
Polyethylene Tanks _________________________________________
Steel Tanks with Lining ______________________________________
Tank Linings and Coatings ___________________________________
Pipe Work and Valves _______________________________________
Fume Scrubber ________________________________________________
Absorber ___________________________________________________
Water Storage _________________________________________________
Acid Mix/Transfer Tank ________________________________________
Liquid Additive System ________________________________________
Dry Additive System __________________________________________
Pipe Work, Valves, and Fittings ________________________________
Acid Transfer __________________________________________________
Pressure Transfer ___________________________________________
Transfer Pumps _____________________________________________
Delasco Pump __________________________________________
Air-Over-Fluid Chugger Pump __________________________
Other Pumps ____________________________________________
Standalone Centrifugal Pumps _______________________________
Liquid Additive Pumps ________________________________________
Transfer Hoses and Connections ______________________________
Connections ________________________________________________
Hoses ______________________________________________________
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6-11
6-12
6-13
6-13
6-14
6-15
6-17
6-18
6-18
6-19
6-20
6-22
6-23
6-24
6-26
6-27
6-28
6-30
6-31
6-31
6-32
6-32
6-33
6-33
6-35
6-37
6-38
6-39
6-40
6-40
6-41
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6-1
6-1
Acid Storage
JET 10,
Acid
Equipment,
Storage,
JETMixing,
Manual
Acid Handling,
Spills
10, WS
andAcid
Training
Disposal,
Trans
& portation,
Development,
Acid
Acid
Acid storage (Figure 6-1) refers to equipment used primarily at the district or job
site to hold acid until it is needed for a job.
The equipment used at Schlumberger districts for acid storage varies widely
depending on location, local laws and regulations, and the level of acidizing
services provided.
The preferred storage facility for an acid plant includes
acid storage tanks
water storage tanks
transfer pumps
mix tanks and other mixing equipment
acid fume scrubber
liquid additive system and additive storage facilities
revetment with a protective coating
loading dock.
The facility may also include warehouse storage for acid tote tanks, drums, or
both. Some facilities may have a single high volume bulk storage capacity for
more than one acid type with several acid storage tanks in it. There is a wide
variety of tanks and facilities across different locations.
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Figure 6-2 through Figure 6-7 show the Hassi-Messaoud, Algeria, facility.
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Figure 6-8 through Figure 6-11 show the Midland, Texas, USA, facility.
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Figure 6-12 through show the Jebel Ali, UAE, facility. Figure 6-12 shows the
secondary containment and warning signs on rubber-lined tanks.
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Figure 6-16 through Figure 6-19 show the Tengiz, Kazakhstan, facility.
Figure 6-16: General View of Acid Storage Tanks, Water Supply Tank,
and Fume Scrubber (with Lagged Point)
Figure 6-17: Acid Storage Tanks, Piping, and Walkway (Notice Secondary Containment
Wall)
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Figure 6-20 through Figure 6-24 show the Montrose, Scotland facility.
Figure 6-22: 2 x 30,000-galUS Rubber Lined Acid Tanks and Fume Scrubber with
Secondary Containment and Warning Signs
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Figure 6-25 shows the plant at Aracaju, Mexico. Figure 6-26 through Figure
6-29 show a few more plants.
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Figure 6-30 shows the Galaxie stimulation vessel in West Africa with 28,400
galUS raw acid storage capacity.
Figure 6-31 shows the BIGORANGE 25 stimulation vessel in the Persian Gulf.
With acid tanks installed on its back deck, the raw acid storage capacity is
120,000 galUS.
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As shown in Figure 6-34, the DeepSTIM has an 8,400-galUS raw acid storage
capacity on the back deck.
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6.1
Safety Equipment
The minimum safety requirements for acid plants are stated in WS QHSE Std
04: Equipment, InTouch content ID# 3313678. The type and quantity of safety
equipment available must be determined by the requirements on the MSDS
and the number of workers at the plant.
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6.1.1
6-12
The secondary containment must hold no less than 110% of the volume of the
largest container in the storage area. In addition, while not required by the
standard, an additional 12 inches of revetment wall height is recommended as it
will aid in spill containment.
Both the containment area and the loading slab must have a slope so that any
spills are collected in a sump.
Note
All containers and tanks in the plant must be clearly marked with their contents.
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6.1.2
Note
Follow all coating manufacturers requirements to ensure a leak-free coating.
6.1.3
Loading Slab
In the area where trucks will be loaded or unloaded, a loading slab must be
installed to prevent any spills from entering the ground. The loading slab must
have a slope to collect any spills in a sump.
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6.1.4
6-14
Signage
All bulk storage vessels must have signs (Figure 6-41) that display the following
items:
contents of the container
correct hazard warning labels for the country
hazard warning signs (e.g., Flammable or No Smoking)
Confined Space Permit Required decal or sign on each hatch of the storage
vessel.
In addition to these tank labeling requirements, the location of fire extinguishers,
first aid kits, spill kits, muster points, and exits must be well marked throughout
the acid storage facility.
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6.1.5
6-15
Use only clean drinking water in both the safety showers and eye wash stations.
Never use any other solution; your eyes could be damaged on contact.
