RMX Manual PDF

Cementing Services — SCM Unit Operator Training Manual
Sanjel Cyclonic Mixer

(with Mark IV AT)
International Twin
Cementing Skid
Operation and Maintenance
Manual
Version 1.1
SCM W/MK IV AT Skid Operation and Maintenance
Cementing Services SCM W/MK IV AT International Twin Cementing Skid ii

Operator Training Manual – Version 1.1
Table of Contents
1.0 JOB OPERATIONS.........................................................................1-1

1.1 Objectives ............................................................................................... 1-1
1.2 Introduction ............................................................................................. 1-1
1.2.1 Operation Principles .......................................................................... 1-4
1.2.2 Configuration of the Skid ................................................................... 1-7
1.2.3 High Pressure Triplex Pump Power System.................................... 1-10
1.2.4 High Pressure Triplex Pump Power Distribution System................. 1-11
1.2.5 Hydraulic System............................................................................. 1-12
1.2.6 Fluid Displacement System ............................................................. 1-18
1.2.7 SCM High Energy Mixing System.................................................... 1-23
1.2.8 Ground Mixing System .................................................................... 1-41
1.2.9 High Pressure Pumping System...................................................... 1-46
1.2.10 Air System ....................................................................................... 1-49
1.2.11 Operation and Display System ........................................................ 1-50
1.3 Safety Precaution ................................................................................. 1-58
1.4 Pre-job Preparation............................................................................... 1-59
1.4.1 Spotting and Inspecting the SCM Skid ............................................ 1-59
1.4.2 Rigging In ........................................................................................ 1-61
1.4.3 Setting the Automation System ....................................................... 1-68
1.4.4 Simulating the Recipe...................................................................... 1-70
1.5 On-job Procedures................................................................................ 1-71
1.5.1 Checking the Instrumentation, Bulk Cement Control Valve, and
Centrifugal Pumps ........................................................................... 1-71
1.5.2 Bulk Unit/P Tank Operation ............................................................. 1-71
1.5.3 Starting the Mixing Process............................................................. 1-78
1.5.4 When Slurry is Finished Mixing ....................................................... 1-80
1.5.5 Switching from Lead to Tail ............................................................. 1-82
1.5.6 Carrying on Mixing Process in Manual Control................................ 1-83
1.6 HMI Program Operation (U.S. Units) .................................................... 1-84
1.6.1 Initial Operation ............................................................................... 1-84
1.6.2 HMI Screens.................................................................................... 1-85
Cementing Services SCM W/MK IV AT International Twin Cementing Skid iii
Table of Contents
1.7 Post-job Procedures ........................................................................... 1-119

1.7.1 Rigging out .................................................................................... 1-120
1.7.2 Cleaning up the High Energy Mixing System ................................ 1-121
1.7.3 Washing the High Pressure Triplex Pumps ................................... 1-124
1.7.4 Washing up the Ground Mixing System ........................................ 1-126
1.7.5 Greasing the Unit .......................................................................... 1-127
1.7.6 Doing a Walk-around Inspection ................................................... 1-128
2.0 SCM W/MK IV AT INTERNATIONAL SKID MAINTENANCE ........2-1
2.1 Objectives ............................................................................................... 2-1
2.2 Introduction ............................................................................................. 2-1
2.3 Maintenance Interval Schedule............................................................... 2-2
2.3.1 250 Hour Service Inspection ............................................................. 2-2
2.3.2 Monthly Maintenance ........................................................................ 2-2
2.3.3 Quarterly Maintenance ...................................................................... 2-7
2.3.4 Annual Maintenance.......................................................................... 2-7
2.4 Commissioning the Skid ....................................................................... 2-12
2.5 General Maintenance Requirements .................................................... 2-39
2.5.1 Major Equipment Inspections .......................................................... 2-39
2.5.2 Service and Grease......................................................................... 2-41
2.5.3 Oil Analysis...................................................................................... 2-41
2.5.4 Obtaining an Oil Sample.................................................................. 2-42
2.5.5 Lubrication Change Period .............................................................. 2-42
2.6 Detroit Diesel Engines .......................................................................... 2-46
2.6.1 Fuel System .................................................................................... 2-47
2.6.2 Oil System ....................................................................................... 2-52
2.6.3 Air System ....................................................................................... 2-56
2.6.4 Cooling System ............................................................................... 2-66
2.6.5 Electrical System ............................................................................. 2-69
2.6.6 Miscellaneous maintenance ............................................................ 2-71
2.7 Transmissions....................................................................................... 2-71
2.7.1 Transmission Maintenance.............................................................. 2-72
Cementing Services SCM W/MK IV AT Skid iv
Table of Contents
2.8 Drive Lines............................................................................................ 2-74

