JET_Manual_10_v2_0_OnlinePDF_4221679_01.pdf

JET Manual 10 Acid Storage, Handling, Transportation, and Mixing Version 2.0

JET Manual 10 — Acid Storage, Handling, Transportation, and Mixing Reference: Version: Release Date: EDMS UID: Produced: Owner: Author:

InTouch content ID# 4221679 2.0 04-Jun-2013 1656413344 04-Jun-2013 16:13:09 WIS T&D, WS T&D InTouch-CTS, InTouch-OSP, InTouch-Stimulation, PPC-SET

Private

Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.

JET Developm Tr and ansportation, Disposal, 10, JET ent,Manual Acid AcidStorage, 10, EquWS ipment, Acid Tr aining Mixing, Handling & Spills , Acid

WIS T&D, WS T&D\InTouch-CTS, InTouch-OSP, InTouch-Stimulation, PPC-SET\InTouch content ID# 4221679\2.0\Release Date:04-Jun-2013\EDMS UID: 1656413344\Produced: 04-Jun-2013 16:13:09

JET Manual 10 / Legal Information

Legal Information Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved. This work contains the confidential and proprietary trade secrets of Schlumberger and may not be copied or stored in an information retrieval system, transferred, used, distributed, translated or retransmitted in any form or by any means, electronic or mechanical, in whole or in part, without the express written permission of the copyright owner. Trademarks & Service marks Schlumberger, the Schlumberger logotype, and other words or symbols used 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 other design elements may be service marks, trademarks, and/or trade dress 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*.

Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.


JET Manual 10 / Document Control

Document Control Owner:

WIS T&D, WS T&D

Author:

InTouch-CTS, InTouch-OSP, InTouch-Stimulation, PPC-SET

Reviewer:

Steve Davies

Approver:

InTouch-Stimulation

Contact Information Name: LDAP Alias:

WIS T&D, WS T&D WS-PPC-TechCom

Revision History Version Date

Description

Prepared by

2.0

04-Jun-2013 Revised the manual to include the latest acid storage, handling, transportation, and mixing information. Converted the manual from InDesign to XML format in EDMS.

Author: Deepa Jain (WIS T&D), Muhamad Arifin (InTouch-CTS), Jeff Beckel (InTouch-OSP), Steve Davies (InTouch-Stimulation), Dennis Johnson (PPC-SET), Jocelyn Campitelli (PPC-TechCom)

1.0

31-Jan-2007 First version of the manual.

Author: WS Training & Development



JET Manual 10 / Regulatory Compliance

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.



JET Manual 10 / Foreword

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.



vi

JET Manual 10 / Table of Contents

vi

Table of Contents Regulatory Compliance Foreword

__________________________________________

iv

_________________________________________________________

v

1 1.1 1.2

Introduction ____________________________________________________ Learning Objectives __________________________________________ Safety Warning ______________________________________________

1-1 1-2 1-2

2 2.1 2.2 2.3

Acid Properties and Hazards ___________________________________ Definition of an Acid __________________________________________ Applications _________________________________________________ Acid Properties ______________________________________________

2-1 2-1 2-2 2-2

3 3.1 3.2 3.3 3.4 3.5

Use of Acids in the Oilfield _____________________________________ Current Oilfield Acid Applications ______________________________ Historical Background ________________________________________ Acid System Selection _______________________________________ Description of Acids Used in the Oilfield _______________________ Acid Additives _______________________________________________

3-1 3-1 3-2 3-3 3-5 3-8

4 4.1 4.2 4.3 4.4 4.5

Safety Considerations __________________________________________ 4-1 Safety Standards ____________________________________________ 4-1 Responsibilities ______________________________________________ 4-2 Personal Protective Equipment _______________________________ 4-3 Hazard Communication Documents ___________________________ 4-7 Transportation ______________________________________________ 4-14

5 5.1 5.2 5.3 5.4

Acid Supply ____________________________________________________ Acid Supply Packaging _______________________________________ Material Specifications _______________________________________ Procedure to Receive Acid at the District ______________________ Inventory Control ____________________________________________

5-1 5-1 5-3 5-3 5-4

6 6.1 6.2 6.3 6.4 6.5 6.6

Acid Storage ___________________________________________________ Safety Equipment ___________________________________________ Acid Storage Tanks _________________________________________ Fume Scrubber _____________________________________________ Water Storage ______________________________________________ Acid Mix/Transfer Tank ______________________________________ Liquid Additive System ______________________________________

6-1 6-11 6-18 6-24 6-27 6-28 6-30



vii

JET Manual 10 / Table of Contents

6.7 6.8 6.9 6.10 6.11

vii

Dry Additive System ________________________________________ Pipe Work, Valves, and Fittings ______________________________ Acid Transfer _______________________________________________ Liquid Additive Pumps _______________________________________ Transfer Hoses and Connections ____________________________

6-31 6-31 6-32 6-39 6-40

7 7.1 7.2

Acid Transport Equipment _____________________________________ Mobile Acid Transporter ______________________________________ Acid Transport Tanks _________________________________________

7-1 7-1 7-3

8 8.1 8.2 8.3 8.4

Acid Tank and Transport Equipment Maintenance ______________ Tank Maintenance ___________________________________________ Trailer and Tractor ___________________________________________ Additional Testing and Inspection _____________________________ Acid Plant Housekeeping and Maintenance ____________________

8-1 8-2 8-7 8-9 8-9

9 9.1 9.2 9.3 9.4 9.5 9.6

Acid Mixing Procedures and Calculations ______________________ HCl-Specific Calculations _____________________________________ Acetic Acid __________________________________________________ Mud Acid ____________________________________________________ Clay Acid ____________________________________________________ Other Acids __________________________________________________ AcidMIX Formulator __________________________________________

9-1 9-1 9-3 9-4 9-5 9-5 9-5

10

Operating Requirements and Procedures

_____________________

10-1

Acid Spills and Disposal ______________________________________ Reporting ___________________________________________________ Spill Prevention and Control Plan ____________________________ MSDSs _____________________________________________________ Spill Kits ____________________________________________________ Disposal ____________________________________________________

11-1 11-2 11-3 11-4 11-4 11-5

12

Matrix Key Service Quality Requirements

_____________________

12-1

13

Check Your Understanding

____________________________________

13-1

11 11.1 11.2 11.3 11.4 11.5



viii

JET Manual 10 / List of Figures

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

Measuring Specific Gravity with a Hydrometer (Read at the Bottom of the Meniscus)_________________________________________________________ 2-3 pH Scale __________________________________________________________ 2-4 pH Meter__________________________________________________________ 2-5 Pumping Acid in the Old Days ______________________________________ 3-2 Limestone_________________________________________________________ 3-4 Sandstone ________________________________________________________ 3-4 Goggles __________________________________________________________ 4-4 Face Shield _______________________________________________________ 4-4 Protective Suit_____________________________________________________ 4-5 Respirator_________________________________________________________ 4-6 Breathing Mask____________________________________________________ 4-6 US Chemical Label for 15% HCI ___________________________________ 4-10 EU Chemical Label for 33% HCI ___________________________________ 4-11 Canadian Chemical Label for 15% HCI_____________________________ 4-12 Fire Diamond NFPA 704 __________________________________________ 4-13 Transport Placards _______________________________________________ 4-14 ADR TREM Card for 15% HCl _____________________________________ 4-15 Commercial Acid Transporter_______________________________________ 5-1 Acid Railcar in Kazakhstan _________________________________________ 5-1 Acid Tote Tank (IBC) _______________________________________________ 5-2 220-Liter Acid Drums ______________________________________________ 5-2 Acid Storage Tanks at a Schlumberger Location _____________________ 6-1 Fume Scrubber with Electric Water Pump ___________________________ 6-2 Acid and Water Storage Tanks______________________________________ 6-2 Wilden Transfer Pumps and Acid Mix Tank __________________________ 6-2 Acid Mixing Tank with Electric Paddle _______________________________ 6-2 Liquid Additive Storage Tanks and Pumps___________________________ 6-2 Acid Loading Area with Loading Arm/Hose __________________________ 6-2 Acid Storage Tanks and Loading Area ______________________________ 6-3 Control Panel for Acid Plant ________________________________________ 6-3 Liquid Additive Storage Tanks and Fume Scrubbers__________________ 6-3 Liquid Additive Storage Totes, Fume Scrubbers and Loading Arm_____ 6-3 20,000 galUS Acid Storage Tanks with Suction and Filler-Up Lines____ 6-4 Rear of Acid Storage Tanks ________________________________________ 6-4 Acid Valve and Suction on Acid Storage Tanks ______________________ 6-4 Restricted Access to Acid Plant_____________________________________ 6-4 General View of Acid Storage Tanks, Water Supply Tank, and Fume Scrubber (with Lagged Point) ________________________________________________ 6-5 Acid Storage Tanks, Piping, and Walkway (Notice Secondary Containment Wall)______________________________________________________________ 6-5 Eye Wash Station (Notice Lagging for Cold Weather) ________________ 6-5 Acid Plant with Acid Railcar to be Offloaded _________________________ 6-5 Acid Bulk Plant Tank _______________________________________________ 6-6


