Nitrogen Losses

Nitrogen Losses
Nitrogen is lost when it escapes back into the atmosphere before it can be used as a well
treatment fluid. This loss cannot be totally avoided, but it can be minimized. This article
attempts to show the sources of, operations involving, and economics of nitrogen loss.
Throughout most of the oil/gas well servicing industry, nitrogen is stored as a liquid,
pumped as a liquid, and then heated up to a gas. It is as a high pressure compressed gas
that it has value as a well treatment fluid. The coldest temperature at which the liquid
nitrogen is stored is -320 F (-196 C), its boiling point at atmospheric pressure. This boiling
liquid is induced to flow without cavitating by being pressurized. This pressurization occurs
inside its tank and, possibly further, by a boost (centrifugal) pump. The pressurized liquid
then flows into a high pressure (downhole) pump. Downstream of the high pressure pump
the liquid nitrogen is heated, which causes it to expand into a gas. This high pressure
source of gas is then available for well service.
Sources
The primary sources of nitrogen loss are heat energy, kinetic energy, and direct loss. Heat
energy and kinetic energy both cause the liquids temperature to rise, while direct loss is any
liquid or vapor that escapes directly into the atmosphere. All of these result in nitrogen that
is lost, and therefore is not available to be pumped downhole.
Heat energy flows into the nitrogen from the atmosphere. This is usually from warmer air
surrounding a colder nitrogen tank or pipe. Heat is always transferred from a warmer object
to a colder object, and the air temperature on earth (record low of about -100 F/-73 C) is
always warmer than that of liquid nitrogen (stored at about -320 F/-196 C). As heat
enters, the nitrogens temperature and pressure will both increase.
Kinetic energy is energy contained in the motion of a fluid. This motion causes the nitrogen
molecules to bump into each other more frequently (releasing heat energy), which results in
a temperature rise in the liquid. Examples of causes of this motion are sloshing inside a tank
or a boost pumps impeller turning.
All of the energy that has been gained as heat must be removed before the liquid nitrogen
can be effectively pumped. If the heat energy is not removed, bubbles will form as the
liquid nitrogen boils. These bubbles will buildup and cause the high pressure pump to
operate poorly and/or loose prime.
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Nitrogen Losses
Direct losses of nitrogen are primarily caused by leaks, cooldowns, and trapped liquid or
vapor. All of these result in nitrogen that flows back into the air, such that it cannot be
used. A cooldown is where the temperature of an object, like the high pressure pump, must
be reduced (literally cooled down) to near that of liquid nitrogen in order for it to work
properly. Nitrogen may become trapped, either as liquid or cold gas, inside some portions of
its piping. As these trapped fluids eventually warm up and expand they are vented into the
air.
Operations
Several operations are involved in Halliburtons handling of nitrogen. Many of these result in
the loss of some nitrogen. The following is a list showing many of these operations, their
source(s) of their nitrogen loss, and a brief explanation.
Storing liquid nitrogen inside a tank - heat energy
A new liquid nitrogen storage tank is expected to have a Normal Evaporation Rate (NER) of
between 0.5 to 1.0 % (of a full tank) per day. For a 1000 gallon (3.79 m
3
) tank this is a loss
of 466 to 931 scf (13.2 to 26.4 scm) of gas per day. This is from heat entering the nitrogen
through the walls of this highly insulated tank. A tank that is not in good condition can lose
substantially more than this.
Transporting liquid nitrogen to a job site - heat energy/kinetic energy/direct loss
During the transportation of liquid nitrogen to a job site, not only does heat energy enter
through walls of the tank, but kinetic energy also enters as the liquid sloshes around inside
the tank. As was stated earlier, the addition of heat, whether it is from heat energy or
kinetic energy, causes the temperature and pressure in the liquid nitrogen tank to rise.
When the pressure exceeds the setting of the road relief valve (usually 15 psi/103 kPa),
vapor will vent into the air.
Pressurizing a tank - heat energy
In order to pressurized a tank, an amount of liquid nitrogen is allowed to flow through an
air-to-nitrogen heat exchanger called a pressure building coil. The heat energy gained by
the nitrogen here causes it to expand. This expanded gas then flows back into the tank,
where it pressurizes the gas pocket at the top.