2.8.1 Drive Lines Maintenance ................................................................. 2-74
2.9 High Pressure Triplex Pumps ............................................................... 2-77
2.9.1 Plungers Packing Oiler System ....................................................... 2-78
2.9.2 Triplex Pump Power End Lube System ........................................... 2-83
2.9.3 Valves, Springs, and Keepers ......................................................... 2-87
2.9.4 Repacking the Triplex Pumps.......................................................... 2-89
2.9.5 Triplex Pump Troubleshooting......................................................... 2-95
2.10 Iron ....................................................................................................... 2-99
2.10.1 Routine Maintenance....................................................................... 2-99
2.10.2 Annual Maintenance...................................................................... 2-105
2.11 Recirculation Pump and Pressurizer Pump ........................................ 2-106
2.11.1 Recirculation Pump and Pressurizer Maintenance ........................ 2-107
2.12 Mix Water Pumps ............................................................................... 2-112
2.12.1 Mix Water Pump Maintenance ...................................................... 2-113
2.13 High Energy Mixing System................................................................ 2-117
2.13.1 Bulk Cement Control Valve ........................................................... 2-117
2.13.2 Mix Head Assembly....................................................................... 2-123
2.14 Hydraulic System................................................................................ 2-124
2.14.1 Hydraulic Tank .............................................................................. 2-124
2.14.2 Caterpillar C9 Engine .................................................................... 2-128
2.14.3 Funk Gearbox................................................................................ 2-154
2.14.4 Key Hydraulic Notes ...................................................................... 2-156
2.14.5 Hydraulic System Component Specifications ................................ 2-157
2.15 Plumbing System................................................................................ 2-159
2.15.1 Plumbing System Maintenance ..................................................... 2-161
2.16 Pressure Relief Valves........................................................................ 2-163
2.16.1 Pressure Relief Valves Maintenance............................................. 2-165
2.17 Skid Structural Frame Maintenance.................................................... 2-174
2.18 Lifting and Transporting the Skid ........................................................ 2-174
2.18.1 Lifting and Transporting the Main Skid using a Winch Truck......... 2-175
Cementing Services SCM W/MK IV AT Skid v
Table of Contents
2.18.2 Lifting and Transporting the Iron Skid using a Winch Truck .......... 2-177
2.18.3 Lifting the Main Skid using Cranes (with the Skid Assembled)...... 2-177
2.18.4 Lifting the Main Skid using Cranes (with the Skid Disassembled) . 2-180
2.18.5 Four Point Lifting using Two Cranes (for the Iron Skid) ................. 2-187
2.19 Equipment Pressure Testing............................................................... 2-188
2.19.1 Pressure Relief Valve Adjustment & Testing ................................. 2-188
2.19.2 System Pressure Calibration ......................................................... 2-190
2.19.3 Onsite Pressure Testing ................................................................ 2-192
2.19.4 Additional Regulations for Pumping............................................... 2-194
2.20 SCM Skid Process Troubleshooting ................................................... 2-198
2.21 Top 10 Maintenance Items ................................................................. 2-204
3.0 APPENDIX A ...................................................................................3-1
3.1 MARK IV AT system description and troubleshooting (for electricians) .. 3-1
3.2 System Overview .................................................................................... 3-1
3.3 Detailed System Description................................................................... 3-2
3.4 Process Variables ................................................................................... 3-5
3.4.1 Rates ................................................................................................. 3-5
3.4.2 Pressure ............................................................................................ 3-7
3.4.3 Density .............................................................................................. 3-9
3.5 System Inputs and Outputs................................................................... 3-10
3.5.1 Inputs (PLC) .................................................................................... 3-10
3.5.2 Outputs (PLC) ................................................................................. 3-14
3.6 Miscellaneous Operator Panel Controls................................................ 3-15
3.6.1 High Pressure Return Valve ............................................................ 3-15
3.6.2 Emergency Shutdown ..................................................................... 3-15
3.6.3 Master Water Valve Open/Close ..................................................... 3-15
3.7 Miscellaneous Components.................................................................. 3-16
3.7.1 Weight Display on Surge Can (Tank) .............................................. 3-16
3.8 Cement and Mix Water Hydraulic Valve Control Components.............. 3-17
3.9 Process Ranges ................................................................................... 3-20
3.9.1 Mix Water ........................................................................................ 3-20
Cementing Services SCM W/MK IV AT Skid vi
Table of Contents
3.9.2 Bulk Cement Delivery ...................................................................... 3-20

3.9.3 Mix Head Water Pressure ............................................................... 3-20
3.9.4 Mix Head Recirculation Pressure .................................................... 3-20
3.9.5 2" Coriolis Pressure......................................................................... 3-20
3.9.6 Down Hole Triplex Pump Boost Pressure ....................................... 3-21
3.9.7 Mix Water Centrifugal Pumps.......................................................... 3-21
3.9.8 Recirculation Centrifugal Pump ....................................................... 3-21
3.9.9 Down Hole Boost Pump RPM ......................................................... 3-21
3.10 Start Mixing/Pause Conditions Summary.............................................. 3-22
3.10.1 Automatic Corrective Actions .......................................................... 3-22
3.10.2 Alarms/Notifications......................................................................... 3-23
3.11 System Troubleshooting ....................................................................... 3-24
3.12 Process Error Codes from E&H Manual ............................................... 3-27
3.13 System Error Messages from E&H Manual .......................................... 3-28
3.14 Glossary................................................................................................ 3-29
4.0 TRAINING MANUAL FEEDBACK ................................................4-30
Cementing Services SCM W/MK IV AT Skid vii