viii


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

Manifolding Between Acid Tanks____________________________________ 2 x 30,000-galUS Rubber Lined Acid Tanks and Fume Scrubber with Secondary Containment and Warning Signs _________________________ Safety Shower and Equipment at Loading Point _____________________ Acid Transfer Pumps_______________________________________________ Acid Bulk Plant ____________________________________________________ Acid Storage Plant_________________________________________________ Bakersfield, California, Acid Bulk Plant ______________________________ Loading Acid, Villahemosa, Mexico (View 1) _________________________ Loading Acid, Villahemosa, Mexico (View 2) _________________________ Galaxie Stimulation Vessel _________________________________________ BIGORANGE 25 Stimulation Vessel ________________________________ DeepSTIM Stimulation Vessel ______________________________________ DeepSTIM III Stimulation Vessel____________________________________ DeepSTIM Acid Storage __________________________________________ BIGORANGE XVIII (North Sea)____________________________________ BIGORANGE XVIII Liquid Additive Storage and Pumps _____________ BIGORANGE XVIII _______________________________________________ Revetment Area Before the Installation of Acid Tanks _______________ Protective Lining Laid in Acid Tank Area, View 1 ____________________ Protective Lining Laid in Acid Tank Area, View 2 ____________________ Safety Signs on Acid Tank_________________________________________ Safety Shower and Eye Wash Station ______________________________ Typical Mobile Spill Kit ____________________________________________ Spill Kit Contents _________________________________________________ 12,000 galUS HDXLPE Acid Storage Tank _________________________ Schematic of Acid Tank ___________________________________________ 15,000 galUS Rubber-Lined Acid Tank _____________________________ 6,000 galUS Butyl-Lined Acid Tank ________________________________ Acid Fume Scrubber ______________________________________________ Schematic of Acid Fume Scrubber _________________________________ Marsh Pump Used for Fume Scrubber _____________________________ Fume Scrubber Absorption Efficiency ______________________________ Acid Mix Tank ____________________________________________________ Liquid Additive Tank (TuffTank II) __________________________________ Dry Powder Mixer Schematic ______________________________________ Delasco Pump (SUS-239) _________________________________________ Delasco Pump Schematic _________________________________________ Wilden Pump (SUS-271), Example of Chugger Pump _______________ Wilden Pump Schematic __________________________________________ Ramparts Acid Centrifugal Pump __________________________________ March Series-10 Centrifugal Pump_________________________________ Liquid Additive Skid (SUS-533) ____________________________________ 2-in WECO Figure 206 Union______________________________________ Hose for Wilden and Delasco Pumps ______________________________ 4-in Orange Hose Covers on Discharge Lines ______________________ STF-151 Acid Transporter __________________________________________ STF-144 Acid Transporter __________________________________________ Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.

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


x


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

1,000 galUS Acid Transport Tank (SSS-111) ________________________ 2,000 galUS Acid Transport Tank (SSS-121) ________________________ Containerized Acid Transport Tank__________________________________ Top Hatch of SSS-111 Acid Tank with Safety Devices ________________ Crack in Weld on Bottom Suction of a Transport Trailer ______________ Blister in Rubber Lining Wrongly Used to Transport Solvents _________ Check the Tractor _________________________________________________ Prejob Check of Trailer_____________________________________________ AcidMIX Formulator Input Screen 1 _________________________________ AcidMIX Formulator Input Screen 2 _________________________________ Acid Spill_________________________________________________________ Acid Spill from 55-galUS Drums ___________________________________ Acid Spill Exercise in Kazakhstan __________________________________ Matrix Key Service Quality Requirements __________________________


x

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


xi

JET Manual 10 / List of Tables

xi

List of Tables 3-1 4-1 8-1 8-2 8-3 9-1 9-2 11-1 11-2

Properties of Common Acids Used by Schlumberger_________________ Approved PPE for Handling Different Acid Types ____________________ Acid Plant Housekeeping and Maintenance Checklist, Page 1 _______ Acid Plant Housekeeping and Maintenance Checklist, Page 2 _______ Acid Plant Housekeeping and Maintenance Checklist, Page 3 _______ Acetic Acid Preparation ____________________________________________ AcidMIX Formulator Calculation Output _____________________________ Spill Response Measures on MSDS for 15% HCl ___________________ Disposal Considerations for 15% HCl from MSDS __________________


3-5 4-3 8-10 8-11 8-12 9-3 9-7 11-4 11-5


1-i

JET Manual 10 / Introduction

1 1.1 1.2

1-i

Introduction Learning Objectives ____________________________________________ Safety Warning _________________________________________________


1-2 1-2


1-1


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.



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).



2-i

JET Manual 10 / Acid Properties and Hazards

2 2.1 2.2 2.3 2.3.1 2.3.2

2-i

Acid Properties and Hazards Definition of an Acid ___________________________________________ Applications ___________________________________________________ Acid Properties ________________________________________________ Hydrochloric Acid Strength ___________________________________ pH Scale ____________________________________________________


2-1 2-2 2-2 2-2 2-4


2-1


2

2-1

Acid Properties and Hazards JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

This section describes the properties and dangers of acids.

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.



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

Hydrochloric Acid Strength 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. Maximum concentration of commercial grade HCl is about 36% by weight. This is then diluted to lower concentrations (in the 5 to 28% HCl range) by the addition of water.



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.

Figure 2-1: Measuring Specific Gravity with a Hydrometer (Read at the Bottom of the Meniscus)



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.

Figure 2-2: pH Scale

Water is a neutral liquid with a pH of 7 (green). Acidic solutions have a pH of less than 7, and the lower the number, the stronger the acid. The opposite of an acid is a base. Base or alkaline solutions have a pH of over 7. The higher the pH, the stronger the alkali. Testing the pH helps to quickly identify fluids and to check if an acid has been neutralized. The pH of a fluid can be measured using • red litmus paper: the paper turns red when touched by an acid. • chemical indicators: color changes in chemicals, such as cobalt chloride, Congo red, methyl orange, phenolphthalein, and turmeric, are used to measure different ranges of pH.



2-5


• electronic pH meter (Figure 2-3): a probe containing an acidic aqueous solution encased in a special glass membrane allows the migration of hydrogen ions (H+). If the water has a pH different from that of the solution within the probe, an electric potential results that registers on the meter.

Figure 2-3: pH Meter


2-5


3-i

JET Manual 10 / Use of Acids in the Oilfield

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

Use of Acids in the Oilfield Current Oilfield Acid Applications ______________________________ Historical Background _________________________________________ Acid System Selection _________________________________________ Description of Acids Used in the Oilfield _______________________ Hydrochloric Acid ____________________________________________ Hydrofluoric Acid _____________________________________________ Mud Acid ____________________________________________________ Clay Acid ____________________________________________________ Acetic Acid __________________________________________________ Formic Acid _________________________________________________ Other Acid Systems __________________________________________ Acid Additives _________________________________________________ Inhibitors and Inhibitor Aids ___________________________________ Surfactants __________________________________________________ Foaming Agents ____________________________________________ Mutual Solvents _____________________________________________ Antisludge Agents ___________________________________________ Nonemulsifying Agents ______________________________________ Iron-Control Agents _________________________________________ Specialty Additives __________________________________________


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


3-1


3

3-1

Use of Acids in the Oilfield JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

The choice of different acids used in the oil industry is based on • their reactivity with different reservoir rocks and damage type • by-products formed when they react • properties of the reservoir, reservoir fluids, and well tubulars.

3.1

Current Oilfield Acid Applications Acids are used in the oilfield to • stimulate wells to improve well production – wellbore cleanup: The wellbore is filled, washed, and allowed to soak with acid to remove inorganic and organic deposits from the tubulars and the formation face. – acid fracturing: Acid is injected into low-permeability carbonate formations at pressures greater than the formation fracturing pressure. – matrix acidizing: Acid is injected radially into the matrix structure of the formation below the fracturing pressure. The acid reacts with rock and plugging materials, removing damage and restoring permeability to the near-wellbore reservoir rock. • remove scale and buildup of compounds on the inner walls of pipes used in oil and gas wells • clean perforations before fracturing treatments • provide reactive environment during perforation operations to enhance perforation clean up • help free stuck pipe • provide miscellaneous other uses.



3-2


3.2

3-2

Historical Background The use of acids in oil wells began over 100 years ago (Figure 3-1).

Figure 3-1: Pumping Acid in the Old Days

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.