Note
Install a water hose that will reach all parts of the high-risk area in addition to the
safety shower and eye wash station.
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When water is left in the eye wash stations, there is a risk of bacteria. To prevent
this problem, add a water treatment chemical to the water tank.
Note
Make sure that the water treatment chemical is safe for use in eyes. The eye
wash station must be washed and flushed with clean water every 30 days.
When an object or chemical enters your eyes, do NOT rub the eyes. The best
method to remove the object or chemical is to flush the eye with large quantities
of clean water. Follow these procedures:
1. Go to the nearest eye wash station and push the handle of the valve.
2. Hold your eye lids open with your fingers and keep your eyes in the flow of
clean water.
3. Wash your eyes for at least 15 minutes.
4. Request that a doctor check your eyes to make sure that the object or
chemical is removed.
You must remove chemicals that come in contact with your eyes within 15 to
30 seconds.
Know the location of the eye wash stations and the safety showers.
Know how to use all the safety equipment in an area that handles hazardous
chemicals.
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6.1.6
6-17
Spill Kit
Each location must have an emergency spill kit (Figure 6-43 and Figure 6-44)
for a chemical spill. The size of the kit and the amount of equipment in it are
determined by the quantity of products stored.
A spill kit typically includes the following equipment:
shovels to remove contaminated dirt or chemical absorbent materials
bags of absorbent material to absorb chemical or oil spills
brooms to contain spills within one area
chemical spill drums to contain the dirt or absorbent materials
soda ash to neutralize HCl spills
Note
If HF acid is used at the location, use calcium carbonate to control the HF
acid.
new drums to neutralize leaking drums of chemicals.
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6.1.7
6-18
Fire Extinguisher
Note
Fire extinguishers must be easily available in case of a fire.
Fire extinguishers must be
located in the loading dock area and the area where acids are mixed.
installed on hangers or in brackets. Install signs above the fire extinguishers
that show their position.
inspected monthly and tagged with a label to track the inspections.
6.2
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6.2.1
6-19
Polyethylene Tanks
High-density cross-linked polyethylene (HDXLPE) tanks are the standard vertical
storage tanks for acid used by Schlumberger (refer to Figure 6-45 and Figure
6-46). They are typically 12,000-galUS, 12-ft diameter, vertical tanks with ladders
to the top for access to the manway cover and level sensor. Each acid tank
discharge is designed to be double valved.
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6.2.2
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Note
Make sure that you check the manufacturers specifications to determine the
compatibility of fluids to be stored and transported with the coating and lining
used under local conditions.
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6.2.3
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bonded polyethylene: much more expensive than the vinyl ester lining,
but will last for a very long time with little maintenance. It can be applied to
storage tanks as large as 10,000 galUS and can be used to store all acids.
Avoid strong xylene in these tanks.
stainless steel tanks: not suitable for storing acid. Hydrochloric acid will
destroy the passivating layer of the stainless steel. Stainless steel tanks can
be used to mix acid but any acid must be neutralized and the tanks and lines
must be well cleaned after every job.
Note
Other materials are sometimes used, but check with the supplier for compatibility
with acids and other fluids used before filling a tank made of some other material.
6.2.4
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6.3
6-24
Fume Scrubber
Hydrogen chloride gas and mist emissions must be controlled because they have
a corrosive effect on human tissue, potentially damaging respiratory organs,
eyes, skin, and intestines. The fumes are also very corrosive to equipment and
buildings.
Therefore, an acid fume scrubber (Figure 6-49 and Figure 6-50) should be used
to prevent acid fumes from venting into the atmosphere while the acid tank is
being filled, acid is being transferred, or during normal venting from the storage
tank.
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The acid fumes enter the bottom of the scrubber tower and are absorbed into
water as the fumes travel upward and removed from the air.
A scrubber recirculation pump (e.g., a Marsh TE-7K-MD, Series 7 seal-less
magnetic drive centrifugal pump as shown in Figure 6-51) is used to ensure that
the scrubber tower packing is wetted. During acid fill and transfer operations,
the pump should be run continuously to ensure proper scrubbing of the fumes.
During normal venting, the pump should be set to run 15 to 20 minutes every
2 hours when the temperature is above 32 degF. At temperatures below 32
degF (0 degC), the pump should run frequently enough that water does not
freeze in the pipe.
6.3.1
Absorber
The absorber scrubs vent gas from 36% HCl storage tanks during filling and
when tank vapors thermally expand. It has the following features and functions:
The maximum recommended gas flow rate into the absorber is 150 cfm. The
tower floods at a gas rate of 325 cfm.
The absorber tower is 12 inches in diameter with 9 ft of 1-in polypropylene
pall ring packing.
The absorbing liquid is recirculated from the absorber integral storage sump
to create an HCl solution that is periodically replaced. The absorbing liquid
recirculation flow is 8 galUS/min.
The absorber will scrub with an efficiency of 99% when the scrubbing liquid
temperature is below 122 degF and the HCl concentration is below 22%.