Unit 1
SCM W/MK IV AT Unit Operation and Maintenance
1.0 JOB OPERATIONS

1.1 Objectives
The objectives specify what you should know and the tasks you should be able to
perform by the end of the unit. Upon completion of the unit you will be able to:
• Identify the major components of the SCM W/MK IV AT skid unit.
• Understand all aspects of the unit.
• Perform job procedures accurately, properly and safely.
1.2 Introduction
The newly designed Sanjel Cyclonic Mixer with Mark IV Automation Technology (SCM
W/MK IV AT) skid is used for performing primary and remedial cementing jobs (Figure
1-1). It is a unit combining the slurry mixing system and high pressure pumping system,
which allows the operator to perform slurry mixing and pumping on the same unit. It is
offered on a oilfield skid that is capable of mixing at slurry rates up to 1.8 m3/min (11.34
bbl/min) and densities up to 2400 kg/m3 (20 lb/gal).
Cementing Services SCM W/MK IV AT Skid 1-1

Unit 1
Figure 1-1: SCM W/MK IV AT International Twin Cementing Skid
The unit consists of the following major systems:
• High Pressure Triplex Pump Power System
• High Pressure Triplex Pump Power Distribution System
• Hydraulic System
• Air System
• Fluid Displacement System
• High Energy Mixing System
• Ground Mixing System
• High Pressure Pumping System
• Operation and Display System

Unit 1
The major components of the unit are illustrated in Figure 1-2 and Figure 1-3. The
operation principles and function of each component are given as follows.
Figure 1-2: Major Components of SCM W/MK IV AT International Skid (road side view)
Figure 1-3: Major Components of SCM W/MK IV AT International Skid (curb side view)

Unit 1
1.2.1 Operation Principles

1.2.1.1 Basic Principles
The SCM W/MK IV AT (abbreviated as SCM) unit’s mixing system is driven by the
hydraulic system and the high pressure pumping system is driven by the two Detroit
diesel engines. Sanjel’s high energy mix head mixes pneumatically delivered bulk
cement with water and recirculated slurry to generate the quality cement slurry. The
slurry density can be controlled either manually or automatically by the automation
system to the desired density. The slurry, mixed at the preset density, is transferred
continuously to the down hole high pressure Triplex pumps, and then is pumped down
the casing to fulfill the cementing job.
1.2.1.2 General Principles

The bulk cement is pneumatically delivered to the bulk cement control valve. The bulk
cement control valve regulates the flow rate of the bulk cement flowing to the high
energy mix head. When the system is in the automatic mode, the MK IV AT system
functionally runs the bulk cement control valve and the mix water control valve to mix
water and recirculated slurry with the dry cement to produce the new slurry. The new
slurry is then discharged into the mix tank through a cyclonic mixing chamber. Once the
new slurry reaches the mix tank, it is evened out with the existing slurry in the tank by a
tank agitator and then is recirculated by the recirculation centrifugal pump back to the
mix head. The 2” Coriolis flow meter, assembled in the recirculation line, senses the
actual density and a portion of the flow rate of the recirculated slurry and sends them
back to the MK IV AT system.

Unit 1
When the mix tank becomes full, the slurry flows over a weir into the averaging tank in
order to be averaged and discharged to the high pressure Triplex pumps. The 3”
magnetic flow meter mounted in the mix head water line measures the mix head water
flow rate and feeds the signals back to the MK IV AT system.
The MK IV automation system analyzes measured values of density, water rate, and the
bulk cement control valve position plus the slurry design parameters to decide the new
bulk cement control valve position, which is recalculated every second. The automation
system continually instructs the hydraulic actuator to adjust the opening of the bulk
cement control valve. As the result, the slurry density is controlled within the preset
density range.
In addition, the automation system also monitors and records the following parameters:
• Time
• Mix Water Rate
• 2" Coriolis Rate
• 4" Coriolis Rate
• Triplex Rate (combined)
• Triplex Rate (road side)
• Triplex Rate (curb side)
• Mix Water Pump (road side) RPM
• Mix Water Pump (curb side) RPM
• Recirculation Pump RPM
• Pressurizer Pump RPM

Unit 1
• Mix Head Pressure
• Mix Water Pressure
• 2" Coriolis Pressure
• Mix Water Rate Set-point
• Mix Water Valve Position (at set-point)
• Bulk Cement Rate Set-point
• Bulk Cement Rate Calculated Delivery
• Charge Pressure
• 2" Coriolis Density
• 4" Coriolis Density
• Job Total
• Stage Total
• Mix Water Valve Position (actual)
• Cement Valve Position (actual)
• Auxiliary Rate 3
• Auxiliary Rate 4
• Auxiliary Pressure
• Discharge Pressure
• 2" Coriolis Excitation Current
• 4" Coriolis Excitation Current

Unit 1
1.2.2 Configuration of the Skid

The SCM skid unit consists of three sub-skids which include: a primary top skid, a
secondary bottom skid, and a treating iron skid.
• Primary Top Skid: is composed of a hydraulic skid, a pump skid, and an engine
skid (Figure 1-4).
Figure 1-4: Configuration of Primary (Top) Skid
• Secondary Bottom Skid: provides structural support and elevation to the primary
skid. Figure 1-5 points out the location of the secondary bottom skid.