3-3


3-3

February 1932: The first use of an inhibited acid on a limestone formation was by Dow Chemical Company, which siphoned 500 galUS of HCl containing 2 galUS of an arsenic inhibitor through a garden hose into a well owned by the Pure Oil Company. The acid was then displaced with an oil flush and the previously dead well began producing 16 bbl/d. November 1932: Dow Well Service Group was renamed Dowell in November 1932 to provide acidizing services. 1933: A patent for the use of hydrofluoric acid (HF) in sandstone formations was issued to J. R. Wilson of the Standard Oil Company. Wilson’s patent suggested in-situ generation of HF in HCl by using sodium fluoride (NaF). It was not known that NaF, in the presence of HCl, produces the insoluble compound Na3SiF6. 1933: Halliburton Services performed the first treatment using HF blended with HCl in a 1,500-ft well. The results were disappointing due to possible plugging effect on the well permeability, and as a result, Halliburton discontinued the use of HF blends until the 1950s. 1935: Halliburton Oil Well Cementing Co. started providing a commercial acidizing service in Kansas. 1940: Schlumberger accomplished the first commercially successful use of mixtures of HCl and HF in the Gulf Coast area by using mud acid. The HF was generated in a solution of HCl by using ammonium bifluoride (NH4HF2). Mud acid dissolved the drilling mud deposited as a filter cake during the drilling process. 1949: Halliburton performed the first hydraulic fracturing treatment. The first treatments were probably performed with acid, although they were not recognized as such at the time. Wells in tight carbonate formations usually will not accept acid until a critical pressure is reached. Once this pressure is reached, acid can easily be injected at high rates. It was later recognized that these wells had been hydraulically fractured.

3.3

Acid System Selection The two main acid systems used in the oil industry are designed to treat either carbonate (limestone, dolomite, and oolite) or sandstone (silica, quartz, feldspar, clay) reservoirs. For the two formation types, the following acids used are • Carbonates (e.g., limestone; refer to Figure 3-2): HCl is the most common acid used in carbonate acidizing because of its low cost, availability, and soluble reaction products. Organic acids, such as acetic and formic acids, are Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.


3-4


3-4

used for high-temperature applications, because of their low corrosiveness, ease of inhibition, and retarded reaction characteristics. Blends of HCl with either formic or acetic acids are also used because of cost efficiency and the reduced corrosivity provided by the organic acids.

Figure 3-2: Limestone

• Sandstones: Sandstone formations (refer to Figure 3-3 for an example) are typically treated with a mixture of hydrochloric acid (HCl) and HF, commonly called mud acid. The acid and other fluids used in sandstone formations depend on the mineralogy of the rock as well as on the damage type. Other acids used in sandstone formations include lower concentrations of HCl and HF with fluoboric acid (HBF4) added. These mixtures are called clay acids and are designed specifically for acidizing sensitive sandstone formations and providing stabilization of clays and other fines.

Figure 3-3: Sandstone



3-5


3.4

3-5

Description of Acids Used in the Oilfield Table 3-1 lists the properties of common acids used by Schlumberger in the oilfield. Table 3-1: Properties of Common Acids Used by Schlumberger Chemical Product Name Code

Form

SG at 60 degF

Flash Point (degF)

pH

H005

Hydrochloric acid (HCl) 5%

Colorless liquid

1.025

> 200

≍0

H075

Hydrochloric acid 7.5%

Liquid

1.037

> 200

≍0

H010

Hydrochloric acid 10%

Liquid

1.050

> 200

≍0

H015


Colorless-light yellow liquid

1.075

> 200

≍0

H020


Liquid

1.100

> 200

≍0

H028



1.140

> 200

≍0

H036



1.18

> 200

≍0

H152

HCl/HF acid 25/20

Colorless to yellow liquid

1.20

> 200

≍0

H200

Hydrofluoric (HF) acid 20%

Colorless liquid

1.20

> 200

4.1 at 20% (wt)

H700

Hydrofluoric acid 70%

Used by Schlumberger vendor to prepare 20% HF in our storage tanks

Y001

Intensifier Y1 ammonium bifluoride

White crystals

H948

Dilute mud acid

Colorless liquid

1.50

> 200

2 at 0.5% (wt)

> 200

≍0

Any solution with up to 7.5% HCl and 1.5% HF H949

Regular mud acid

Colorless liquid

1.10

> 200

≍0

Colorless liquid

1.10

> 200

≍0

Any solution with 7.6% to 12% HCl and 1.6 to 3.0% HF H950

Super mud acid Any solution with 12.1% to 16% HCl and 3.1% to 6% HF



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3-6

Chemical Product Name Code

Form

SG at 60 degF

Flash Point (degF)

pH

Y006

White granular powder

1.40

> 200

5.1 at

Intensifier Y6

1% (wt) H813

Full strength clay acid

Colorless liquid

1.1

> 200

≍1

Colorless liquid

1.1

> 200

≍0

Colorless liquid

1.1

> 200

<2

Colorless liquid

1.1

> 200

≍ 0.1

7.8% HBF4 + 0.6% HF + 0.3% HCl H814

Full strength clay acid LT 7.8% HBF4 + 0.6% HF + 5.5% HCl

H913

Half-strength clay acid 4.1% HBF4 + 0.3% HF + 0.15% HCl

H914

Half-strength clay acid 4.0% HBF4 + 0.3% HF + 2.9% HCl

L400

Glacial acetic acid (100% acetic acid)

Colorless liquid

1.05

109

1.0 at 70% (wt)

L401

Acetic acid solution

Colorless liquid

1.00 to 1.05

90

1.0

L036

Formic acid

Colorless liquid

1.20

64 degC (147 degF)

2.2

Additives, such as inhibitor, iron stabilizers, surfactants, demulsifying agents, and mutual solvents can be added as required depending on the fluid design for the particular job.

Concentrated HF is dangerous to handle. Schlumberger employees are NOT permitted to handle HF concentrations greater than 20% by weight. Higher concentrations must be transported and mixed by vendors.



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]



3-8


3-8

• half-strength clay acid • half-strength clay acid LT.

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

Other Acid Systems There are many other acid systems that are mixtures of the acids discussed in the previous sections with alcohols, oils, gelling agents, and surfactants. Other acids, such as citric acid, are used in some industrial cleaning applications. For details, refer to the Matrix Materials Manual (MMM), InTouch content ID# 4013354.

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 Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.


3-9


3-9

• a surfactant to reduce surface tension, suspend fines, or create foam • a mutual solvent • an iron ion stabilizer • an acid diverter.

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 An acid corrosion inhibitor is added to acid to decrease the destructive reaction of acid with metals. The inhibitor eliminates more than 99% of the metal losses that would occur if the inhibitor were not present. Inhibitor type and concentration depends on the acid system and the temperature. Inhibitor aids are used to extend the performance range of acid inhibitors. Corrosion testing is performed to determine the concentrations of inhibitor and inhibitor aid required to give the desired protection time. Inhibitor examples include A261, A262, A270, and A272. The most common inhibitor aid is A201.

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



3-10


3-10

• reduce surface or interfacial tension and capillary force • control or change rock wettability • prevent or break water blocks and emulsions • disperse and suspend fines. Common surfactants include F78, F103, and F105.

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.



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.



4-i

JET Manual 10 / Safety Considerations

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


4-i


4-1


4

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.



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.



4-3


4.3

4-3

Personal Protective Equipment Personal Protective Equipment (PPE) must be worn while working as mandated in Schlumberger QHSE Standard S003 (Personal Protective Equipment), InTouch content ID# 3260259. When handling acids and acid additives, any additional PPE required is listed in the MSDS for each product (visit http://slb-chemicals.slb.com/Msds.cfm). Refer to Table 4-1 for a list of the approved PPE for each type of acid. Table 4-1: Approved PPE for Handling Different Acid Types Hand Protection Gloves (Impervious)

acids (HCl)

Respirator

Protection

Acid

Hydrochloric

Eye & Face

Butyl

Neoprene

Nitrile

X

X

X

Hydrofluoric

X

acids (HF)

X

PVC

Protection

Viton X

X

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).

X

(L400, L401) Formic acid

X

(L036) Mud acids (HCl + HF)

X

X

X

X

X

X

Clay acids (HBF4 + HF + HCl) Y001 intensifier

X

NIOSH-approved respirator with

Y006 intensifier

dust and mist X

Skin & Body

protection (3M 8210).



4-4


4.3.1

4-4

Eye and Face Protection Wear close-fitting chemical splash goggles (indirect-vented chemical goggles) at a minimum. Where splash hazard to face is present, also wear a full-length transparent face shield (refer to Figure 4-1 and Figure 4-2). Protection should meet ANSI standard Z87.1 - 1989 or European Standard 166. Note Do NOT wear contact lenses; they could contribute to severe eye damage.