The scrubbing liquid should be changed out when the HCl concentration
reaches 22%. The absorber efficiency is a function of the opening
temperature and the HCl concentration in the absorber sump. Efficiency
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6.4
Water Storage
The water storage tank should be a 10,000-galUS tank and may be constructed
of HDXLPE or steel. It can be located any place near the acid tanks except in the
revetment. A float valve keeps the tank filled. A 6-in air break between the fill line
and the maximum water level is required.
Note
The water for the eye washes and yard hydrants must not be taken from the
water tank used to supply the acid plant.
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A process water pump is used to provide water to the mix/transfer system and
the acid fume scrubber.
6.5
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6.6
6-30
A 30-galUS/min air diaphragm pump, such as the Wilden Pump (refer to Section
6.9.2.2), is used to transfer the additives. A batch-controller flow meter is used
for measuring and controlling the liquid additive feed. The liquid additives can be
pumped into the mix tank or fed directly to a transport. The tote tanks can also
be filled by the liquid additive feed pump.
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6.7
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6.8
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Note
These valves need to be checked regularly for corrosion and swelling or
deterioration of the rubber seats.
More expensive Kynar discs, Hypalon seats, and other parts are available for
use in corrosive fluids.
6.9
Acid Transfer
Acid transfer operations require special equipment.
6.9.1
Pressure Transfer
In some installations, such as the stimulation vessels and some acid storage
plants, low air pressures are used to transfer acid from tank to tank, from tank to
transporter, or from tank to acid blender.
Note
All tanks and equipment used in the transfer of acid using compressed air, such
as tote tanks, acid tanks, and transfer lines, must be designed, built, and tested
as pressure vessels with working safety pressure relief valves (PRVs).
Safety risks are inherently associated with using air pressure to transfer acid.
Well-documented operating and maintenance procedures must be in place
and a HARC should be performed to address the added risks involved using
acids under pressure. Ensure that the SSS-111 and SSS-121 transport vessels
are properly inspected prior to use. Refer to the Well Services STEM-I Forms
(InTouch content ID# 4972546).
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6.9.2
6-33
Transfer Pumps
Several acid-resistant pumps from different suppliers are used to transfer acid.
These pumps must be well maintained to ensure good performance and help
prevent leakage of hazardous materials. The most commonly used pumps are
described in the following sections.
6.9.2.1
Delasco Pump
The skid-mounted, diesel-driven Delasco pump, also known as the SUS-239,
(refer to Figure 6-56 and Figure 6-57) is a peristaltic pump, in which a pressurized
fluid flow is created by the rotation of stainless steel rollers pressing against the
outside of a special flexible tube in a housing called a stator.
The advantages of peristaltic pumps are that the fluid does not come into contact
with any internal parts and seals and valves are not needed as in other pumps.
Peristaltic pumps are also reversible and can be flushed to clean out the tubing
or hose. Self priming is automatic on startup and does not require any special
equipment. A flooded suction is only required for viscous products. Occasional
dry running is possible without damage occurring.
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Always have a spare tube available and lubricate the tube regularly. Do NOT
leave the tube full of acid or other chemicals. In cold weather the fluid will freeze
and you will risk breaking the clutch when you try to restart it.
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6.9.2.2
6-35
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Note
For maintenance, the pump should be well cleaned and emptied after each job,
and the air filter and lubricator should be checked regularly. Spare diaphragms
should be kept in the location and ensure the correct diaphragms are used for
the fluid(s) pumped.
The suction pipe size should be at least as large as the suction inlet. The suction
hose must be noncollapsible, reinforced type because these pumps are capable
of pulling high vacuums. All fittings and connections must be airtight, or a
reduction or loss of pump suction capability will result.
6.9.2.3
Other Pumps
Many other pumps are used to pump acid and other hazardous materials. Some
of the most frequently used ones are described in the following:
Flowserve GRP centrifugal pump. This pump is used on the BIGORANGE
XVIII (BOXVIII) stimulation vessel. It produces approximately 300 galUS/min.
The GRP pumps have mechanical seals that are water flushed and require
very little maintenance.
Ramparts centrifugal pump. The Ramparts centrifugal pump is an
elastomer-lined (Nordel) centrifugal with an 80 Durometer impeller used for
transferring acids (refer to Figure 6-60).
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6.9.3
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6.10
6-39
Before every job, a bucket test should be performed to test the accuracy of
the liquid additive pumps. If you dont know how to do a bucket test, ask your
supervisor.
There are various other liquid additive pumps on some equipment. Some of
these are progressive cavity pumps, some are gear pumps, and others are piston
or plunger pumps. Various piping arrangements are also used, some of which
do not allow the use of a bucket test.
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6.11
6-40
6.11.1
Connections
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6-41
Hoses
2-in hoses: Various hose types are used to transfer acid and acid additives
(refer to Figure 6-64 for an example). Some types used with Delasco and
Wilden pumps are a PVC hose or layered hose with UHMW/PE inside and
EPDM outside, and with wire reinforcement.
Note
Care should be taken to ensure these hoses are not crushed and that they
are well flushed with water and then emptied after each use.
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6-41
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6-42
4-in hoses: Suction and discharge hoses with 4-in Figure 206 unions are
recommended by Schlumberger for use when transferring acids on location
using the standard centrifugal pumps.