Unit 1
Figure 1-5: Location of Secondary Skid
• Treating Iron Skid: carries the treating iron, surge tank, and major components of
the ground mixing system. Figure 1-6 shows the configuration of the treating iron
skid. Table 1-1 lists all the treating iron carried by the iron skid.
Figure 1-6: Treating Iron Skid Profile

Unit 1
Table 1-1: Iron List
Description Quantity
2"x10' 1502 Weco Long Joint 30
2"x4' 1502 Weco Pup Joint 6
2" Single Wing Swivel Joint (Chicksan) 6
2" SPM Double Wing Swivel Joint (Chicksan) 4
2" 1502 Weco Jack Knife 3
2" Crossover (FxF) 2
2" Crossover (MxM) 3
2" Integral Tee (FxMxF) 2
2" Wye (FxFxM) 2
2x2 Plug Valve 6
Relief Valve 2

Unit 1
1.2.3 High Pressure Triplex Pump Power System

The power driving the high pressure Triplex pumps is provided by two diesel engines
mounted on the engine skid via the transmissions and flexible drive lines. The engines
are remote-controlled from the operator’s control console. Sanjel’s SCM International
skids are equipped with Detroit Diesel Series 60 engines (Figure 1-7).
Figure 1-7: Detroit Diesel Series 60 Engine

Unit 1
1.2.4 High Pressure Triplex Pump Power Distribution

System
The power of the two Detroit diesel engines is distributed to the high pressure Triplex
pumps via two transmissions (Figure 1-8) and two flexible drive lines (Figure 1-9). The
transmissions are mounted on the output side of the two engines. The drive lines are
installed between the transmissions and the Triplex pumps. The transmissions are
remote-shifted from the operator’s control console. They are equipped with power shift
and lock up mode. Sanjel’s SCM international skids are equipped with two Allison 4700
automatic transmissions.
Figure 1-8: Allison 4700 Transmission Figure 1-9: Drive Line

Unit 1
1.2.5 Hydraulic System

The hydraulic system is mounted on the hydraulic skid (Figure 1-10). It provides
hydraulic power to all the equipment on the skid unit that is hydraulically driven.
Figure 1-10: Hydraulic System

Unit 1
1.2.5.1 Major Components

The hydraulic system consists of the following major components.
• Hydraulic Pumps
• Hydraulic Motors
• Relief Valves
• Control Valves
• Pre-charge Filters
• High Pressure Filters
• Hydraulic Oil Reservoir (0.8 m3 [200 gal])
• Oil Level Sight Glass
• Hydraulic Oil Cooler
• Plumbing and Hoses
The hydraulic system drives the following functions:
• Pressurizer Centrifugal Pump
• Recirculation Centrifugal Pump
• Mix Water Centrifugal Pumps
• Mix Tank Agitation Paddle
• Averaging Tank Agitation Paddles
• Displacement Tank Agitation Paddles
• Bulk Cement Control Valve Actuator
• Mix Water Control Valve Actuator
• High Pressure Return Line Control Valve
• Skid Mounted Hydraulic Oil Cooler Fan Motor

Unit 1
1.2.5.2 Power System

The hydraulic system is driven by a diesel engine mounted on the skid. Sanjel’s
international skids are equipped with a Caterpillar C9 engine (Figure 1-11).
Figure 1-11: Hydraulic Power System (Caterpillar C9 Engine)
1.2.5.3 Power Distribution System

The power of the diesel engine is distributed to the hydraulic pumps via a multi-pad
Funk gearbox (Figure 1-12).
Figure 1-12: Hydraulic Power Distribution System (with Funk gearbox)

Unit 1
1.2.5.4 Hydraulic Pumps

The hydraulic system has six hydraulic pumps driving the hydraulic motors. The six
pumps are shown in Figure 1-13. They are attached to the Funk gearbox.
1. Cessna Hydraulic
Pump for Bulk
Cement Valve and
Mix Water Control
Valve
2. Sundstrand
Hydraulic Pump for
Five Agitation
Paddles
3. Sauer Sundstrand
Hydraulic Pump for
Road Side Mix
Water Pump
4. Sauer Sundstrand
Hydraulic Pump for
Curb Side Mix
Water Pump
5. Sauer Sundstrand
Figure 1-13: Hydraulic Pumps Hydraulic Pump for
Recirculation
Pump
6. Sauer Sundstrand
Hydraulic Pump for
Pressurizer Pump

Unit 1
1.2.5.5 Hydraulic Motors

The hydraulic system is equipped with nine hydraulic motors driving the recirculation
pump, the pressurizer pump, the mix water pumps, and the five agitation paddles, as
shown in Figure 1-14 to Figure 1-20.
Figure 1-14: Sauer Danfoss Hydraulic Motor for Figure 1-15: Sauer Danfoss Hydraulic Motor for
Recirculation Pump Pressurizer Pump
Figure 1-16: Sauer Sundstrand Series 90 Hydraulic Figure 1-17: Sauer Sundstrand Series 90 Hydraulic
Motor for Mix Water Pump (road side) Motor for Mix Water Pump (curb side)

Unit 1
Figure 1-18: Char-Lynn Hydraulic Motor for Agitation Paddle of Mix Tank
Figure 1-19: Char-Lynn Hydraulic Motors for Agitation Paddles of Averaging Tank
Figure 1-20: Char-Lynn Hydraulic Motors for Agitation Paddles of the Displacement Tank