Figure 4-1: Goggles

Figure 4-2: Face Shield



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

Skin and Body Protection You must wear a chemical-resistant apron and chemical-resistant boots, such as neoprene or polyvinyl chloride (PVC) (refer to Figure 4-3). Ensure that all potentially affected body parts are covered, using such precautions as taping sleeves and pant legs to gloves and boots and buttoning clothing to the neck.

Figure 4-3: Protective Suit

Note A safety shower and eyewash station should be located in the immediate work area.



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).

Figure 4-4: Respirator

Figure 4-5: Breathing Mask



4-7


4.3.5

4-7

Treating HF Acid Exposure Hydrofluoric acid (HF) will cause excruciatingly painful, deep-seated skin burns that are slow to heal. The effects of dilute solutions (<20%) do not usually become apparent until several hours after exposure. If skin comes in contact with HF, rinse thoroughly with water and massage calcium gluconate gel or benzalkonium chloride solution into the burn site. This gel is not PPE, but it is a special requirement when handling or mixing HF. Apply the gel every 15 minutes and massage until pain/redness resolves or until medical care is available. The first aid provider should wear gloves when applying the gel to prevent contact with the acid.

4.4

Hazard Communication Documents Several documents identify the hazardous nature of acids and acid additives. The documents state the nature of the materials, PPE and safety precautions and requirements, potential hazards, and what to do in the case of an incident. The documents are • Material Safety Data Sheets (MSDSs) • product labels • shipping pages • EU – ADR TREM Cards • US – Shipping Papers • Canada – Shipping Manifests. These documents are available at the following Web site, which is also a useful source of information: http://slb-chemicals.slb.com/Msds.cfm.



4-8


4.4.1

4-8

Material Safety Data Sheets The Material Safety Data Sheet (MSDS), InTouch content ID# 5277326, is the reference document for all material hazard, safety, and handling information for each acid or acid additive. A complete list of MSDSs can be found at http://slb-chemicals.slb.om/Msds.cfm. The following requirements include all Well Services (WS) and Well Intervention Services (WIS) chemicals, purchased products, and purchased maintenance materials, which are hazardous items: • The identity of the material on the container label must be the same as that on the MSDS. This identity enables the correct MSDS to be found using the material name or code. • For locally purchased products, a copy of the vendor MSDS must be kept on file. • The local manager is responsible for making sure that a current MSDS is on file for any material or product from other companies. • Current MSDSs must be available to any person in the workplace who works with or has exposure to hazardous materials. • MSDSs must be in the work areas where they are easy to find. • MSDSs must be supplied for any materials purchased from WS or WIS and to customers upon request.

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%).



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

Dangerous Goods Warning All containers for materials must be marked with a warning that defines the possible hazards of the product. The design of this label can change in different locations, but it is normally included with the product label. • HMIS (Hazardous Materials Identification System) Label (Figure 4-6): All products from the US must have the HMIS label, which contains three boxes: – health hazard – flammability hazard – reactivity hazard. Each of the boxes contains a number from 0 to 4 indicating the hazard level: 0 = no risk; 4 = high risk. • EU Label (Figure 4-7): Products from Europe must have the EU label, which shows a series of symbols to define physical, health, and environmental hazards. These symbols do NOT indicate the potential hazards. • Canadian WHMIS Label (Figure 4-8): Products from Canada must have the Canadian WHMIS label, which has symbols that define physical, health, and environmental hazards.



4-10 JET Manual 10 / Safety Considerations

Figure 4-6: US Chemical Label for 15% HCI

Private


4-10



Figure 4-7: EU Chemical Label for 33% HCI

Private


4-11



Figure 4-8: Canadian Chemical Label for 15% HCI

Private


4-12


4-13


4-13

NFPA 704 is a standard maintained by the U.S. National Fire Protection Association. It defines the fire diamond used by emergency personnel to quickly and easily identify the risks posed by hazardous materials. This helps determine if any specialty equipment should be used, procedures followed, or precautions taken during the first moments of an emergency response. For example, Figure 4-9 shows the fire diamond for hydrochloric acid; each color represents a hazard type and each number rates the hazard. The higher the number, the greater the hazard. COR means it is corrosive.

Figure 4-9: Fire Diamond NFPA 704



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

Hazardous Materials Transportation Placards Transportation regulations in the majority of countries require hazardous materials (HAZMAT) placards when shipping hazardous materials or dangerous goods. Acids are classified as Class 8: corrosive fluids, so they will likely have a HAZMAT placard, depending on the country. These placards should be placed in the placard holders on acid transport trailers and tanks (refer to Figure 4-10). Ensure compliance with all applicable and country-specific placarding requirements.

Figure 4-10: Transport Placards

4.5.2

EU TREM Cards In Europe, the ADR (L’accord européen 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.




Figure 4-11: ADR TREM Card for 15% HCl

Private


4-15


5-i

JET Manual 10 / Acid Supply

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 ______________________________________________


5-1 5-3 5-3 5-4


5-1


5

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

Acid Supply Packaging Acid is purchased and supplied in four ways (in descending order of volumes): • bulk acid in road transporters: conventional acid transporters (Figure 5-1) provided by the acid supplier or Schlumberger. Various capacities are used depending on availability. The transporters are usually rubber lined.

Figure 5-1: Commercial Acid Transporter

• 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.

Figure 5-2: Acid Railcar in Kazakhstan



5-2


5-2

• intermediate bulk containers (IBCs): IBCs are 1000-liter or 250-galUS tote tanks (Figure 5-3) made of a steel-tube cage with an inner container made out of high-density polyethylene. When containing fluids of SG = 1.30, they can be stacked in threes. IBCs have a fill port equipped with a 2-in sealed screw cap, and discharge through a 2-in butterfly valve at the bottom. The dimensions are: 1.2 m x 1.0 m x 1.16 m with a tare weight of 59 kg. Note In the US, IBC containers and drums must be removed from the transport vehicle and set on the ground prior to unloading contents unless there is proper exemption from the regulations.

Figure 5-3: Acid Tote Tank (IBC)

• 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.

Figure 5-4: 220-Liter Acid Drums Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.


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

Procedure to Receive Acid at the District Acid is delivered to the Schlumberger facility and typically is transferred to bulk acid storage tanks. If the district does not have bulk acid storage, the acid is stored in a chemical warehouse, and then either mixed at the district and sent to the job site in acid transport tanks or the concentrated acid is sent in its containers to the job site to be mixed on location. Bulk plant personnel should follow these guidelines: 1. Ensure that all necessary PPE is available and worn by personnel. Spill equipment should be available. The eye wash station and emergency shower must be functional. Current MSDSs must be available for all materials received. 2. Make sure that all bulk materials from other companies delivered to Well Services (WS) or Well Intervention Services (WIS) facilities must be controlled by a WS or WIS employee authorized to operate that bulk facility. Loading and unloading areas must be clearly marked.



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.



6-i

JET Manual 10 / Acid Storage

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 ______________________________________________________


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


6-1


6

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.

Figure 6-1: Acid Storage Tanks at a Schlumberger Location

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.



6-2


6-2

Figure 6-2 through Figure 6-7 show the Hassi-Messaoud, Algeria, facility.

Figure 6-2: Fume Scrubber with Electric Water Pump

Figure 6-3: Acid and Water Storage Tanks

Figure 6-4: Wilden Transfer Pumps and Acid Mix Tank

Figure 6-5: Acid Mixing Tank with Electric Paddle

Figure 6-6: Liquid Additive Storage Tanks and Pumps

Figure 6-7: Acid Loading Area with Loading Arm/Hose



6-3


6-3

Figure 6-8 through Figure 6-11 show the Midland, Texas, USA, facility.

Figure 6-8: Acid Storage Tanks and Loading Area

Figure 6-9: Control Panel for Acid Plant

Figure 6-10: Liquid Additive Storage Tanks and Fume Scrubbers

Figure 6-11: Liquid Additive Storage Totes, Fume Scrubbers and Loading Arm



6-4


6-4

Figure 6-12 through show the Jebel Ali, UAE, facility. Figure 6-12 shows the secondary containment and warning signs on rubber-lined tanks.

Figure 6-12: 20,000 galUS Acid Storage Tanks with Suction and Filler-Up Lines

Figure 6-13: Rear of Acid Storage Tanks

Figure 6-14: Acid Valve and Suction on Acid Storage Tanks

Figure 6-15: Restricted Access to Acid Plant



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6-5

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)

Figure 6-18: Eye Wash Station (Notice Lagging for Cold Weather)

Figure 6-19: Acid Plant with Acid Railcar to be Offloaded



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6-6

Figure 6-20 through Figure 6-24 show the Montrose, Scotland facility.