Note
Regular checks must be performed on the condition of the hoses and
connections for wear and corrosion. They must be well flushed with water and
stored correctly after use.
Hose covers (Figure 6-65) on the discharge hoses are recommended for acid
treatments. These will prevent acid or other hazardous fluids from being sprayed
all over the location if a hose or connection failure occurs.
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7
7.1
7.2
7.2.1
7.2.2
7.2.3
7-i
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7-1
7-3
7-3
7-5
7-5
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7-1
7-1
Acid is transported to the job site from the Pressure Pumping Services (PPS)
district in the concentrated form or premixed with water and additives added.
This is done in mobile transporters dedicated to hauling acids or in skid-mounted
transport tanks.
The standard equipment used in Schlumberger is described in the following
sections. Filling and discharge procedures are detailed in the equipments
operations manual. Refer to Section 4.5 for safety considerations regarding
transportation.
7.1
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7-2
7-2
Note
The transporters have linings that are NOT designed to store concentrated acids
for long periods of time.
Many transporters are also used that are lined with rubber. Care should be taken
NOT to use them for transporting inhibited acids (the acid inhibitor will degrade
the rubber lining), and solvents such as xylene, U66, and diesel.
Refer to the lining manufacturers recommendations for compatibilities of fluids.
The gravity-flow discharge outlets are located at the bottom rear of the tank.
Discharge line butterfly valves are remote air-operated and the tanks are
equipped with a spring return relief valve. A fill and recirculation manifold
connects at the rear. A vacuum breaker equalizes air pressure during unloading
operations. Manways are located at the top of the tanks for performing
maintenance operations.
Acid transport vehicles MUST have the following:
valves on all openings open vents are not allowed
rollover protection to protect top valves and piping
shear groves on piping protruding outside of the rollover protection
PRV and vacuum breaker on each compartment.
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7-3
7.2
7-3
7.2.1
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7-4
Versions of these acid transport tanks are also made using vertical tanks instead
of horizontal tanks.
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7-5
7.2.2
7-5
7.2.3
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7-6
Figure 7-6: Top Hatch of SSS-111 Acid Tank with Safety Devices.
1. 2-in butterfly valve (Teflon cover with 316 SS disc and Viton sear)
2. GITS pop-off valves (12-psi) and gauge
3. Air regulator and gauge
4. Air input
5. Air vent (1-in ball valve)
6. 3-in Girard GE-IMF44 relief valve (64-psi) and gauge with rupture disc 70-psi)
7. 3-in butterfly valve
8. 3-in discharge line with cap
9. 20-in manway with Viton gasket
10. 8-in hatch
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7-6
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7-7
Use caution when opening the cap because hazardous vapors or mist may
be expelled.
vent lines: Tanks must be equipped with a vent line for the air supply and
to relieve any pressure that may build up inside the tank during storage and
transport.
pressure gauges: A pressure gauge must be included, to monitor air
pressure supplied when unloading the tank and a pressure gauge to monitor
vapor pressure inside the tank.
Before opening the cap, verify that there is no positive pressure indicated
on the relief valve gauge. Any positive pressure reading indicates that the
rupture disc has failed and needs to be replaced. STOP and notify supervisor
before continuing.
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7-8
relief valve: This valve will relieve pressure that builds up inside the tank into
the vent line. The type of valve and its setting will depend on the tank type.
Note
The relief valve must be checked regularly as described in WS QHSE
Standard 04, Guideline 01: Low-Pressure Vessel, Relief Valve, and Gauge
Inspection and Test Procedure (InTouch content ID# 3313678).
rupture disc (also known as a burst disc): This disk is a non-reclosing
pressure relief device, which provides a leak-tight seal. If a vessels internal
pressure rises to a predetermined level, the rupture disc bursts, providing
an instantaneous, unobstructed full relief of pressure. The disc must be
replaced after such a relief.
The settings of the relief valve and burst disc type and rating must be
according to the tank manufacturers recommendations. DO NOT change
them.
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8-i
8.1
8.1.1
8.1.2
8.1.3
8.1.4
8.1.5
8.1.5.1
8.1.5.2
8.1.5.3
8.1.6
8.2
8.3
8.4
8-i
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8-2
8-2
8-4
8-4
8-4
8-5
8-5
8-6
8-6
8-7
8-7
8-9
8-9
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8-1
8-1
Many different kinds of tanks are used to store and transport acids. Proactive
maintenance on the tanks and all related equipment is necessary to prevent
failures and the possible catastrophic consequences of failure, and to increase
their useful lifespan.
This section covers the basic maintenance checks that should be performed.
Many locations will have location-specific maintenance checks that must be
performed. Check with your local Maintenance Department.
Note
Make sure that you review WS QHSE Std 04: Equipment (InTouch content ID#
3313678) and WS QHSE Std 12: Permit to Work (InTouch content ID# 3313688)
before performing any maintenance.
Before starting any work or inspection remember the following:
Wear all required PPE.
Review previous STEM 1 inspection reports.
Be sure that tanks are empty and isolated from any delivery systems, which
could fill or pressurize, the tanks.
Be sure that tank manways or entrances are clear at all times.
