API Foam Capture · scft/min Foamer gal/min Choke 1000 20.00% 13.254 1.2 6.74 1.68 116 0.565 0.09" 1000 30.00% 11.681 0.7 3.93 1.68 116 0.330 0.09" 500 40.00% 9.976 0.7 3.93 2.62

API Foam Capture

HalliburtonApril 9, 2014

© 2014 HALLIBURTON. ALL RIGHTS RESERVED. 2

API Foam CaptureObjective

Sample Pressure(psi)

FoamQuality

1000 20.00%1000 30.00%500 40.00%500 30.00%500 20.00%500 10.00%

Base SlurryDensity 16.4 #/gal

Yield 1.07 cft/sk

Water Req 4.49 gal/sk

The objective was to provide foam capture and samples to API using procedures and materials similar to those used previously in support of this effort. Halliburton reviewed the lessons learned and modified the procedures to address these items. The execution sequence was based on the data above.


API Foam CaptureApproach Highlights

▌Bottled N2 gas was used in this procedure versus cryogenic nitrogen in previous tests. The advantage in using bottled N2 was the ability to mix and pump at a lower rate while maintaining an accurate foam quality. This allowed for reduced volumes required for each sample which reduced the environmental impact.

▌A static capture manifold or split manifold was used for the foam capture. This allowed for foam isolation while maintaining the defined rates and pressures and the ability to maintain pressure during the transfer.

▌A foam accumulator chamber was added to the static capture manifold. This was charged with foam and subsequently displaced with N2 while filling the sample cylinder. This enabled the capture pressure to be maintained.


API Foam CaptureApproach

▌Sample chambers were pre-charged with N2 above the piston with the piston in the lower most position. (0%). Pre-charge pressure was ±50 psi above the desired capture pressure. This eliminated any significant differential pressure or flow rate across the ball valve inlet on the sample chamber.

▌ Lotorq valves and piping to the sample chambers were purged prior to filling the chambers with foam cement. This occurred after the static manifold was isolated.

▌All isolation valves upstream of the sample chambers were opened fully prior to filling the sample chambers to minimize any impact on the foam distribution in the cylinder. Fill rate was controlled by bleeding off N2 above the piston.

▌Sample chambers were filled slowly. A minimum of 60 seconds was defined. Average time to fill was 120 seconds.

▌ 3rd party line restraints were used on all 2” 1502 discharge iron.


API Foam CaptureApproach


TargetQuality

FOAM#/gal

Rate Slurry bbl/min

Slurry cft/min

N2cft/min

N2scft/min

Foamergal/min Choke

1000 20.00% 13.254 1.2 6.74 1.68 116 0.565 0.09"1000 30.00% 11.681 0.7 3.93 1.68 116 0.330 0.09"500 40.00% 9.976 0.7 3.93 2.62 92 0.330 0.09"500 30.00% 11.582 1 5.61 2.41 84 0.471 0.09"500 20.00% 13.188 1 5.61 1.40 49 0.471 0.0625”500 10.00% 14.794 1.8 10.11 1.12 39 0.848 0.0625”

Bottled N2 Source bbl Slurry scft N2Initial 2700psi 11 1066Final 1500psi 7 1163

Differential 1200psi 7 918Initial Volume 101599scft 10 843

% Available for test 44% 10 49245155scft 18 393

Total 63 4874


API Foam CaptureLayout

Zoneseal InjectionSkid

Gaseous Nitrogen Source

Cement Slurry Bulk Storage

Nitrogen Injection Control Package

Upstream CMT Data

Waste Tank

Defoamer Inlet

Lo‐TorQ

Check

Upstream Plumbing

Sample Fill Section

Discharge Section

Choke

v

AdjustablePop Off

Adjustable Choke

TemperaturePressureFlow Rate (SCF/MIN)

Density (lb/gal)PressureFlow Rate (bbl/MIN) Upstream

CMT Data

Density (lb/gal)PressureFlow Rate (bbl/MIN)

Foam Generator

HP CMT Pump

Sample Chambers(Vertical) 4ft pup joints to increase loop

volume (Vertical)N2 bottle to maintain pressure


API Foam CaptureFoam Generation Section


Foamer InjectionSkid

Gaseous Nitrogen Source

Cement Slurry Bulk

Storage

Upstream CMT Data

Lo-TorQ Valve

Check Valve

Choke TemperaturePressureFlow Rate (SCF/MIN)