Figure 6-20: Acid Bulk Plant Tank

Figure 6-21: Manifolding Between Acid Tanks

Figure 6-22: 2 x 30,000-galUS Rubber Lined Acid Tanks and Fume Scrubber with Secondary Containment and Warning Signs

Figure 6-23: Safety Shower and Equipment at Loading Point

Figure 6-24: Acid Transfer Pumps



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6-7

Figure 6-25 shows the plant at Aracaju, Mexico. Figure 6-26 through Figure 6-29 show a few more plants.

Figure 6-25: Acid Bulk Plant

Figure 6-26: Acid Storage Plant

Figure 6-27: Bakersfield, California, Acid Bulk Plant

Figure 6-28: Loading Acid, Villahemosa, Mexico (View 1)

Figure 6-29: Loading Acid, Villahemosa, Mexico (View 2)



6-8


Figure 6-30 shows the Galaxie stimulation vessel in West Africa with 28,400 galUS raw acid storage capacity.

Figure 6-30: Galaxie Stimulation Vessel

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.

Figure 6-31: BIGORANGE 25 Stimulation Vessel


6-8


6-9


Figure 6-32 through Figure 6-37 show various DeepSTIM* vessels.

Figure 6-32: DeepSTIM Stimulation Vessel

Figure 6-33: DeepSTIM III Stimulation Vessel


6-9


6-10


6-10

As shown in Figure 6-34, the DeepSTIM has an 8,400-galUS raw acid storage capacity on the back deck.

Figure 6-34: DeepSTIM Acid Storage

Figure 6-35: BIGORANGE XVIII (North Sea)

Figure 6-36: BIGORANGE XVIII Liquid Additive Storage and Pumps



6-11


Figure 6-37: BIGORANGE XVIII

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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6-12


6.1.1

6-12

Acid Bulk Plant Area Note All chemicals, except for bulk dry chemicals, must be stored on concrete pads that provide secondary containment (refer to Figure 6-38).

Figure 6-38: Revetment Area Before the Installation of Acid Tanks

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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6-13

Each location must have a current Spill Prevention, Control, and Countermeasures (SPCC) plan. This plan must be updated as described in SLB QHSE Standard S008 (Environment), InTouch content ID# 3605373.

6.1.2

Lining for Acid Storage Area Acid storage areas must have an acid-resistant lining. Numerous suitable coatings and linings are available. Refer to Figure 6-39 and Figure 6-40 for examples of linings.

Figure 6-39: Protective Lining Laid in Acid Tank Area, View 1

Figure 6-40: Protective Lining Laid in Acid Tank Area, View 2

Note Follow all coating manufacturer’s 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.



6-14


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.

Figure 6-41: Safety Signs on Acid Tank. 1. Product content 2. Hazard warning labels 3. Material label 4. Hazard warning



6-15


6.1.5

6-15

Safety Shower and Eye Wash Stations Eye wash and safety shower stations must be installed according to WS QHSE Std 04: Equipment, InTouch content ID# 3313678. An eye wash station and a safety shower must be on the loading dock area and in the area where additives are mixed (Figure 6-42).

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.

Figure 6-42: Safety Shower and Eye Wash Station. 1. Emergency shower 2. Eye wash station



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6-16

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.

Figure 6-43: Typical Mobile Spill Kit

Figure 6-44: Spill Kit Contents



6-18


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.

Do NOT block access to the fire extinguisher.

6.2

Acid Storage Tanks Acid storage tanks are normally either steel tanks with an acid-resistant lining or polyethylene tanks. The capacity of tanks can vary from 5,000 to 20,000 galUS. • For stationary storage tanks in an acid plant, tanks made of high-density cross-linked polyethylene (HDXLPE) are recommended. Alternatively, tanks made of carbon steel with bonded crosslinked polyethylene inner liner can be used. However, the size of the tank is limited because the size of the curing ovens available to make these tanks is limited. Fiberglass is also used for acid storage tanks and for smaller acid transport tanks. • For mobile acid transports, tanks made of carbon steel with bonded crosslinked polyethylene inner liner are preferred, but again the size is limited.



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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.

Figure 6-45: 12,000 galUS HDXLPE Acid Storage Tank



6-20


Figure 6-46: Schematic of Acid Tank. 1. 12,000 galUS acid storage tank 2. Level gauge 3. Fill line 4. Tank level controls 5. Safety relief valve 6. Vent line to the fume scrubber 7. To the mix/transfer line

6.2.2

Steel Tanks with Lining Steel storage tanks must be lined with a material that is resistant to acid. Rubber-lined (Figure 6-47) or butyl-lined (Figure 6-48) tanks have been used with normal capacities ranging from 6,000 to 15,000 galUS.


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6-21


Figure 6-47: 15,000 galUS Rubber-Lined Acid Tank

Figure 6-48: 6,000 galUS Butyl-Lined Acid Tank

Note Make sure that you check the manufacturer’s 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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6-22


6.2.3

6-22

Tank Linings and Coatings The type of material and the type of lining used for acid storage and transportation tanks are dependent on the application, product availability, and cost. Some of the types of material and lining used are: Note Mark all tanks to show the coating and lining used and the fluid compatibility. • rubber: can only be used for straight acid, noninhibited acid, and zero additives. It should NOT be used to store solvents, such as xylene or toluene. Any tank with a rubber lining must have a sign marked, Rubber-Lined Tank—Do not cut or weld. Note NEVER pull a vacuum on an HCl tank car. It could damage the rubber liner. • tank-in-a-tank: used for many International Maritime Organization (IMO) offshore tanks. A polyethylene lining is installed inside a steel tank and the annulus filled with foam. This design is intolerant to both vacuum and high pressures, limits the number of openings in the tank, prohibits baffles, is costly for large tankers, and is difficult to repair. Avoid strong xylene in these tanks. • vinyl ester lining: primarily used for transport tanks. This type should not be used to store concentrated acids for extended time periods (more than 2 to 3 days). Recent additive mixtures plus the lack of tank flushing have caused the life of the vinyl ester lining to decrease in recent years. • plural component lining: new liners that mix two components at the spray gun tip have provided improved performance compared to the older vinyl ester linings. These linings have been installed in tanks or transports that are too large to have the bonded linings used since about year 2000. These liners resist both HCl and HF acids and Xylene mixtures. Typical uses are acid frac tanks larger than 4200 gallons, relining of older transports that were originally built with vinyl ester lining, and the coating of metallic acid blender tanks and piping. Approved plural component liners are – Tnemec Series 390 – Catagra Frac Shield.



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6-23

• 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

Pipe Work and Valves The recommended pipe work for use with hydrochloric acid is made from fiberglass-reinforced plastic (FRP). The valves are fiberglass composite valves. For stationary acid tanks, all piping and valves must be independently supported. The pipe work should not be rigid; some flexibility is required to counter expansion or contraction effects. Weather-exposed water lines must be heat traced and insulated where hard freezes are possible.



6-24


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.

Figure 6-49: Acid Fume Scrubber



6-25


Figure 6-50: Schematic of Acid Fume Scrubber. 1. Gas outlet 2. Spray head 3. 12-in OD Absorber tower filled with polypropylene saddles 4. Spray inlet 5. Overflow (1 in) 6. Spray glass 7. Gravity drain (1 in) 8. Polyethylene base 9. Gas inlet from HCl tanks (4 in) 10. Water fill inlet (2 in) 11. Water outlet (1 in) 12. To the mix or holding tank 13. Fume scrubber circulation C-pump on mounting plate Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.

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6-26


6-26

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.

Figure 6-51: Marsh Pump Used for Fume Scrubber

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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6-27

decreases with an increase in temperature and with an increase in HCl concentration. A graph showing the removal efficiency versus HCl concentration in the sump is shown in Figure 6-52. Note A log of absorbing liquid HCl concentration and change-out frequency should be kept to assure that the absorber scrubbing efficiency is maintained.

Figure 6-52: Fume Scrubber Absorption Efficiency

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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6-28

A process water pump is used to provide water to the mix/transfer system and the acid fume scrubber.

6.5

Acid Mix/Transfer Tank The acid mix/transfer tank is a 6,800-galUS, cone-bottom, HDPE tank (Figure 6-53). The inlet piping enters the top and extends downward to half the height of the tank. A single 200-gpm centrifugal pump is used to transfer water and acid to the mix tank, mix the contents of the tank, pump water through the dry additive feed process, and pump the finished product to the transport truck. The various functions of the pump can be controlled and metered using a batch flowmeter. In addition, there are several portable stainless steel dual mix tanks that are used for blending acid. These tanks are approved to blend acid wihen the insides of the tank and piping are lined. Blending acids in unlined stainless steel tanks is NOT approved.