Unit 1
1.2.6 Fluid Displacement System

The fluid displacement system holds and supplies pre-hydrated Bentonite, spacer, acid,
and displacement fluids that are pumped into the well for various purposes, and water
that is discharged into the mix head to create slurry. The system consists of the
following components:
• Fluid Displacement Tank
• Plumbing System
• Fill Lines
1.2.6.1 Fluid Displacement Tank and Fill Lines

The fluid displacement tank (Figure 1-23) consists of two 2 m3 (12.5 bbl) compartments
with each having graduated markers measuring in increments of 0.08 m3 (0.5 bbl) for a
tank total volume of 4 m3 (25 bbl). The tank is constructed of stainless steel for the
purpose of carrying acid and bearing weight. Each compartment of the displacement
tank has a 152.4 mm (5") air actuated discharge port and a hydraulic driven agitation
paddle. The butterfly valves on the ports allow the operator to remove fluid from one or
both compartments.

Unit 1
The displacement tank is filled from an off board source through the 76.2 mm (3")
external fill line or with the mix water centrifugal pumps. The filling of the displacement
tank is controlled by the two manual valves installed on the two fill lines. The dumping of
the tank is controlled by the two air actuated valves with the control switches mounted
on the side of the tank. The process piping feed of the displacement tank is controlled
by the actuated valves whose switches are located on the lower control console. A high
pressure return line is connected from the Triplex pumps to allow the pump pressure to
be discharged into the displacement tank.
Figure 1-21: Displacement Tank (road side) Figure 1-22: Displacement Tank (curb side)
The tank can be filled by the 3x2 mix water pumps from either side of the tank from an
external source via a 4" hose or from an off board source via a 3" hose. The
displacement fluid in the displacement tank is fed to the Triplex pump either by the aid
of gravity or the pressure from the pressurizer pump. The fluid used to create slurry is
pumped by the mix water pump to the mix head.

Unit 1
Figure 1-23 to Figure 1-26 show the components of the displacement tank.
1. Top Fill Line

2. Fill Line
Controls
(Manual)
3. Triplex Pop-
off Relief Flow
Back/Auxiliary
Fill Line
4. High Pressure
Return Lines
5. Air Actuator
Controls (for
the suction
valves)
6. Agitation
Paddle
Controls
7. Agitation
Figure 1-23: Components of Displacement Tank Paddle Motors
8. Overflow
Lines
9. Fluid Level
Metering
Gauges
Figure 1-24: Components of Displacement Tank (cont’d)

Unit 1
10. Agitation
Paddle (road
side
compartment)

11. Agitation
Paddle (curb
side
compartment)

Unit 1
1.2.6.2 Mix Water Centrifugal Pumps

The two mix water centrifugal pumps receive water from an external source and charge
the displacement tank. They also receive fluid from the displacement tank and
discharge to the high energy mix head, ground mixing tree, or back to the displacement
tank. The two pumps are located beneath the operator’s control console and beside the
Triplex pumps. Sanjel’s SCM skids are equipped with 3x2 mission pumps (Figure 1-27
and Figure 1-28).
Figure 1-27: Mission Mix Water Pump (road side) Figure 1-28: Mission Mix Water Pump (curb side)
1.2.6.3 Plumbing System

The plumbing system of the fluid displacement system consists of a series of manually
controlled tank main valves, pneumatically and manually controlled isolation valves,
pneumatically controlled short suction and long suction valves, and pipes.

Unit 1
1.2.7 SCM High Energy Mixing System

The function of the high energy recirculation mixing system is to mix dry cement and
water together, with the recirculated slurry, to create slurry of a desired density. The
system consists of the following components:
• Surge Tank
• High Energy Mix Head Assembly
• Mixing Chamber
• Cyclonic Mixing Chamber
• Mix Tank
• Mix Tank Agitation Paddle
• Averaging Tank
• Averaging Tank Agitation Paddles
• Recirculation Centrifugal Pump

Unit 1
1.2.7.1 Surge Tank

The surge tank (Figure 1-29) is mounted on the iron skid. It is used to create a steady,
and constant, flow of dry bulk cement and delivers the cement to the high energy mix
head, at a reduced pressure. It also acts as a buffer when changing “P” tanks. It has a
maximum volume of 2.1 m3 (75 ft3), with a minimum usable working volume of 1.2 m3
(45 ft3). It is equipped with two sight glasses, a hydraulic load cell, a remote weight
indicator, and a pressure relief valve. The pressure relief valve is used to ensure that
the surge tank is not over pressured during SCM mixing, and to make sure that the
pressure in the surge tank remains constant.
Figure 1-29: Surge Tank Figure 1-30: Surge Tank Weight Display
A daylight readable LED display (Figure 1-30) is mounted to the leg of the surge tank.
The purpose of the display is to provide a weight indication of the product in the surge
tank. This indication will assist the operator with keeping the cement level constant
during mixing operations.