Before entering the tank, ensure that all requirements of confined space
entry have been met.
Before performing any hot work inside the tank, confirm that no gases or
flammable fumes are present.
Relieve all pressure from equipment and lines before attempting repairs.
Do not tamper with safely valves.
Repair all leaks as soon as possible.
Be sure that all replacement parts and accessories are clean and suitable for
use at the temperature and pressure of the intended service.
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8-2
8-2
Note
Because hazardous materials are stored and transported in these tanks and
some tanks are defined as pressure vessels, some inspections and certifications
will need to be performed by approved third-party inspectors in compliance with
local regulations (e.g., DOT or IMDG/ADR).
8.1
Tank Maintenance
All acid tanks must be inspected and tested in accordance to WS QHSE Std 04:
Equipment, Guideline 02, InTouch content ID# 3313678, in addition to any client
or local regulatory requirements. The following sections provide a high-level
overview of tank maintenance procedures. Refer to the tanks maintenance
manual for detailed instructions.
Note
All acid storage tanks must be completely drained, neutralized, and have all lines
flushed, including those lines that are not regularly used during operations. This
must be done whenever feasible and when the tanks are back at the base or
when it is safe and acceptable to do so.
8.1.1
External Vessel
The external vessel must regularly be checked/maintained as follows:
Regularly check the cleanliness of the vessel. Wash and clean as required.
Check for obvious signs of damage to the outer jacket, such as dents, pitting,
or rust. Damage, such as this, could indicate that the internal lining of the
tank has been damaged.
For polyethylene tanks, check for cracking, crazing, and brittle appearance.
Check carefully the areas around fittings where different planes of the tanks
join.
Check the condition of the paint on the vessel and pipe work. Clean, repair,
and paint as required.
Check hazardous warning and capacity labels/signs.
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8-3
8-3
Check for rust, pits, and leaks in welds (refer to the example in Figure 8-1).
Check welds on the tanks cradles or tank supports, which could crack
because of fatigue, and check any tie-down bolts to ensure they are tight.
Check the manway hatch and ensure it seals properly. Inspect the lid gasket
for tears, rips, or worn spots.
Check to ensure the dome guard drain hose is not blocked or damaged. This
hose is fitted to a hole in the side of the guard around the dome lid. The hose
runs down the side of the tank to the bottom. Any spills around the dome lid
are confined and fall through this hose.
Ensure that the tank is neither venting excessively nor has a pressure buildup.
Ensure all pipe work is secure on the tank. Ensure drip trays, if present,
are fitted and secure.
Ensure that level indicators, if present, are clean, working, and leak free.
Repair any leaks.
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8-4
8.1.2
8-4
8.1.3
Instrumentation
Instrumentation must be checked before each use.
Check the operation and condition of pressure gauges, if the tank is fitted
with them. Ensure that connections are not leaking and the glass face is
not broken.
Check the operation and condition of gauge manifold valves.
8.1.4
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8-5
8.1.5
8-5
8.1.5.1
Lined Tanks
The majority of lining failures occur because of
storage or transport of incompatible fluids. Check the manufacturers
recommendations.
striking of the lining with metal gauge sticks and dropping hammers.
Perform the following inspections and maintenance on lined tanks.
Check all lap seams and lining for defects caused by physical damage.
Inspect the lining surface for blisters and looseness by sighting down the
surface with an explosion-proof drop light. These defects will be seen as
shadowed areas on the lighted surface. For an example of a blister, refer
to Figure 8-2.
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8-6
8-6
Look for cracks and check for possible contamination to the lining by oil,
extreme hardness or softness, and loss of resilience of the lining.
If failure of the lining is suspected and/or if major repair work has been
carried out on the vessel, conduct the Holiday Spark Test. The procedures to
do this are described in the Well Services QHSE Standard 04 Guideline 02:
Acid Tank Inspection and Test (InTouch content ID# 3313678). These tests
must be performed by trained personnel.
Check for spot patching. Spot patching is inadequate to seal a modified
section of the rubber lining.
Check the lining in vinyl ester-lined tanks. The lining in some vinyl ester-lined
tanks can be repaired using special repair kits from approved suppliers. In
some cases, these repairs must be performed by trained personnel. Check
with your maintenance supervisor when in doubt.
8.1.5.2
Unlined Tanks
Check for rust, pits, and cracks in and near welds.
8.1.5.3
Polyethylene Tanks
It is important that the inside and outside of the tank are clean. Use a bright light
source to inspect the interior of the tank for cleanliness, from the manway cover.
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8-7
8.1.6
8-7
8.2
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8-8
8-8
Check trailer hook-up and condition (Figure 8-4): Check hoses, glad-hand
connections, fifth-wheel connection, and trailer lights.
Check tires: Check the air pressure and condition of the tires of the tractor
and trailer. Are chock blocks available and used when the unit is parked?
Check that all lock nuts are in place and tight.
Ensure that all safety and regulatory paperwork is available.
Ensure that all safety equipment is available and in good condition.
Ensure that correct transport decals, placards, and labels are properly used
and clearly visible.
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8-9
8-9
Note
Any modifications to equipment must be done via an Equipment Modification
Request (EMR) and properly approved.
