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Baker Oil Tools

This document contains Confidential Information of Baker Hughes Incorporated (Baker) and is furnished to the customer for information purposes only. It isrequested that this document not be reproduced in any way whatsoever, in part or in whole, or distributed outside the customer organization without first obtainingthe express written authorization of Baker. This document is the property of Baker and returnable on request of Baker. July, 1999, Baker Hughes Incorporated.

FLUID PUMPING SERVICESTECHNICAL UNIT

GFI Vertical-Leaf Filtration System

Product No. 489-95

Description

The GFI Vertical-Leaf Filtration System com-bines 400 to 800 ft2of vertical pressure leaf filters,an 18-1/2 bbl DE blender, and a dual-cartridge fil-ter pot into a compact single skid. All vessels, pip-ing, and internals are made of corrosion-resistantstainless steel to prevent contamination of the flu-ids being filtered. Each cartridge filter pot houses

nineteen 40-inch long, pleated cartridges.

Specifications

Dual-Cartridge Filter Nineteen 40-inchVessels: cartridges per vessel

Pre-Coat/Body-FeedBlending Tank: 18-1/2 bbl

Piping: Stainless steel

Width: 5 ft

Length: 12 ft

Height: 9 ft Weight: 7,500 lbs

Pressure/Temperature: 100 psi at 200oF

Flow Capacity: Approximately 1 gpmper ft2 of filter mediawith fresh water

NOTE: Flow rates will be significantly reduced withincreased specific gravity, viscosity, or contaminant

load.

Drawing No. 671-284-1

Unit No. 5678Index: 443.60

Date: July 8, 1999Page:1 of 6


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Unit No. 5678Index: 443.60 Page 2 of 6

WARNINGUse of Baker equipment contrary to

manufacturers specification may result inproperty damage, serious injury or fatality.

Operating Procedures

The GFI filter unit employs several pieces ofequipment in its operation. Accompanying the GFIDE filter unit is a blender and an integral cartridge-type filter unit. Check all items given in the check-list under the Maintenance section before startingfiltration.

Rigging Up the System Dirty Fluid Line: from the rig mud pits to the

mixing blender riser line.

Pump Suction/Blender Line: from the blenderdischarge line to the operation pump suction.

Pump Discharge Line: from the operation pumpdischarge to the GFI DE unit inlet line (bottomleft line at skid end).

Pre-Coat Line: from the GFI DE unit pre-coatline (before the cartridge pod) to the mixingblender (hard piped line between the DE unitand the mixing blender).

Filter Discharge Line: from the cartridge filterunit (discharge) to the clean tank line (upper

middle line at skid end). Drain Line: from the unit drain (bottom right line

at skid end) to the waste pit.

Pre-Coating

Pre-coating is the process of establishing a thinlayer of DE cake on the septa. This cake is the ini-tial filtering media and must be done with thecleanest fluid available. With clean fluid, 10 lbs ofDE and 2 lbs of pre-co-floc material per 100 ft2offilter septa or 1/8 in. of pre-coat cake is sufficient tobegin filtering. Circulation for 10 to 15 minutes atthe maximum pump rate is sufficient to produce aclear filtrate with no traces of DE. A high pre-coatflow rate is important for establishing a uniformpre-coat. During this step, the downstream car-tridge-type filter unit is bypassed to allow the DE tobridge on the septa and pre-coat cake.

1. Close all valves on the filter unit.

2. Fill the blender with vessel volume of 13 bblplus 5 bbl for the lines. After the first cycle, re-

tain a full blender of clean fluid for the next cy-cle.

3. Dump the required amount of DE and pre-co-floc into the blender. GFI-650 requires 65 lbsDE and 13 lbs pre-co-floc.

4. Open the air vent valve on top of the GFI DEunit to release any air in the vessel.

5. Line up the valves to circulate between theblender and the GFI DE unit.

a. Start or engage the operation pump.

b. Open the inlet valve on the GFI DE unit.

c. Open the manifold discharge valve to thepre-coat line.

d. Close the DE unit air vent valve once all airhas been displaced by fluid.

e. Open the pre-coat valve above the blender.6. Circulate the fluid at a rate of 1 gpm per ft2of

filter area. The maximum GFI-650 rate is either15 bpm or the maximum pump rate.

7. Circulate the blender/DE filter until the filtrate isclear (about 10 to 15 minutes).

8. The pre-coat is then complete, and the unit isready to start filtering.

Filtration

Lining up the valves will put the unit on line.

1. Open only one cartridge filter unit inlet. Vent thecartridge filter through the lid valve. Close thevalve when vented.

2. Open the dirty fluid line to supply dirty fluid tothe blender and to observe the proper supply ofdirty fluid from the pump.

3. Add a sufficient quantity of DE material to theblender. Slowly open the cartridge filter dis-charge line (the clean fluid line) supplying cleanfiltered fluid to the rig tank.

4. Throttle back on the pre-coat valve to balance

the fluid level in the blender with the operationalpump rate and the dirty fluid supply. At times,this valve may be completely closed. The oper-ational pump, if desired, can be throttled backto maintain the required flow rate, but it shouldbe run at maximum for pre-coating.