Unit 1
1.2.7.2 High Energy Mix Head Assembly

The high energy mix head assembly consists of:
• SCM High Energy Mix Head
• Hydraulic Actuated Bulk Cement Control Valve
• Make-up Water Line
• Hydraulic Actuated Mix Water Control Valve
• Mix Head Water Line
• Pneumatically Actuated Master Water Control Valve
• Recirculation Line
• 3" Magnetic Flow Meter
• 2" Coriolis Mass Flow Meter
• Process Pressure Transducers

Unit 1
The components of the high energy mix head assembly are illustrated in Figure 1-31
and Figure 1-32.
1. Bulk Cement Control

Valve Potentiometer
Valve Hydraulic Actuator
Valve
4. Master Bulk Shut-off
Valve
5. Bulk Cement Inlet
6. Vacuum Breakers
Valve Hinge
8. Recirculation Lines
9. Mix Head Water Line
10. 2" Mix Head Water Line
Shut-off Valve
11. 3" Recirculation Line
Shut-off Valve
12. Water Control Valve
Potentiometer
13. Water Control Valve
Hydraulic Actuator
14. Mix Water Control Valve
15. Make-up Water Check
Valve
16. Make-up Water Line
17. “Y” Strainer
18. Master Water Control
Valve
19. Master Water Shut-off
Valve Air Actuator
Figure 1-31: High Energy Mix Head Assembly (view from 20. Mix Head Water Line
operator’s platform) Pressure Transducer
21. Wash Up Line
22. Pressurizer Pump Line
(to 4" Coriolis Down
Hole)
23. Automatic Water Control
Valve Assembly

Unit 1
24. SCM High Energy Mix

Head
25. Mixing Chamber
26. 3" Mix Head
Recirculation
Pressure Transducer
27. 2" Coriolis
Recirculation
Pressure Transducer
28. 2" Coriolis Mass Flow
Meter
29. 4" Coriolis Mass Flow
Meter
30. 2" Averaging
Recirculation Valve
31. 2" Averaging
Recirculation Manual
Valve Handle
32. 2" Mix Head Water
Pressure Transducer
Figure 1-32: SCM High Energy Mix Head Assembly (curb side
view)
1.2.7.2.1 SCM High Energy Mix Head
The SCM high energy mix head mixes materials from three sources (Figure 1-33):
• Water from a water source
• Recirculated slurry from the mix tank
• Dry bulk cement powder from the cement storage bin

Unit 1
Figure 1-33: Cross-section of the Mix Head
The high energy mix head receives dry cement (pneumatically) from the surge tank and
mixes the cement with water coming from the mix water pump and also with recirculated
slurry from the recirculation pump. The recirculated slurry is drawn from the mix tank.
The delivering rate of bulk cement is metered by the bulk cement control valve located
on the top of the mix head. A portion of the recirculated slurry density is measured by
the 2" Coriolis flow meter and the water flow is measured through the 3" magnetic flow
meter. The 2" Coriolis flow meter is installed in the recirculation line and the 3" magnetic
flow meter is installed in the water line. The slurry density, and slurry mixing rate, are
controlled manually (or automatically) by rotating the bulk cement control valve and the
mix water control valve.

Unit 1
The bulk cement sleeve (Figure 1-33) seats on the top of the mix head and directs the
flow of bulk cement, the recirculated slurry, and the mix water towards the throat of the
mix head. The sleeve also isolates the bulk cement from the water, and recirculated
slurry, and prevents the dry cement from being “wetted” before the appropriate stage in
the mix head.
The mix water diffusion plate (Figure 1-33) is installed in the mix head, at the bottom of
the bulk cement sleeve. It creates high velocity water jets that will wet the bulk cement
and break up any clumps prior to the cement being introduced to the recirculated slurry
streams. The jets also induce shearing in the slurry to ensure a homogeneous mixture.
1.2.7.2.2 Bulk Cement Control Valve
The bulk cement control valve (Figure 1-34) controls the amount of dry cement being
delivered to the mix head. Its opening is shown by the position of the indicator bonnet
located beneath the hydraulic actuator. When the system is in the automatic mode, the
position of the bulk cement control valve is automatically controlled by the
Programmable Logic Controller (PLC) and is adjusted by the hydraulic actuator. When
the system is in the manual mode, the position of the bulk cement control valve can be
changed by manually rotating the potentiometer on the upper control console. In
addition, if the hydraulic control fails, simply switching the hydraulic “Auto/Hand”
selector switch from “Auto” to “Hand” (Figure 1-35), then the position of the valve can be
changed manually with a bar that is provided with the unit.

Unit 1
Figure 1-34: Bulk Cement Control Valve
Figure 1-35: Hydraulic Auto/Hand Selector Switches

Unit 1
1.2.7.2.3 Make-up Water Line and Mix Water Control Valve
The make-up water line bridges the mix head water line and the recirculation line. The
water being delivered to the recirculation line, from the make-up water line, is used for
changing the mixing rate during the job.
The flow rate in the make-up water line is regulated by a hydraulically actuated water
control valve called the mix water control valve installed in the middle of the line. This
valve directs water into the circulating loop of the mixing side of the process. The
position of the valve can be changed automatically (by the PLC) or manually (by the
switches and potentiometer) on the upper control console. However, if the hydraulic
control fails, simply switching the hydraulic “Auto/Hand” selector switch from “Auto” to
“Hand” (Figure 1-35), then the valve can be controlled manually with a bar that is
provided with the unit.
1.2.7.2.4 Mix Head Water Line and Master Water Valve
The mix head water line conveys water from the mix water pump to the mix head and
the make-up water line. When the PLC is in “auto” mode, the water flow rate is enabled
or disabled by a pneumatically controlled 3" master water control valve installed in the
mix head water line.
The master water valve is a pneumatic butterfly valve that sends an “opened” or
“closed” feedback signal to the PLC. It can be controlled automatically by the PLC or
manually via the “Open/Close” toggle switch on the operator’s upper control console.
When opened, it directs water to the high energy mix head and to the mix water valve.