8.3
8.4
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8-10
8-10
Yes
No
Comments
Signs:
a) Goggles Must be Worn When Handling Chemicals
b) Watch Out For Fork Lift Trucks
c) Proper type of hazard warning poster
d) No Smoking
e) Individual ID signs for stored chemicals with PPE pictograms
mounted by the chemical
f) Exit/No Exit
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8-11
Items
Yes
No
Comments
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8-11
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8-12
Items
Yes
No
Comments
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8-12
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9-i
9
9.1
9.2
9.3
9.4
9.5
9.6
9-i
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9-1
9-3
9-4
9-5
9-5
9-5
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9-1
9-1
Before any acid mixture can be prepared, it is necessary to calculate the correct
volumes of water, concentrated acid, and additives.
The basic mixing procedure for all acid systems is as follows:
1. Put required volume of water in mix tank.
2. Add corrosion inhibitor and inhibitor aid.
3. Mix water and inhibitors thoroughly.
4. Add other acid additives and mix thoroughly.
5. Add concentrated acid and mix thoroughly.
Make sure that you ask local management to explain the proper use of local
loading facilities and mixing procedures. In addition, refer to the appropriate
equipment operations manual(s) for detailed operating procedures.
Note
The Matrix Materials Manual (MMM), InTouch content ID# 4013354, is referenced
throughout this section.
9.1
HCl-Specific Calculations
Concentrated HCl is normally supplied at concentrations of 33 to 36%. This
concentration is then diluted to the desired strength by adding to the proper
amount of water and additives (liquid or solid) to strengths of 5 to 28% HCl.
The formula to calculate the amount of concentrated acid that is needed to make
a required volume of dilute acid is
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9-2
9-2
Note
The specific gravity of different acid strengths can be found in tables in the
Field Data Handbook and Matrix Materials Manual (MMM), InTouch content
ID# 4013354.
Example
To prepare 5,000 galUS of 15% HCl with 5 galUS/1,000 galUS A262 inhibitor
and 1 galUS/1,000 galUS F104 surfactant, with concentrated acid of 34%,
perform the following calculation:
SG 15% HCl = 1.0749
SG 34% HCl = 1.1709
5, 000 15 1.0749
1.1709 34
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9-3
9.2
9-3
Acetic Acid
Acetic acid concentrations can be prepared as shown in Table 9-1 using the
indicated amounts of stabilizing agents L400 or L401.
Remember that you use L400 to make glacial acetic acid solution, or L401 to
make a low freezing point acetic acid solution.
All concentrations of acetic acid from 2 to 12% require the same concentration
of inhibitor for a specific temperature.
Table 9-1: Acetic Acid Preparation
Acetic Acid
Concentration
SG at 68 degF
L400 (galUS)
L401 (galUS)
2%
1.0012
19
26
3%
1.0025
25
39
4%
1.004
38
52
5%
1.0055
48
65
6%
1.0069
58
78
7%
1.0083
67
91
8%
1.0097
77
104
9%
1.0111
87
117
10%
1.0125
97
130
11%
1.0139
106
144
12%
1.0154
116
157
Note
Subtract the corrosion inhibitor volume and the volume of all other additives
from the fresh water volume.
To mix:
1. Add approximately half the water to the mix tank.
2. Add the inhibitor(s).
3. Add the L400 or L401 and mix thoroughly.
4. Add and mix the remaining mix water.
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9-4
9.3
9-4
Mud Acid
Mud acid can be prepared in one of three ways:
blending a 20% solution of HF and HCl
diluting a storage mixture of 25% HCl and 20% HF solution with water
dissolving intensifier Y001 in HCl acid to obtain the desired concentration.
Follow these principles for mixing mud acid:
Work at dock level; stay off tracks.
All chemicals must be pumped through a closed system using a
remote-controlled pump. Do NOT leave the pump unattended while
operating.
Add ingredients to a stationary mixing tank at the loading dock. Ingredients
and additives must be added through fixed piping. You should install an
eductor in the fill line for adding solids.
Mixing must be done by jet circulation (no paddle shafts to leak). Do NOT
air lance. Do NOT perform any mixing in the truck tanks. After mixing by
circulation, transfer the mud acid to the truck tank through one hose.
Acid facilities should be constructed so that all lines can be flushed with
water and emptied by gravity into the truck tanks. Drain all lines and hoses
before unhooking them or knocking unions loose.
Keep all clothing and equipment dry. Be sure nothing is spilled, but water.
Use only clean, fresh water for mix water. Do NOT use sea water to prepare
mud acid.
HF is highly corrosive to the skin. Use extreme care when loading mud acid.
Each location should have specific written instructions about mixing and loading
mud acid, taking into account each locations specific loading dock.
For detailed information about mud acid solution preparation, refer to MMM 3.2
Mud Acid in MMM Section 3: Hydrofluoric Acid, InTouch content ID# 4319815.
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9-5
9.4
9-5
Clay Acid
The various clay acid systems can be prepared using one of three methods:
by mixing concentrated HCl with Y001 (ammonium bifluoride)
by mixing concentrated HCl with HF 20% (H200)
by mixing HCl/HF Acid 25/20 H152 as a component with Y001.