Flowing liquid through a piping system - heat energy/kinetic energy/direct loss
The piping system acts as a heat exchanger to let heat energy flow into the liquid nitrogen
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Nitrogen Losses
as it passes through. Kinetic energy also enters as the liquid is stirred up during its
movement through the piping system, especially at tees, elbows, and valves. If a boost
pump is used to help move the fluid, then significantly more kinetic energy enters the fluid
from the rotating impeller. Also, when using a boost pump, as liquid is recirculated back into
the tank it carries heat with it, causing the tank liquids temperature to rise faster than
normal. Some liquid and vapor is lost directly into the air from leaks. Other liquid is lost as it
becomes trapped between valves in the piping system, as liquid flow ceases. These losses
apply to flowing liquid from the tank to the high pressure pump, transferring liquid from one
tank to another, and several other situations.
Blowing down a tank - heat energy/kinetic energy
The physical loss of nitrogen occurs during the blow down operation. The actual loss has
already occurred prior to this, and is due to the heat gained by the liquid in the tank from
heat energy and kinetic energy. As stated before, the addition of heat causes the
temperature and pressure in the liquid nitrogen tank to rise. This heat must be removed
before the liquid can be effectively pumped. As the tank pressure is relieved to atmosphere
(literally blown down), the liquid nitrogen boils. This thermodynamic process carries heat
out with the venting vapor and actually cools the liquid back down to its atmospheric boiling
point (-320 F/-196 C). In blowing a tank down from 15 psig (103 kPa) to 0 psig (0 kPa)
about 6 % of the tanks contents are lost. For a tank that contains 1000 gallons (3.79 m
3
)
this is a 5590 scf (158 scm) loss of gas. In blowing a tank down from 75 psig (517 kPa) to
15 psig (103 kPa) about 14 % is lost. For 1000 gallons (3.79 m
3
) the loss of gas is 13,040
scf (369 scm).
Cooling down - direct loss
In cooling down, cold nitrogen liquid and vapor is flowed through objects in order to reduce
their temperature. The nitrogen used for this vents into the atmosphere and is lost. Objects
that are cooled down are the high pressure pump, its suction piping, and a "hot" (empty for
a time) nitrogen tank. To cool each pound of stainless steel from 75 F (24 C) to -320 F (-
196 C) requires 2.65 scf of gas (0.166 scm/kg).
Pump blowby - kinetic energy
The portion of liquid nitrogen that enters into the high pressure pump and is used to
lubricate the piston rings is called blowby (what has blown by the rings). In moving by and
lubricating the piston rings, this nitrogen gains a significant amount of kinetic energy. As
piston rings become worn, seen as high blowby pressure, more and more nitrogen is lost as
it blows by the rings.
Economics
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Nitrogen Losses
In the following examples nitrogen is assumed to cost about $0.34 per 100 scf ($0.12/scm).
The cost is what is costs to replace the product, not the lost revenue.
1. A 2000 gallon (7.57 m
3
) tank has an NER of 1 %. The tank loses 1862 scf (52.7 scm)
of gas per day. This is $6.33/day in lost product.
2. A tank containing 2000 gallons (7.57 m
3
) is blown down before a job from 15 psig
(103 kPa) to 0 psig (0 kPa). The gas lost is 11,170 scf (316 scm). This is $37.98 in
lost product.
3. A nitrogen pumping unit, containing 1000 lb (454 kg) of stainless steel in its high
pressure pump cold ends and suction piping, is cooled down before a job. The gas
lost is 2,650 scf (75 scm). This is $9.01 in lost product.
4. A tank containing 1000 gallons (3.79 m
3
) is blown down after a long job from 75 psig
(517 kPa) to 15 psig (103 kPa). The gas lost is 13,040 scf (369 scm). This is $44.34
in lost product. If the above four examples all occured to the same pumping unit in
the same day, the total loss of gas would be 28,722 scf (812.7 scm). This is $97.66 in
lost product.



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