During the filtering operation, it will be neces-sary to throttle the pre-coat and dirty fluidvalves and adjust the operation pump rate in or-der to balance the blender fluid level and tomaintain the required flow rate to the rig.

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GFI Vertical-Leaf Filtration System Unit No. 5678Index: 443.60 Page 3 of 6

Periodically, opening the air vent valve on thetop of the unit will release any accumulated air andprotect the filter cake on the filter leaves.

DE must be added to the blender throughoutthe filtering operation on a continuous basis to pre-

vent the dirty fluid fines from plugging the DE filtermedia.

For a faster response to the addition of the DE,keep only 5 to 7 bbl of fluid in the blender. The rateat which DE must be added is dependent upon theamount of solids contained in the fluid. The rangefor DE addition is between 1 to 4 parts DE to onepart contaminates. Filtering at a faster rate or filter-ing dirtier fluid requires the addition of more DE. Acentrifuge test can assist the experienced operatorin determining how much DE to add. A sample

from the dirty fluid line and a sample from the topof the DE unit vent (vent some fluid through the linebefore catching the sample) placed in the centri-fuge will indicate the amount of DE added-in ratioto the solids content of the fluid being filtered. Thistest will assist in determining if the proper amountof DE body feed is being added to the blender bycomparing the solids level in each sample.

One indicator of adding too little DE is an in-crease in filtering pressure that is not attributed toan increase in pump speed. This shows that fluid

fines are beginning to blind off on the filter cake. Ifthe pressure becomes so high as to cause the flowrate to decrease below a minimum acceptablerate, the unit will have to be cleaned. (The suggest-ed pressure on the DE filter unit is 85 psi for easein cleaning the unit; however, the maximum oper-ating pressure is 100 psi). The other criterion forcleaning the GFI unit is that it holds a maximum of15 bags of DE material. When this limit is reached,the unit must be cleaned before filtering can becontinued.

The downstream cartridge filter unit should alsobe periodically checked for the proper operatingdifferential pressure across the cartridge elements.The elements should be changed out when themaximum differential pressure across the ele-ments is 35 psi or if the discharge flow is below thatrequired to keep up with the rig.

Clean-Out

In order to clean out the GFI unit, shut off allines going to the unit and bleed off the pressurethrough the air vent on top of the vessel. The airvent valve connection can be used in conjunction

with rig air to blow down the unit, removing the fluidin the vessel to the dirty fluid pit in order to avoidlosing fluid. The fluid is then transferred throughthe vessel inlet (open inlet valve) back to the blend-er or dirty fluid rig tank through the centrifugapump. This is only possible if there are no checkvalves in the pump or foot valve on the end of thesuction hose. A drain line is then run overboard oto the pit from the wash-out connection to disposeof wash water and filter cake. Raise the lid andwash the filter cake from the filter leaves with a water hose. The water supply need only be of standard water pressure. If available, a nozzle on thewater hose should be used to minimize the cleaning time. While the unit is open, an inspectionshould be made to ensure that the leaf spreader isin the proper position not to allow the filter leavesto touch each other, preventing proper filter cakedistribution. To get back on line, shut the lid, closethe wash-out valve, and begin the operation oveagain by pre-coating as described previously.

Maintenance

Maintenance on the GFI filtration systemshould be performed often to ensure proper func-tioning. The following checklist will assist the operator in keeping the unit in top condition:

1. Check all leaves for holes and DE leaks. Makerepairs by patching holes and leaks with J&Bweld epoxy on the screen surface.

2. Check all O-rings for damage. Replace anydamaged O-rings.

3. Change cartridges inside of the cartridge filteunit. Check the micron size and beta rating fo

proper sizing as requested by the customer.

4. Wash the outside of the unit. Steam clean andpaint as required.

5. Repair all valves as required. (It is recommended that the valves be operated regularly whenthe unit is not being used.)

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GFI Vertical-Leaf Filtration SystemUnit No. 5678Index: 443.60 Page 4 of 6

6. Check the vessel wall for any rust spots. Re-move any rust spots.

7. Check the lid O-ring groove and seal edge onthe DE vessel.

8. Check all gages for accuracy and re-calibrate if

necessary.

9. Repair all leaking hoses and unions. Check allseals and replace as required.

10.Wash out the DE filter unit vessel after eachuse.

Vessel Exterior Maintenance

The GFI DE unit vessel is made of stainlesssteel and, therefore, requires little maintenance.However, care should be taken to keep the vesselclean from rust, as occasionally bumps and

scrapes from carbon steel objects deposit on thevessel and cause rust. These spots should be re-moved to prevent damage to the vessel.

Vessel Interior Maintenance Lid O-ring:Each time the vessel lid is opened,

a visual inspection of the O-ring should bemade. If the O-ring has any signs of damage, itshould be replaced. Thoroughly clean andinspect the O-ring groove before replacing withthe new O-ring. Pull the new O-ring into placeand splice it at the appropriate length by cutting

the O-ring at a 30o

angle to allow an overlap inthe strip ends; fuse together using Super Glue.Do not over stretch the rubber strip or O-ring;this will cause them to pull apart at the joint orsplice.