For more information, refer to MMM 3.3 ClayAcid in MMM Section 3:
Hydrofluoric Acid, InTouch content ID# 4319815. Example calculations for mixing
clay acid are also presented in MMM 3.3 ClayAcid.
9.5
Other Acids
Determination of mix components for other acid systems can be found in the
Matrix Materials Manual (MMM), InTouch content ID# 4013354.
9.6
AcidMIX Formulator
Acid mixing calculations can also be performed using the AcidMIX Formulator
via the Schlumberger Web site at e-Engineering Solutions:
http://e-engineering.sugar-land.oilfield.slb.com/
The acid mixing calculations determine the amounts of the various components
necessary to generate the specified volume of the acid listed, including additives.
The majority of Schlumberger acid systems can be calculated. A maximum of
four fluid systems can be formulated at the same time.
The sequence to perform a calculation is as follows (also refer to Figure 9-1
and Figure 9-2):
Describe the acid system (HCl, HCl-HF, SXE, etc.) and enter bottomhole
temperature (BHT), type of tubulars to be used, and whether or not H2S is
present.
Give volume and strength of dilute acid required and the strength of the
concentrated acid to be used.
Specify the type of acid additives in the system.
Specify the additive concentrations.
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Using the example for HCl in Section 9.1, the results shown in Table 9-2 were
generated by AcidMIX Formulator.
Table 9-2: AcidMIX Formulator Calculation Output
System 1: 5,000 galUS HCl 15
Mixing Instructions
Product
HCl
405
2,025
Water
589
2,945
A262
25
F104
Total volume =
5,000 galUS
Acid density
9.0 lbm/galUS
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JET Manual 10 / Operating Requirements and Procedures
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Operating procedures will vary from one district to another, depending on the
equipment used, the acid and additive types, and the location (acid bulk plant or
wellsite).
Acid mixtures can be prepared at the bulk plant and transported to the wellsite,
where they are either transferred to acid storage tanks or remain in the transport
tanks. The acid mixture will then be pumped from the tanks when the job is
performed.
Concentrated acid and the additives may be delivered separately to the job
site, where they are prepared and mixed with water to provide the required acid
mixture.
Note
Make sure that you ask local management to explain the proper use of local
loading facilities and mixing procedures.
All personnel must understand and ensure that the following requirements are
met before any operation is performed:
Correct PPE must be worn. Safety equipment (shower, eye wash, and so on)
must be available and have been function tested before the operation begins.
Review the MSDSs to determine the PPE required.
Fall protection may also be required if working on top of tanks.
Spill control equipment must be available, the location should have a Spill
Response Plan, and personnel must have been trained in treating spills. A
supply of neutralizing agent (e.g., soda ash for HCl) must be available in
sufficient quantities to neutralize the maximum possible spillage. A water
supply must be available near the storage or mixing site to dilute and flush
any neutralized spillage.
All personnel must be up to date in the required Well Services (WS) and Well
Intervention Services (WIS) safety training.
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Note
In addition, all personnel must understand and follow the Schlumberger,
WS, and WIS safety standards. The safety standards can be found on the
InTouch Support Web site (www.InTouchSupport.com).
All personnel must have received operations training and be deemed
competent in the tasks they are required to perform. All trainees will be
assigned mentors.
A risk assessment must be performed and reviewed with all personnel
involved for each operation. Contingencies must be discussed. Personnel
should sign off attendance at this review.
Transferring chemicals should only take place through the use of closed
system transfer pumps. Chemicals must NOT be added with open top
buckets. All transfer pumps and equipment shall be flushed with water after
use.
All personnel involved must be assigned responsibilities for which they are
trained and understand.
STEM 1 maintenance checks must be performed on all equipment and
the equipment must be green tagged to indicate no maintenance or repair
is currently required.
Equipment used to store, transport, and mix acid must be clean and rust-free.
Acid from a supplier generally contains <180 ppm iron. Higher concentrations
of iron and other organic and inorganic compounds that can be picked up from
dirty equipment will have a detrimental effect on the stimulation treatment.
For specific equipment operating and maintenance procedures, visit InTouch
(www.InTouchSupport.com). On InTouch, you can search for a product model,
code, or name to locate important documents and manuals, as well as safety
standards and proven best practices, lessons learned, and solutions.
The following are product information examples available on InTouch:
SSS-111 Maintenance Manual and Parts List, InTouch content ID# 3732497
Stimulation Vessel DeepSTEM 1, InTouch content ID# 4996928
Schlumberger - Health Safety Environment (HSE), InTouch content ID#
3312250
WS Quality Management System - QHSE Standards, InTouch content ID#
4055049
STEM-I Forms, InTouch content ID# 4972546
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11.1
11.2
11.3
11.4
11.5
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Acid spills must be prevented at all costs: clean up and remedial work is very
expensive, the environment is damaged, and Schlumbergers reputation is
harmed.
Even small volumes of spills cause damage and extra work. Refer to Figure 11-1
for an example of an acid spill (in South America) when it flows over the ground.
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11.1
Reporting
Spills must be reported to Schlumberger and may also need to be reported to the
client and local regulatory authorities, depending on their reporting requirements.
