API SC 10, Work Group 3 Update:
Revision of 10B-4, Recommended Practice on
Preparation and Testing of Foamed Cement Slurries
at Atmospheric Pressure
Sub-Committee 10
June 2013
Erick Cunningham, Gunnar Debruijn, D.W. Lawrence
API WG 3: Foamed Cement
Agenda: Tuesday, June 25th (10:15 AM – 11:45 AM)
1.
2.
3.
4.
5.
Revisit actions from Winter Session
Revisit WG Charge and work plan (Erick)
Update on progress since the Summer Session
i.
RP 10B-4 document status (Erick)
ii. Update on Phase 2 work:
i.
Collection of field foamed cement samples (Gunnar & Woody)
ii. NETL Laboratory work (Barbara)
Conclusion and plan forward (Erick)
Adjourn
Acrions from previous meeting
1.
2.
3.
4.
5.
6.
7.
10B-4 Document – Action to complete one additional comment session with SC10 and submit document for Letter Ballot (Completed)
Discussed action to execute project to collect foamed cement samples at
Schlumberger’s Kellyville Training Center aligned with Laboratory work
performed by NETL. (Completed)
Follow up with BHI to explore additional field trial opportunity. (In planning Tomball)
James Heathman to follow up with HAL to explore additional field trial opportunity
at Duncan
Explore opportunities to increase pressure rating of the aluminum sample
container, e.g. carbon fiber coating, an aluminum sleeve inserted inside regular
1502 treating iron (No action will review for BHI Yard Test)
Consider capturing foam qualities of 50+% to get closer to what is executed in
the field on foam jobs (40% targeted close to 50% captured)
Evaluate impact of shear rate on BSD in foamed cements generated with field
equipment (action was taken to evaluate shear rate impact in the lab,
documented in KTC yard test, future work could be designed evaluate this with
further with field generated equipment)
Agenda: Tuesday, June 25th (10:15 AM – 11:45 AM)
1.
2.
3.
4.
5.
Revisit actions from Winter Session
Revisit WG Charge and work plan (Erick)
Update on progress since the Summer Session
i.
RP 10B-4 document status (Erick)
ii. Update on Phase 2 work:
i.
Collection of field foamed cement samples (Gunnar & Woody)
ii. NETL Laboratory work (Barbara)
Conclusion and plan forward (Erick)
Adjourn
Work Group Charge:
•
Produce a revision of API RP 10B-4, Preparation and testing of
Foamed Cement Slurries at Atmospheric Pressure to improve test
methods for high pressure and/or high temperature applications
Phase One:
1.
2.
3.
4.
Review of current apparatus and procedure for the generation of foamed
cement under atmospheric pressure. Agree to retain current method,
modify current method or suggest alternate or additional test methods.
If required develop new procedures and verify new procedures for the
evaluation of atmospherically generated foamed cement slurries
Redraft of API RP 10B-4 with enhanced atmospheric procedures and
publish.
Assess feasibility and Work Group commitment to progress to Phase
two.
Phase Two:
1.
2.
3.
4.
Explore methods to evaluate impact of increased pressure, temperature
and shear rate on foamed cement properties such as, bubble size
distribution, foam stability, and mechanical properties of set cement.
Develop and approve a procedure and standard equipment to develop
foamed cement slurries under elevated pressures (1000 psi or greater)
and elevated temperature.
Define test methods and write procedures for generation of foamed
cement slurries and testing of foamed cement slurries and foamed set
cement.
Draft an API Technical Report or an amendment to API RP 10B-4 and
publish.
Agenda: Tuesday, June 25th (10:15 AM – 11:45 AM)
1.
2.
3.
4.
5.
Revisit actions from Winter Session
Revisit WG Charge and work plan (Erick)
Update on progress since the Summer Session
i.
RP 10B-4 document status (Erick)
ii. Update on Phase 2 work:
i.
Collection of field foamed cement samples (Gunnar & Woody)
ii. NETL Laboratory work (Barbara)
Conclusion and plan forward (Erick)
Adjourn
Comment resolutions and latest draft on Work Group site
Document has been submitted for API Letter Ballot
Agenda: Tuesday, June 25th (10:15 AM – 11:45 AM)
1.
2.
3.
4.
5.
Revisit actions from Winter Session
Revisit WG Charge and work plan (Erick)
Update on progress since the Summer Session
i.