Unit 1
1.2.7.2.5 Recirculation Line
The recirculation line connects the mix tank and the high energy mix head. It
recirculates the pre-mixed slurry, from the mix tank to the mix head, to mix with the new
incoming water and dry cement.
1.2.7.2.6 3" Magnetic Flow Meter
The 3" magnetic flow meter (Figure 1-36), that is installed in the mix head water line,
measures the rate of water being pumped to the mix head and the make-up water line.
The readings of the flow meter are displayed on the HMI screen and the E&H monitor
(Figure 1-37).
Figure 1-36: 3" Magnetic Flow Meter Figure 1-37: 3" Magnetic Flow Meter Transmitter
(with local display)
1.2.7.2.7 2" Coriolis Mass Flow Meter
The MK IV automation system is equipped with a 2" Coriolis mass flow meter, located in
the recirculation line with the function of monitoring the recirculated slurry density, flow
rate, and temperature.

Unit 1
Density measurement is very important in the recirculation section because it allows the
MK IV automation system to modify the process inputs before slurry is pumped down
hole. By this modification, density variations can be initially corrected in the recirculation
section and any remaining variations then are dampened down in the down hole
section, which results in more consistent down hole slurry.
The 2" Coriolis flow meter samples the density signal and sends it to the Programmable
Logic Controller (PLC) where the density signal is converted to the actual cement
delivery rate. Then the PLC adjusts the cement control valve according to the actual
cement delivery rate (and some control law) to maintain the cement delivery set-point;
therefore, maintaining the density set-point. The Coriolis recirculation flow meter
readings are displayed on the HMI screen and the transmitter (Figure 1-38).
Figure 1-38: 2" E&H Transmitter (with local display)

Unit 1
1.2.7.2.8 Process Pressure Transducers
The high energy mixing system is equipped with three process pressure transducers,
which include: a 2" mix head water pressure transducer, a 3" mix head recirculation
pressure transducer, and a 2" Coriolis recirculation pressure transducer (Figure 1-39).
Figure 1-39: Process Pressure Transducers
• 2" Mix Head Water Pressure Transducer
o This transducer measures the water pressure at the high energy mix
head. The measuring range is 0 – 160 psi. It is located in the mix water
line near the high energy mix head.

Unit 1
• 3" Mix Head Recirculation Pressure Transducer
o This transducer measures the pressure in the circulating line of the mixing
side of the process. The measuring range is 0 – 160 psi. It is located in the
recirculation line near the high energy mix head.
• 2" Coriolis Recirculation Pressure Transducer
o This sensor measures the pressure in the 2" Coriolis flow meter. The
measuring range is 0 – 160 psi. The circulating line branches off and
directs a portion of the slurry through the 2" Coriolis flow meter and then
into the bottom of the mix tank. A bean (a fixed choke) and the 3"
recirculation valve work together to constrict flow and pressurize the slurry
going through the 2" Coriolis flow meter. A minimum of 20 psi back
pressure is required for the Coriolis meter to function optimally. The
transducer is located between the outlet of the Coriolis meter and the 2"
recirculation valve.
1.2.7.3 Mixing Chamber

The mixing chamber is mounted at the bottom of the mix head, connecting the mix head
to the cyclonic mixing chamber. It is the point where the mix water, recirculated slurry,
and dry cement meet, and then mix.

Unit 1
1.2.7.4 Cyclonic Mixing Chamber

The cyclonic mixing chamber (Figure 1-40) is located on the left side of the mix tank. It
separates the air used to deliver bulk cement, from the slurry, before the slurry goes into
the mix tank. It helps reduce the air entrainment of the slurry, and gets rid of the dust in
the mix tank in normal operation conditions.
Figure 1-40: Cyclonic Mixing Chamber (inside mix tank)
1.2.7.5 Mix Tank

The mix tank (Figure 1-41) receives mixed cement, mix water, and slurry from the outlet
of the mixing chamber and cyclonic mixing chamber. When the slurry enters the mix
tank, it is blended by the agitation paddle and recirculated back to the mix head by the
recirculation pump. Then it flows over the weir into the averaging tank. The mix tank is
approximately 1.1 m3 (7 bbl) in volume.

Unit 1
Figure 1-41: Mix Tank
1.2.7.6 Mix Tank Agitation Paddle

The mix tank has one hydraulic driven agitation paddle (Figure 1-42) to aid in mixing.
The paddle turns clockwise to push the slurry down.
Figure 1-42: Mix Tank Agitation Paddle

Unit 1
1.2.7.7 Averaging Tank

The averaging tank (Figure 1-43) receives slurry, from the mix tank, over a weir near the
top of the mix tank. It is approximately 2.7 m3 (17 bbl) in volume. The small fluctuations
of density in the mix tank are averaged out by the volume of slurry in the averaging
tank. It is very important to maintain a proper fluid height in the mix tank because it
allows good mixing and permits the cyclonic mixing chamber to do its job. Proper fluid
height also reduces the possibility of entraining additional air in the slurry, as it passes
over the weir.
Figure 1-43: Averaging Tank
1.2.7.8 Averaging Tank Agitation Paddles

The averaging tank has two hydraulic driven agitation paddles (Figure 1-44 and Figure
1-45) to aid in mixing and circulation. The agitation paddles push the slurry up. One
agitator turns counterclockwise and the other one turns clockwise with the flow.