The details and contact numbers should be included in the site-specific spill
response plan and/or emergency response plan.
Per SLB QHSE Standard 2 (HSE Event Reporting and Management), InTouch
content ID# 3260257, or the Web site http://www.hub.slb.com/display/index.do?i
d=id16324), all spills must be reported in QUEST. Incident severity is classified
by the volume of spill as follows:
Light < 100 liters
Serious > 100 < 1,000 liters
Major > 1,000 < 10,000 liters
Catastrophic > 10,000 liters.
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MSDSs
The MSDS for each product provides details of actions required if a spill occurs.
Table 11-1 shows details from the MSDS of 15% HCl for the Accidental Release
Measures required.
Table 11-1: Spill Response Measures on MSDS for 15% HCl
Main physical hazards
Corrosive to metals.
Other hazards
Personal precautions
Dam up. Neutralize with lime milk or soda and flush with
plenty of water.
Flush residual with plenty of water.
Environmental precautions
11.4
No information available.
Spill Kits
Each acid storage and mixing facility must have a spill kit. Refer to Section
6.1.6: Spill Kit for more information. All personnel must be trained in the use
of the spill kit.
Note
When materials from the spill kit are used, they must be replaced as soon as
possible.
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Disposal
Disposal of acid waste from spills or from empty and used acid or acid material
containers and drums must also be performed according to proper procedure.
Disposal requirements are detailed in the MSDS sheet. Refer to Table 11-2,
which shows an example of the Disposal Considerations from the MSDS sheet
for 15% HCl.
Table 11-2: Disposal Considerations for 15% HCl from MSDS
Waste from residues
Contaminated packaging
D002
Empty totes and drums should be returned to the location unless they have
become the property of the client. Empty drums should be triple-cleaned
and sent to an approved drum reconditioner if permitted by regulations. If
reconditioning is not an option, empty drums should be sent to an approved
sanitary landfill for disposal.
Note
Check with your location manager or QHSE manager for proper disposal
procedures and regulations at your location.
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The Key Service Quality Requirements (KSQR) list a set of specific requirements
that must be implemented on every job to help prevent Service Quality failures
in Service Delivery. All requirements specified in the KSQR are critical and
compliance is mandatory as per WS QHSE Std 01: Service Delivery, InTouch
content ID# 4348728.
The following figure shows the Matrix Key Service Quality Requirements
(KSQR). These requirements are periodically reviewed and updated. Refer to
InTouch content ID# 4147783 for the latest Matrix KSQR.
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JET Manual 10 / Check Your Understanding
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10. What is the order of mixing if you have to prepare 15,000 gallons of 15%
HCl with 20 galUS/1,000 galUS A262 + 3 galUS/1,000 galUS W54?
a. ___ Add concentrated acid
b. ___ Add inhibitor
c. ___ Add water
d. ___ Add demulsifier
11. Which WS safety standard should you know and follow if you must inspect
the inside of a 12,000-galUS acid tank?
a. WS QHSE Std 5
b. WS QHSE Std 20
c. WS QHSE Std 25
12. What is the capacity of the STF-143 acid transporter?
a. 5,000 galUS
b. 6,000 galUS
c. 8,000 galUS
d. 7,500 galUS
e. none of the above
13. If a vehicle accident occurs and spill from an acid transporter taking 5,000
galUS of acid to a location, which of the following information must the driver
provide?
a. place or location of incident
b. time of incident
c. damage incurred
d. police and fire brigade informed
e. type of spill
f. all of the above
14. If you have to neutralize a small acid spill in your location, what two products
could you use?
a. cement
b. soda ash
c. calcium chloride
d. caustic soda
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15. How often should the revetment of an acid storage plant be hydrotested?
a. every 6 months
b. every 12 months
c. every 24 months
d. not required
16. An acid spill has occurred in your acid bulk plant. You estimate that 200 L of
acid has been lost. How should you report the spill in QUEST?
a. No need to report incident
b. RIR light incident
c. RIR serious incident
d. RIR catastrophic incident
17. What three fluids can you store in a rubber-lined storage tank?
a. 20% HCl
b. water
c. xylene
d. inhibited acid
e. diesel
f. 7.5% HCl
18. What is the standard union for use in low pressure acid transfer and liquid
additive hoses?
a. Camlock mild steel
b. WECO Figure 1502
c. Camlock brass
d. WECO Figure 206
e. all of the above
19. What is the mixing order when preparing 5,000 gallons of mixing HF acid
with Y001 ammonium bifluoride?
a. ___ Add corrosion inhibitor
b. ___ Add 2/3 water volume
c. ___ Add Y001
d. ___ Add 1/3 water volume
e. ___ Add concentrated HCl acid
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20. You have to set up an acid storage plant that will be home to the following
tanks:
1 15,000-galUS acid storage tank
2 6,000-galUS acid storage tank
1 6,000-galUS water storage tank
4 300-galUS chemical tote tank
A concrete slab measuring 12 m x 12 m has been built. How high should the
surrounding wall be?
a. 25 in
b. 12 in
c. 39 in
d. 29 in
e. no wall required
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