Filter Leaves:A visual inspection of the filterleaves should be made each time the vessel isopened. Repair any minor damage to theleaves using an epoxy to seal the small piecesof filter septa over the damaged area. Shouldthe leaf need to be removed, care should betaken to avoid damage to the adjacent leaf

when removing the spreader bars.

Periodically, the filter leaves should be re-moved for a full inspection and complete pres-sure washing to remove any particles adhered

to the surface and also to replace the collectionnozzles, O-rings, and washers. This should bedone if an increase in the pre-coat pressure isnoticed over time, indicating that the surfacesof the filter leaves are beginning to plug.

NOTE:A mild solution of HCL may be used to helpremove the adhered particles, but extreme care

must be taken to neutralize the filter leavescompletely with soap and water after the process.

Header manifold plugs are provided to allow forthe removal of one or more leaves. The mani-fold hole can be plugged, so that the filter unitcan be put back into operation while an individ-ual leaf is being repaired or cleaned. A shaftwith a threaded end is provided, so that themanifold plug can be installed without removingall the leaves.

Leaf Spreader Bar:Each time the filter vesselis opened for inspection, the tightness of theleaf tab/spreader bar bolts and the spreaderbar/vessel tab bolts should be checked toensure that the unit functions properly.

Diffuser Plate: A visual inspection of thediffuser plate, located at the bottom of thevessel, should be made to ensure that it isproperly attached and located in the center ofthe vessel for proper diffusion of incoming fluid.

Safety

CAUTION

Even very low pressure can be verydangerous. Do not disconnect any hose untilall the pressure has been bled off.

Make sure the lugs holding down the hatchesare in good condition, as these lugs preventthe lid from blowing off and, thus, must holdlarge forces while the unit is in use.

NOTE: The hatch has an approximate radius of 24

inches; for every increment of 10 psi, the total force on

the lid is 14,830 lbs.Beware of slippery areas and wear protective clothing.Always know the safety properties of the fluid being

filtered. A safety-conscious worker is the best safetydevice.

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GFI Vertical-Leaf Filtration System Unit No. 5678Index: 443.60 Page 5 of 6

Miscellaneous

Filtering Equations1. Darcys Law:

Q = KAdP

twhere Q = Flow Rate

K = ConstantA = AreadP = Differential Pressure= Viscosityt = Cake Thickness

2. Pump Horsepower:

3. Specific Gravity Ratio:

4. Density - Specific Gravity:

Fresh Water Density = 8.34 lbs/galSpecific Gravity = 1.0

5. Horsepower (Hp) Requirement:

Actual (Hp) = Hp (Fresh Water) xSpecific Gravity (Brine)

6. Filter Media DE Requirements:

ft3of solid = # bbl dirty fluid x% solids x 5.615 ft3/bbl

50 lbs of wet DE material = 2.5 ft3

1:1 ratio of solids to DE

Job Example

Filter 8.7 ppg completion fluid on a 10,000-foowell with 7-5/8-inch casing, a hole volume of 450bbl, and a surface storage volume of 350 bbl. Cir-culating 600 to 800 bbl filtered 8.7 ppg NaCl would

be efficient to produce very clean returns, 20 NTUwith no noticeable solids in a shake-out test. It isexpected to have 1% solids in the completion fluidduring different phases of the completion. A total o8,000 bbl NaCl water is to be filtered.

DE to Solids Volume Ratio 1:1

Solids Volume =Fluid Volume x % Solids x

Conversion Factor or 5.61 ft3/bbl

488 ft3= 8,000 bbl x .01 x 5.61 ft3/bbl

DE Requirements with 1:1 Ratio= 448 ft3at 20 lbs ft3(wet)

8960 lbs = 488 ft3/20 ft3/lbs

Bags of DE 179.2 = 8960 lbs at 50 lbs/bag

Pump Requirements for 10 bpm at 50 PSIGwith 50% pump efficiency

The use of a 40-Hp to 50-Hp diesel engine or electric motor with 5x6 centrifugal is recommended.

Horsepower (HP) =(Rate, bpm) (Pressure, psi)

(40.8) (Pump Efficiency)

Specific Gravity (Brine)

=

Pressure (Brine)

Specific Gravity(Fresh Water)

Pressure(Fresh Water)

Density (Brine)=

Specific Gravity (Brine)

Density (Fresh Water) Specific Gravity

Bags of DE =ft3Solids

2.5 ft3/bag

HHP 24.5 HP =10 bpm x 50 PSIG

.50 x 40.8

Parts List

Item

No.Description

No.

Reqd

1 Filter Vessel 1

2 Cartridge Filter Pot 2

3 Blender 1

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Unit No. 5678Index: 443.60 Page 6 of 6

GFI Vertical-Leaf Filtration System

GFI Vertical-Leaf Filtration System, Product No. 489-95

Assembly Drawing No. 671-284-1

7-8-99

5678 vertical leaf

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