6-29


Figure 6-53: Acid Mix Tank. 1. Manway with blind 2. Outlet 3. Inlet dip tube 4. Spare with blind 5. Vent 6. Relief 7. Rinse water 8. Level switch 9. Inlet dip pipe 10. Support cradle


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6-30


6.6

6-30

Liquid Additive System The liquid additive storage and feed system consists of up to 10 polyethylene tote tanks of 330-galUS capacity each. The required number will vary depending on the district’s needs. Hoover Materials Handling Group’s TuffTank II IBC tanks are recommended (Figure 6-54). These combine a rotationally molded high-density polyethylene bottle and heavy-duty wire mesh cage with a 2-in valve on the suction. They are available in 220- and 330-galUS capacities.

Figure 6-54: Liquid Additive Tank (TuffTank II)

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

6-31

Dry Additive System In some locations it will be necessary to mix dry powder additives with the acid. A schematic of a typical dry additive mixer is shown in Figure 6-55.

Figure 6-55: Dry Powder Mixer Schematic. 1. 45 min 2. Liquid inlet 3. Dry additive hopper 4. Manual feed control valve 5. Mixed product outlet

6.8

Pipe Work, Valves, and Fittings Pipe work, valves, and fittings must be acid resistant; therefore, they are normally fabricated from PVC. A wide range of fittings and valves are available. Some of the older acid plants may have rubber-lined steel piping and valves. The standard FMC butterfly valves are used in acidizing operations downstream of the acid transport or acid storage tanks. Transport and storage tanks must use acid resistant valves.



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6-32

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.

Figure 6-56: Delasco Pump (SUS-239)



6-34


6-34

Figure 6-57: Delasco Pump Schematic. 1. Pump hose: EPDM injection moulded tube with spine 2. Stator 3. Rotor 4. Connecting sleeve 5. Rollers (stainless steel) 6. Counter

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

Air-Over-Fluid “Chugger” Pump The Air-Over-Fluid “Chugger” pump is used widely to pump acids, acid additives, and other fluids used in Schlumberger (refer to Figure 6-58 and Figure 6-59).

Figure 6-58: Wilden Pump (SUS-271), Example of Chugger Pump



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6-36

Figure 6-59: Wilden Pump Schematic. 1. Diaphragms 2. Common shaft 3. Inlet 4. Discharge check valves 5. Pump chambers 6. Air distribution system 7. Air inlet 8. Suction inlet 9. Discharge

The Wilden pump is a positive displacement, reciprocating, air-operated, double-diaphragm pump. Two diaphragms are connected to a common shaft and act as a separation membrane between the compressed air (white) and the liquid (blue). Two inlet and two discharge check valves open, and then close to direct liquid flow into the pump chambers. The air distribution system alternately supplies air from the air inlet to the right side and then to the left side of the pump.



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6-37

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).

Figure 6-60: Ramparts Acid Centrifugal Pump



6-38


6-38

• March Mfg. Comp: TE-10K-MD Centrifugal Pump (Series 10 - 210 gpm - AC Electric Motor). This pump (Figure 6-61) is used as a transfer pump in acid bulk plants for 5 to 35% HCl and other chemical solutions. The casing and impeller are made of carbon-filled Kynar plastic (PVDF) and pump gaskets from Teflon.

Figure 6-61: March Series-10 Centrifugal Pump

6.9.3

Standalone Centrifugal Pumps A series of larger centrifugal pumps are used on location to transfer, circulate, and pressurize triplex pumps with inhibited acids. Several models are available that use either the standard Well Services RA5x6 or the RA10x12 centrifugal pump. Maintenance of these centrifugal pumps is described in JET Manual 04 – Basic Oilfield Equipment (InTouch content ID# 4127828). Note It is important to perform STEM-1 maintenance checks on the pump and motor before and after every job. Pay particular attention to lubricating the pump to ensure no acid or air leaks into the pump suction. Regular checks should be made on the impeller, impeller lock, and the volute for corrosion.



6-39


6.10

6-39

Liquid Additive Pumps The SUS-533 liquid additive skid is a Waukesha metering pump (Figure 6-62). It is used for pumping corrosive liquid additives from remote or day tanks. The pump speed is adjustable to obtain the variable flow rate required (0 to 0.06 galUS/rev).

Figure 6-62: Liquid Additive Skid (SUS-533)

Before every job, a bucket test should be performed to test the accuracy of the liquid additive pumps. If you don’t 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.



6-40


6.11

6-40

Transfer Hoses and Connections Incorrectly used, poorly maintained, or damaged hoses and hose connections used to transfer acids are the main causes of acid leaks and related incidents. The following sections describe important information and procedures to correctly use, maintain, and inspect hoses and hose connections: Note Be sure to frequently review WS QHSE Std 05: Wellsite Operations (InTouch content ID# 3313681) for updated information.

6.11.1

Connections

Follow Schlumberger standards for Camlok fittings as described in WS QHSE Std 05: Wellsite Operations (InTouch content ID# 3313681). Camlok fittings are ONLY approved for use when crossing over to a vendor fitting, NEVER in Schlumberger equipment. • Various dry break couplings are being used on additive piping systems. Some of these are metallic and some are plastic. The advantage of these connections is that they do NOT drain the materials in the hoses when the hoses are disconnected, and they also work as a secondary closure. These connections need to be clean to properly latch and seal. • The WECO Figure 206 union shown in Figure 6-63 is the standard union for use in low-pressure acid transfer and liquid additive hoses. The 206 union provides a measure of safety that the Camlock union is unable to provide. When breaking a Figure 206 union, the union can separate and relieve pressure while the threads of the union are still engaged.



6-41


Figure 6-63: 2-in WECO Figure 206 Union

• King nipples using bolt-on clamps should be used to secure connections to hoses. They should not be made from aluminum or other materials that react with acid. Note The condition of the king nipples and connections should be checked regularly for excessive corrosion. 6.11.2

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.


6-41


6-42


6-42

Figure 6-64: Hose for Wilden and Delasco Pumps

• 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.

Figure 6-65: 4-in Orange Hose Covers on Discharge Lines



7-i

JET Manual 10 / Acid Transport Equipment

7 7.1 7.2 7.2.1 7.2.2 7.2.3

7-i

Acid Transport Equipment Mobile Acid Transporter ________________________________________ Acid Transport Tanks ___________________________________________ SSS-111 and SSS-121 Acid Transport Tanks __________________ Containerized Transport Tanks ________________________________ Safety Devices on Transport Tanks ____________________________


7-1 7-3 7-3 7-5 7-5


7-1


7

7-1

Acid Transport Equipment JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

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 equipment’s operations manual. Refer to Section 4.5 for safety considerations regarding transportation.

7.1

Mobile Acid Transporter Schlumberger uses different models of acid transporters (e.g., Figure 7-1 and Figure 7-2). The trailers store liquid additives or acids for transportation or use during treatments.

Figure 7-1: STF-151 Acid Transporter



7-2


7-2

Figure 7-2: STF-144 Acid Transporter

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 manufacturer’s 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.



7-3


7.2

7-3

Acid Transport Tanks Many different types and sizes of tanks are used to transport acid in smaller volumes (500 to 2,000 galUS) to offshore and remote locations or when smaller acid volumes are required on location. Various names are used for these tanks: • safraps • carboys • intermodal tanks • IMO/IMDG tanks (conforming to the International Maritime Organization and International Maritime Dangerous Goods shipment requirements) • acid transport tanks or container tanks. The smaller-volume tanks can be made from fiberglass or PVC mounted in a protective lifting cage. Steel tanks can be lined with rubber, a vinyl ester coating, bonded polyethylene, or pluralistic linings in a protective transport skid or the intermodal type of tank-in-a-tank design.

7.2.1

SSS-111 and SSS-121 Acid Transport Tanks The SSS-111 and SSS-121 are two types of Schlumberger acid transport tanks. These are corrosion-resistant, tank-in-a-tank construction with a 3/16-in carbon steel outer skin and a 1/2-in crosslinked polyethylene inner liner. The annulus between the tank and the liner is filled with high-density polyethylene foam. More recent tanks are built with bonded polyethylene linings. These can be manufactured from approved suppliers on several continents. The fill and discharge outlets are located at the top of the tanks. An air unloading system pressurizes the tank for discharging material. Working pressure is 25 psi with rupture disc and relief valve pressure protection devices. A manway is located at the top of the tank for performing maintenance operations. The heavy-duty skid has forklift slots and lifting eye connections on the top. The 1,000-galUS skids are designed to stack on top of each other. The SSS-111 and SSS-121 acid transport tanks are shown in Figure 7-3 and Figure 7-4.



7-4


7-4

Figure 7-3: 1,000 galUS Acid Transport Tank (SSS-111)

Figure 7-4: 2,000 galUS Acid Transport Tank (SSS-121)

Versions of these acid transport tanks are also made using vertical tanks instead of horizontal tanks.



7-5


7.2.2

7-5

Containerized Transport Tanks Acid tanks in a container frame (Figure 7-5) are used for transporting acid offshore in large volumes.