Foam Generator

HP CMT Pump

Nitrogen Injection Control Package


API Foam CaptureSample Capture Section

v

v

AdjustablePop Off

Adjustable Choke

FoamCMT Data


Sample Chambers(Vertical)

4ft pup joints to increase loop volume (Vertical Accumulator)

N2 bottle to maintain Static pressure

Lo-TorQ Valve

Choke


API Foam CaptureWaste Recovery Section

50 bblWaste Tank

Defoamer Inlet downstream of adjustable choke


API Foam CapturePhotos

Base slurry mixing system Foam waste recovery storage

Vertical “accumulator” for foam Bottled N2 source

Sample Chamber


API Foam CapturePhotos

Sample Chamber drain valve

Micro Motion N2 Flow meter and cover

Upper Drain Valve


API Foam CaptureChoke Diagram

Ceramic Choke Nozzle


API Foam CaptureChart Cylinder 1

Build foam to specification

Static chamber fill portion

13.84ppg

1015psi



Purge line to sample chamber

Re-pressure from Accumulator

Fill sample Chamber

Adjust final pressure



10.12ppg

505 psi







15.07 ppg

505 psi


API Foam CaptureResults

▌ The volume of slurry used during the test was 63 bbls in total. All waste foam was treated with a defoamer and captured in a 100 bbl batch mixer. It was subsequently discharged to a transport and discharged to the drying slab for final disposal.

▌ Time required to complete the 6 foam transfers was 2:10.

▌No repeat samples were required and no overpressure condition was evidenced.

▌All cylinders were weighed and internal capacity confirmed prior to testing. This allows an immediate evaluation of foam quality. With a measured weight of the cylinder after filling, the mass of the foam was determined. Dividing the mass by the volume yields a density. Comparison of the measured density with the base density of the slurry results in a calculated foam quality for each cylinder. This is provided in the following tables.



SampleCylinder

#

Recorded Pressure(psi)

Volume(cc)

Empty Cylinder(gr)

Full Cylinder(gr)

Net(kg

Calc Density(gr/cc)

Calc Density(#/gal)

1 6 1015 990 9240 10885 1645 1.66 13.842 5 957 999 9195 10625 1430 1.43 11.923 3 505 992 4480 5685 1205 1.21 10.124 4 495 995 4480 5850 1370 1.38 11.475 2 505 985 4500 6060 1560 1.58 13.196 1 505 995 4470 6270 1800 1.81 15.07

SampleCylinder

#


Target Quality

Calculated Quality

Quality Variance

%Slurrylbm /cft

N2lbm/cft

FOAM#/gal

1 6 1015 20% 16.3% 3.71 102.70 0.830 13.842 5 957 30% 28.5% 1.52 87.74 1.369 11.913 3 505 40% 39.1% 0.90 74.71 1.005 10.124 4 495 30% 30.7% ‐0.70 85.02 0.774 11.475 2 505 20% 19.99% 0.01 98.16 0.514 13.196 1 505 10% 8.3% 1.72 112.52 0.213 15.07

Density from weight table above used as "goal seek" for Calculated Quality



Date Pressure Cylinder bottom gauge(psi)

Cyl #1 Cyl #2 Cyl #3 Cyl #4 Cyl #5 Cyl #69‐Apr‐14 510 515 520 500 1040 105010‐Apr‐14 500 500 500 500 900 95011‐Apr‐14 485 450 485 490 900 95014‐Apr‐14 420 400 470 470 890 890

300

400

500

600

700

800

900

1000

1100

Pres

sure

(psi

)

Date

Bottom Pressure GaugeCyl #1

Cyl #2

Cyl #3

Cyl #4

Cyl #5

Cyl #6


API Foam Capture

Questions??

Documents

API Foam Capture · scft/min Foamer gal/min Choke 1000 20.00% 13.254 1.2 6.74 1.68 116 0.565 0.09" 1000 30.00% 11.681 0.7 3.93 1.68 116 0.330 0.09" 500 40.00% 9.976 0.7 3.93 2.62