RP 10B-4 document status (Erick)
ii. Update on Phase 2 work:
i.
Collection of field foamed cement samples (Gunnar & Woody)
ii. NETL Laboratory work (Barbara)
Conclusion and plan forward (Erick)
Adjourn
Field Generated Foamed Cement - Project Objectives
•
Develop a data set of foam cement samples generated with field
foamed cementing equipment to compare to laboratory generated foam
cement. Utilize this data set to assess current laboratory methods
•
To determine a method to collect these samples without risk to safety or
environment.
•
To capture a set of foamed cement samples at 20%, 30% and 40%
foam quality with varied back pressures (500 psi and 900 psi)
generated with standard foamed cementing equipment.
•
To utilize these samples to conduct laboratory analysis of the set foam
cement to determine bubble size distribution and other properties of the
set foamed cement.
•
Utilize this data to assess suitability of atmospheric foamed cement for
“dynamic” foam stability testing (min to max foam quality during job).
Number of Samples, Pressures & Qualities – Target vs Actual
Cylinder
Type
Target Pressure
Target Quality
A1
Stainless
1000 psi
30%
A2
Stainless
1000 psi
20%
D1
Aluminum
500 psi
30%
D2
Aluminum
500 psi
40%
E1
Aluminum
500 psi
20%
E2
Aluminum
500 psi
20%
Cylinder
Pressure
Captured
Quality
Captured
Pressure 24
Hours
Pressure 48
Hours
A1
940 psi
30%
900 psi
850 psi
A2
780 psi
34%
750 psi
650 psi
D1
390 psi
41%
380 psi
360 psi
D2
320 psi
48%
300 psi
310 psi
E1
320 psi
34%
290 psi
290 psi
E2
Failed - Burst Disk Ruptured.
Rig Up of Sample Manifold Schematic
Upstream:
Cement Unit,
N2 Unit &
Foam
Generator
Pressure Relief Valve
Continuous Flow Line
HP Valves to trap foam cement in bypass line.
Pressure Transducers
Connected to Computer
recording system
Downstream:
Defoaming
Manifold &
Waste
Tanks
Bypass line to sample cylinders
Sample Manifold Details
•
•
•
•
•
•
Upstream cement unit, N2 pump unit, foam
generator, sensors and N2 process control
1 outside line to be used for continuous flow
1 bypass line for collecting foam slurry samples
•
2 HP valves to trap the foam cement
•
2 Tees with HP valves followed by bull
plugs with machined ¾” NPT threads.
•
2 Constant Pressure Sample Cylinders
Pressure Transducers in flow line and in bypass
line to monitor pressure.
HP - Pressure relief valve
Down stream defoamer manifold and disposal
tanks.
TEES with HP
Valves crossed over
with 2’’ Bull Plugs w/
¾ NPT Connection
Upstream – Cement Pump, N2 Pump, Foam Generator
•
•
•
•
•
•
•
•
•
•
Bulk plant and cement pumping unit
Cement mixing equipment
Density scales and samples station
Foam agent & foam stabilizer liquid
additives
Foam agent / stabilizer injection pump
Liquid Nitrogen tank & conversion
pump
Temperature, rate & pressure of N2
sensors
Foam cement slurry generator
Foam cement slurry pressure and
temperature sensors
Process control
Rig Up of Sample Manifold Schematic
Upstream:
Cement Unit,
N2 Unit &
Foam
Generator
Pressure Relief Valve
Continuous Flow Line
HP Valves to trap foam cement in bypass line.
Pressure Transducers
Connected to Computer
recording system
Downstream:
Defoaming
Manifold &
Waste
Tanks
Bypass line to sample cylinders
Sample Manifold Details
•
•
•
•
•
•
Upstream cement unit, N2 pump unit, foam
generator, sensors and N2 process control
1 outside line to be used for continuous flow
1 bypass line for collecting foam slurry samples
•
2 HP valves to trap the foam cement
•
2 Tees with HP valves followed by bull
plugs with machined ¾” NPT threads.
•
2 Constant Pressure Sample Cylinders
Pressure Transducers in flow line and in bypass
line to monitor pressure.
HP - Pressure relief valve
Down stream defoamer manifold and disposal
tanks.