Figure 7-5: Containerized Acid Transport Tank

7.2.3

Safety Devices on Transport Tanks Note Tombstone design and valve actuators must meet requirements as specified in Technical Alert, Must Do Maintenance Bulletin 1357-A: Acid Transport Trailer Roll Over Protection Improvements (InTouch content ID# 5857293), to prevent a possible spill in the event of a rollover. Figure 7-6 shows examples of the safety devices that should be present on acid transporter and tanks to help prevent the unplanned discharge of acid and damage to equipment and/or the environment.



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


7-6


7-7


7-7

The following are descriptions of these safety devices: • protective frame: Tanks are skid-mounted with a crash frame to prevent damage to the tank. • dome guard and drain hose: The hatch and manway area is protected with a rubber-lined, raised lip that acts as a containment area for acid spills. A drain hose is normally connected to this area, allowing acid to fall to the ground. This area must be cleaned with fresh water when contaminated. • blind caps: All discharge and fill lines must be equipped with blind caps, which must be attached to the line with a chain.

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.



7-8


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 vessel’s 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 manufacturer’s recommendations. DO NOT change them.



8-i

JET Manual 10 / Acid Tank and Transport Equipment Maintenance

8

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

Acid Tank and Transport Equipment Maintenance Tank Maintenance ______________________________________________ External Vessel ______________________________________________ Pipe Work and Acid Hose Fittings _____________________________ Instrumentation ______________________________________________ Tests and Inspections ________________________________________ Tank Linings and Interior _____________________________________ Lined Tanks ______________________________________________ Unlined Tanks ____________________________________________ Polyethylene Tanks _______________________________________ Crash Frame, Skid, and Lift Points ____________________________ Trailer and Tractor ______________________________________________ Additional Testing and Inspection ______________________________ Acid Plant Housekeeping and Maintenance _____________________


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


8-1


8

8-1

Acid Tank and Transport Equipment Maintenance JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

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.



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 tank’s 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.



8-3


8-3

• Check for rust, pits, and leaks in welds (refer to the example in Figure 8-1).

Figure 8-1: Crack in Weld on Bottom Suction of a Transport Trailer

• Check welds on the tank’s 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.



8-4


8.1.2

8-4

Pipe Work and Acid Hose Fittings The pipe work and acid hose fittings must be very carefully checked as follows: • Ensure that acid is not trapped in any hoses or connections. • Check all valves for leaks. Check the valves for ease of operation and that all handles are fitted and indicate the correct flow path. Ensure handle stops are in place. • Ensure that caps are fitted to connections. • Check hoses, flanges, and gaskets for leaks. • Check hose barbs used on acid transfer hoses for corrosion. Replace as needed. • Check supports for external piping and plumbing. • Check the condition and stability of independent supports for pipe work and valves to ensure some flexibility is possible.

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

Tests and Inspections The following checks should be performed regularly. • Confirm that the pressure relief valve’s last certification/test date is less than 12 months old. Also check the set pressure of the pressure relief valves to confirm that they are suitable for the application in which they are being used. • Check the date of installation and rating of rupture disc. • Check any certification of tank (if required). Is certification date still valid?



8-5


8.1.5

8-5

Tank Linings and Interior The integrity of acid tank linings must be verified and tested. The internal inspection and testing of the lining must be completed on all compartments of the tank in accordance with the tank manufacturer and lining manufacturer’s recommendations, local laws and regulations and WS QHSE standards. Any acid tank where you cannot gain access to all compartments to verify the integrity of the tank and perform the required internal inspections and testing of the lining must be removed from service. The linings and interior of the tanks should be maintained as described in the following guidelines. • Test acid tank internal linings in accordance with the Well Services QHSE Standard 04 Guideline 02: Acid Tank Inspection and Test (InTouch content ID# 3313678). The date of the test and the next test date must be stamped onto the tank test plate. The test results must be documented in a STEM report and filed in the equipment file. Note The integral linings test must be performed once every 30 months. • Follow the procedures detailed in WS QHSE Std 12: Permit to Work (InTouch content ID# 3313688) before any internal inspections of tanks are performed. • After each venting and cleaning, visually inspect the internal condition of the tank.

8.1.5.1

Lined Tanks The majority of lining failures occur because of • storage or transport of incompatible fluids. Check the manufacturer’s 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.



8-6


8-6

Figure 8-2: Blister in Rubber Lining Wrongly Used to Transport Solvents

• 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.



8-7


8.1.6

8-7

Crash Frame, Skid, and Lift Points The following describe minimum maintenance requirements for the crash frame, skid, and lift points. • Check skid or frame for damage. • Wash, repair, and paint as necessary. • Ensure that drainage plugs are fitted and that plugs are closed before filling the tank. • Check access ladders and roof for damage. Ensure any handrails are stowed for transit. • Replace Haz-Chem stickers as necessary. • Ensure that ground (earth) bosses are fitted and in good condition. • Inspect forklift lift points for damage. • Make sure that all slings and shackles, where fitted, are in place and that the test date shown on the frame stamping plate shows that testing will remain valid during the entire period of the tanks’ upcoming use. • Ensure that the safety and inspection certification is complete and current. • Ensure that fixed asset number stenciling is legible from all sides. • Ensure that tare, pay, and gross weight stenciling are clearly visible.

8.2

Trailer and Tractor The trailer and tractor hauling the tank need to be well maintained. • Check previous STEM 1 of tractor and trailer. • Perform STEM 1 check on the tractor (Figure 8-3): Check oil and water levels; fan belts; condition of air, fuel, and oil hoses; air and electrical systems; cleanliness; and fuel tank level. Correct any discrepancies.



8-8


8-8

Figure 8-3: Check the Tractor

• Check trailer hook-up and condition (Figure 8-4): Check hoses, glad-hand connections, fifth-wheel connection, and trailer lights.

Figure 8-4: Prejob Check of Trailer

• 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.



8-9


8-9

Note Any modifications to equipment must be done via an Equipment Modification Request (EMR) and properly approved. 8.3

Additional Testing and Inspection Additional test requirements and procedures for tanks or transporters used to store and transport hazardous fluids are detailed in the following documents: • WS QHSE Std 04: Equipment (InTouch content ID# 3313678), including – WS QHSE Standard 04 Guideline 01: Low-Pressure Vessel, Relief Valve, and Gauge Inspection and Test Procedure – WS QHSE Standard 04 Guideline 02: Acid Tank Inspection and Test – WS QHSE Standard 04: Access Guidelines. • WS QHSE Std 05: Wellsite Operations (InTouch content ID# 3313681) • Low-Pressure Hose Inspection and Test (InTouch content ID# 5658493).

8.4

Acid Plant Housekeeping and Maintenance Routine inspection and maintenance of the equipment and facilities in the acid bulk plant should be performed and documented. The frequency and detail of these inspections should be established by management of the location. Maintenance procedures should be based on manufacturer’s recommendations. Whenever a defect is identified, it should be repaired immediately and the repairs performed should be documented.



8-10


8-10

A checklist to aid in the housekeeping and maintenance of acid plant equipment is given in Table 8-1 through Table 8-3. Table 8-1: Acid Plant Housekeeping and Maintenance Checklist, Page 1 ACID PLANT HOUSEKEEPING & MAINTENANCE CHECKLIST Items

Yes

No

Comments

Liquid Chemical Storage (Totes, Drums, Palls): Lighting adequate & bulbs protected by guards Chemical storage separate from mechanical parts storage Chemicals stored separate from empty drums and waste chemicals Chemical storage neat & orderly. Pallets stacked safely. Chemicals containers stored closed & in good condition Chemicals properly segregated (flammable, corrosive, reactive) Proper labeling on each container (Name, Hazard, etc.) MSDS information available for chemicals in area Secondary containment & weather protection for chemicals Storage area maintained free of leaks & spills Fire extinguisher accessible & inspected monthly Operational eye wash station and safety shower Hand dollies in good repair Electrical panel labeled with voltage Electrical panel switches labeled with no “Open” slots Floor free from slipping/tripping hazards & spills Adequate verfication Tote tanks used only for designated chemicals Spill kit available and complete

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



8-11


Table 8-2: Acid Plant Housekeeping and Maintenance Checklist, Page 2 ACID PLANT HOUSEKEEPING & MAINTENANCE CHECKLIST

Items

Yes

No

Comments

Chemical Transfer Area: a) Designated area for chemical repackaging identified b) Area free of leaks and spills c) Sump routinely pumped d) Grounding and bonding straps available for use during transfer of flammables; explosion proof transfer pump

Slurry/Bulk Gel Loading and/or Storage Area: All tanks labeled with contents and hazard label Ladders: good condition, free of slip hazards, locked

Acid and Other Liquids: Storage Tanks: a) Clean painted, in good repair. No rust spots & No visible leaks b) Vent line hooked up & fume scrubber in use c) Fume scrubber routinely inspected & maintenance documented d) Return acid tank identified & independent from main bulk system e) Ladders & cages in good repair & locked f) Material, vent & load lines properly marked g) Rubber lined tank test current & marked on tank(s) h) Check valve installed & operational on water main line i) All piping and fittings in good condition with no leaks Secondary containment free of spills & leaks Floor & revetment wall in good repair, free of cracks & erosion (acid area coated with proper material) Sumps maintained empty when not in use & in good repair Warnings Signs & Systems: a) All tanks marked with contents and required hazard signs b) “Safety Shower & Eye Wash+B1017” c) “Googles Must be Work When Handling Chemicals” d) Fire extinguisher (above all extinguishers) e) “Notice: This Tank is Rubber Lined” f) “No Smoking” g) “Flammable”


8-11


8-12


Table 8-3: Acid Plant Housekeeping and Maintenance Checklist, Page 3 ACID PLANT HOUSEKEEPING & MAINTENANCE CHECKLIST

Items

Yes

No

Comments

Safety Equipment Available: a) Operational eye wash stations(s) & safety shower(s) with easy access in all work areas (Painted Distinguishing Color) b) Sticker suits c) Goggles & face shields d) Respiratory protection properly stored and sanitary e) Rubber gloves f) Fire extinguisher(s) (inspected monthly) g) Spill kit available and complete h) Secondary containment in good condition and clean. Last hydrotest documented. Transfer pumps, piping, and hoses in good repair & labeled Floors free of slipping/tripping hazards Explosion proof electrical equipment in use Adequate lighting Extension cords have grounding conductors Grounding system installed for loading area. All tanks or equipment handling flammables grounded.


8-12


9-i

JET Manual 10 / Acid Mixing Procedures and Calculations

9 9.1 9.2 9.3 9.4 9.5 9.6

9-i

Acid Mixing Procedures and Calculations HCl-Specific Calculations ______________________________________ Acetic Acid _____________________________________________________ Mud Acid _______________________________________________________ Clay Acid _______________________________________________________ Other Acids ____________________________________________________ AcidMIX Formulator ____________________________________________


9-1 9-3 9-4 9-5 9-5 9-5


9-1


9

9-1

Acid Mixing Procedures and Calculations JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

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

Volume of Conc. Acid =

(Vol Dilute Acid ) x (% Dilute Acid ) x (SG of Dilute) (SG of Conc.Acid ) x (% Conc.Acid )



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

Vol Conc Acid =

5, 000 × 15 × 1.0749 1.1709 × 34

Volume Conc. Acid = 2,025 galUS 34% HCl A262 Corrosion Inhibitor = 5 x 5 = 25 galUS needed F103 Surfactant = 5 x 1 = 5 galUS needed Subtract the corrosion inhibitor volume and the volume of all other additives from the fresh water volume. The volume of mix water should be reduced by the volume of corrosion inhibitor and other additives to be used, i.e., consider the total volume of water + additives as the mix-water volume. Volume water = (5,000 – 2,025) – (25 + 5) = 2,945 galUS = 70.12 bbl



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

To Make 1000 galUS Solution

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.



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 location’s 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.



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.



9-6


Figure 9-1: AcidMIX Formulator Input Screen 1

Figure 9-2: AcidMIX Formulator Input Screen 2

The results will be calculated and presented on screen or as an Excel spreadsheet and a load-out sheet.


9-6


9-7


9-7

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

QTY per 1,000 galUS

Total QTY (galUS)

HCl

405

2,025

Water

589

2,945

A262

5

25

F104

1

5

Total volume =

5,000 galUS

Acid density

9.0 lbm/galUS



10-i JET Manual 10 / Operating Requirements and Procedures

10

Operating Requirements and Procedures

Private


10-i


10-1

JET Manual 10 / Operating Requirements and Procedures

10

10-1

Operating Requirements and Procedures JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

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.



10-2

JET Manual 10 / Operating Requirements and Procedures

10-2

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



11-i

JET Manual 10 / Acid Spills and Disposal

11 11.1 11.2 11.3 11.4 11.5

11-i

Acid Spills and Disposal Reporting _____________________________________________________ Spill Prevention and Control Plan _____________________________ MSDSs ________________________________________________________ Spill Kits ______________________________________________________ Disposal ______________________________________________________


11-2 11-3 11-4 11-4 11-5


11-1


11

11-1

Acid Spills and Disposal JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

Acid spills must be prevented at all costs: clean up and remedial work is very expensive, the environment is damaged, and Schlumberger’s 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.

Figure 11-1: Acid Spill

Figure 11-2 shows that a little acid can go a long way.

Figure 11-2: Acid Spill from 55-galUS Drums



11-2


11-2

To avoid spills, all personnel must • perform proactive maintenance on all acid handling and storage equipment • establish and follow acid plant operating procedures, which must be updated with lessons-learned as necessary • use all necessary safety equipment, which must be operable • know the procedures and regulations in the country they operate • have a proactive QHSE attitude.

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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11.2

11-3

Spill Prevention and Control Plan SLB QHSE Standard S008 (Environment), InTouch content ID# 3605373, states: “All sites shall establish and maintain a written Spill Prevention and Control Plan if hazardous substances are used or stored on the site, or if required by environmental laws and regulatory requirements. The SPC Plan shall address pollution prevention by identifying potential spill scenarios and developing procedures to prevent and control them.” A spill prevention and control plan helps protect the environment in two ways: • It provides the procedures to prevent oil and chemical spills and waste releases. • Should a spill or release occur, it describes the protocols to minimize any harmful effects, including notification of appropriate government agencies as required by regulations. All personnel involved with the handling of acids must be knowledgeable of the location’s spill response control plan and know what their responsibilities are in the event of an incident. Some personnel will require special training in handling spills and also take part in spill response drills (refer to Figure 11-3 showing a drill in Kazakhstan).

Figure 11-3: Acid Spill Exercise in Kazakhstan



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11.3

11-4

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

Gives off hydrogen by reaction with

Personal precautions

Avoid contact with eyes. Do not get on skin or clothing. Wash thoroughly after handling. Ensure adequate ventilation. Refer also to Section 8: Acid Tank and Transport Equipment Maintenance.

Methods for cleaning up

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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11.5

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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

Dispose of by injection or other acceptable method in accordance with local regulations.

Contaminated packaging

If reusable containers are used, send them back to the product supplier, after the required rinsing. Triple rinse, crush and ship to sanitary landfill unless prohibited by local regulations.

EPA RCRA hazardous waste code

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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JET Manual 10 / Matrix Key Service Quality Requirements

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Matrix Key Service Quality Requirements


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12

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Matrix Key Service Quality Requirements JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

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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Figure 12-1: Matrix Key Service Quality Requirements


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13-i JET Manual 10 / Check Your Understanding

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Check Your Understanding

Private


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JET Manual 10 / Check Your Understanding

13

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Check Your Understanding JET 10, Acid Equipment, Storage, JETMixing, Manual Acid Handling, Spills 10, WS andAcid Training Disposal, Trans & portation, Development, Acid Acid

1. What is the pH of 28% hydrochloric acid? a. 7 b. ≥ 12 c. 9 – 10 d. ≍ 0 e. 2 – 3 2. Which three types of safety gloves should you wear when mixing mud acid (12% HCl + 3% HF)? a. cotton b. butyl c. neoprene d. PVC e. leather f. nitrile 3. What four items would you find in an acid bulk plant? a. surge tank b. Wilden pump c. water storage tank d. spill kit e. weigh-batch blender f. fume scrubber 4. What is the name of the Web-based program that can be used to determine acid system load-out requirements? a. i-District* b. AcidBLEND calculator c. AcidMIX Formulator d. i-Handbook* e. CemCADE* Private Copyright © 2013 Schlumberger, Unpublished Work. All rights reserved.


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5. What is a TREM card? a. trailer repair and equipment maintenance card b. transport emergency card c. trailer emergency clutch d. transport equipment maintenance 6. What safety standard should you know and follow when handling dangerous goods? a. SLB QHSE Standard S008 b. WS QHSE Std 18 c. SLB QHSE Standard S003 d. WS QHSE Std 17 e. all of the above 7. Which safety standard should be followed for inspecting and testing requirements for acid tanks? a. WS QHSE Std 04, Guideline 02 b. WS QHSE Std 09 c. WS QHSE Std 11 d. WS QHSE Std 22 8. What volume of 34% HCl would you require to mix 10,000 gallons of 28% HCl? a. 10,000 galUS b. 5,527 galUS c. 8,022 galUS d. 4,050 galUS e. none of the above 9. Where would you find details of what actions are required if an acid spill occurs in the acid bulk plant? a. product label b. load-out list c. MSDS d. invoice e. TREM card



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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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