TEES with HP
Valves crossed over
with 2’’ Bull Plugs w/
¾ NPT Connection
Pressurized Sample
Containers
Constant Pressure Sample Cylinder
Downstream – Choke Manifold, Foam Breaker, Waste Tanks
•
•
•
•
•
Adjustable choke with pressure
gauges.
Defoamer liquid additive injection
point.
Defoamer liquid additive tank and
defoamer liquid additive pump.
Second adjustable choke.
Waste tanks for storage and disposal
of foam cement slurry.
Rig Up of Sample Manifold Schematic
Upstream:
Cement Unit,
N2 Unit &
Foam
Generator
Pressure Relief Valve
Continuous Flow Line
HP Valves to trap foam cement in bypass line.
Pressure Transducers
Connected to Computer
recording system
Downstream:
Defoaming
Manifold &
Waste
Tanks
Bypass line to sample cylinders
Sample Manifold Details
•
•
•
•
•
•
Upstream cement unit, N2 pump unit, foam
generator, sensors and N2 process control
1 outside line to be used for continuous flow
1 bypass line for collecting foam slurry samples
•
2 HP valves to trap the foam cement
•
2 Tees with HP valves followed by bull
plugs with machined ¾” NPT threads.
•
2 Constant Pressure Sample Cylinders
Pressure Transducers in flow line and in bypass
line to monitor pressure.
HP - Pressure relief valve
Down stream defoamer manifold and disposal
tanks.
TEES with HP
Valves crossed over
with 2’’ Bull Plugs w/
¾ NPT Connection
Pressurized Sample
Containers
Constant Pressure Sample Cylinder
Sample Manifold Rig Up – Sample Ports with Sample Cylinders
Constant Pressure Cylinder C.P.C.
Manufactured by Welker Engineering Company
Aluminum CPC
4 samples collected in Aluminum cylinders
Maximum Allowable Operating Pressure MAOP
600 psi DOT rated
Stainless Steele CPC
2 samples collected in Aluminum cylinders
Maximum Allowable Operating Pressure MAOP
1800 psi DOT rated
Aluminum Constant Pressure Cylinder
Bull Plug With Machined Threads For CPC Connection Cross Over
Manufactured by FMC
Collected Data: Samples D1 and D2
Collected Data: Samples D1 and D2
•
•
Sample Summary
5 Samples Collect
Calculated Cement Foam Quality 30 to 50 Q
A1
A2
E1
D1
D2
2
3
20
3
103
4
30
3
195
5
Target N2 Rate (scf/min))
1
30
3
440
Foam Quality (from sensors)
25
16
25
End of pumping (psi)
1180
790
770
Before Sample (psi)
1180
940
480
490
387
After Sampling (psi)
940
780
323
387
316
Third day (psi)
850
650
290
310
290
30.1
34.4
33.6
41.2
47.8
Sample:
Order Collected
Target Sample Quality (Q%)
Target Slurry Rate (bpm)
Sample Line Pressure
Calculated Cement Foam Quality
Q (% from Pressure)
Lessons Learned
•
Overall the constant pressure cylinders worked well and made the sample collection straight
forward, safe and efficient.
•
Collecting the samples after all the pumps were shut down was a safe and controlled method.
•
20% foam quality requires higher base slurry flow rates (difficult to measure N2 flow rate at low
rates.)
•
600 psi limitation of Aluminum cylinders was also a problem with the 20% foam quality.
•
Sample cylinders need 2 inlet valves and also a check valve.
•
¾” needle valve or flow control valve would be more effective than the ¾” ball valve.
•
Open hammer valve to cylinders with inlet valve open and purge valve closed. Don’t open
inlet valve under pressure – risk of washing out valve.
•
Inject defoamer after the second adjustable choke.
•
Stable foam taken to atmospheric pressure can fill a very large volume in a very short amount
of time – plenty of storage space needed.
•
Fill dead space in the hammer valves with water before connecting cylinders to bull plugs.
Agenda: Tuesday, June 25th (10:15 AM – 11:45 AM)
1.
2.
3.
4.
5.
Revisit actions from Winter Session
Revisit WG Charge and work plan (Erick)
Update on progress since the Summer Session
i.
RP 10B-4 document status (Erick)
ii. Update on Phase 2 work:
i.
Collection of field foamed cement samples (Gunnar & Woody)
ii. NETL Laboratory work (Barbara)
Conclusion and plan forward (Erick)
Adjourn