Unit 1
Figure 1-44: Averaging Tank Agitation Paddle Figure 1-45: Averaging Tank Agitation Paddle
(road side) (curb side)
1.2.7.9 Mix Water Centrifugal Pumps

The two mix water centrifugal pumps are located between the two Allison transmissions
and the two Triplex pumps. One is on the road side and the other one is on the curb
side. They receive fluid from either the displacement tank or an external source
(accessed from either side). They discharge fluid either into the high energy mix head,
through a 3" magnetic flow meter, or into the displacement tank. Sanjel’s SCM
international skids are equipped with two Mission (3x2) centrifugal pumps (Figure 1-46
and Figure 1-47). The 3x2 means an outlet diameter of 2" by an inlet diameter of 3".
Figure 1-46: Mission Mix Water Pump (road side) Figure 1-47: Mission Mix Water Pump (curb side)

Unit 1
1.2.7.10 Recirculation Centrifugal Pump

The recirculation centrifugal pump (Figure 1-48) is located below the displacement tank
on the road side. This pump receives slurry from the bottom of the mix tank and
discharges it through the 2" Coriolis flow meter and to the two recirculation lines on the
high energy mix head. The two recirculation lines direct the recirculated slurry into the
new incoming water and bulk cement mixture. It is also possible for the recirculation
pump to push the slurry to the high pressure Triplex pumps, in the case where the
pressurizer pump has failed. Sanjel’s SCM international skids are equipped with two
Gardner Denver 2045 LX (6x5) centrifugal pumps. One is called the recirculation pump
(below) and the other is called the pressurizer pump. The 6x5 means an outlet
diameter of 5" by an inlet diameter of 6".
Figure 1-48: Recirculation Centrifugal Pump

Unit 1
1.2.8 Ground Mixing System

The ground mixing system (also called jet mixing) performs and accomplishes the slurry
mixing on the ground. The system is used to carry out low pressure jet mixing by
connecting the jet mixing bowl, and the hopper, to the mix slurry tub via a riser hose.
For ground mixing, one of the mix water pumps will pump the pressurized mix water into
the mixing bowl, and both of the Triplex pumps will be available to pump down hole. The
ground mixing system (Figure 1-49) consists of:
• Surge Tank
• Hopper
• Mixing Bowl
• Mix Slurry Tub
• Dust Collector
• Mixing Tree

Unit 1
1. Surge Tank
2. Bulk Direction
Control Flow Spool
3. Hopper
4. Mixing Bowl
5. Dust Collector
6. Cement Loading
Line
7. Mix Slurry Tub
8. Metering Valve
Figure 1-49: Ground Mixing System

Unit 1
1.2.8.1 Surge Tank

The surge tank is mounted on the iron skid. It is used to create a steady, and constant,
flow of dry bulk cement and delivers the cement to the high energy mix head, at a
reduced pressure. It also acts as a buffer when changing “P” tanks. It has a maximum
volume of 2.1 m3 (75 ft3), with a minimum usable working volume of 1.2 m3 (45 ft3). It is
equipped with two sight glasses, a hydraulic load cell, a remote weight indicator, and a
pressure relief valve. The pressure relief valve is used to ensure that the surge tank is
not over pressured during mixing operations, and to make sure that the pressure in the
surge tank remains constant.
1.2.8.2 Hopper
The hopper, also known as a witch’s hat (Figure 1-49), is placed beneath the surge tank
and above the jet mixing bowl. It collects and transports the dry cement from the surge
tank to the mixing bowl and maintains a constant cement flow.
1.2.8.3 Mixing Bowl

The mixing bowl (Figure 1-49) is placed under the hopper. It collects the dry cement
from the hopper and mixes the cement with the water that comes from the 2" water line
and the 11/2" bypass water line. The outlet of the mixing bowl is connected to the mix
slurry tub via a 4" riser hose.
1.2.8.4 Mix Slurry Tub

The mix slurry tub is connected to the mixing bowl, through a 4" riser hose, to hold the
mixed slurry. When conducting ground mixing, the mix slurry tub will be removed from
the iron skid to be mounted on the curb side of the skid (Figure 1-50).

Unit 1
Figure 1-50: Mix Slurry Tub (mounted on Primary Skid)
1.2.8.5 Dust Collector

During ground mixing, the dust collector (Figure 1-49) is used to collect the dust coming
off the bulk cement from the surge tank. Meanwhile, it is a valve that maintains and
adjusts positive pressure during the jet mixing operation.

Unit 1
1.2.8.6 Mixing Tree

The mixing tree (Figure 1-51) is connected to the mixing bowl, to supply water to the
bowl during ground mixing. The mixing tree consists of a 2" main mixing valve, a 2" jet
hose valve, a 11/2" by-pass valve, and a 1" wash up line.
1. Mixing Tree
2. 2" Main Mixing Valve
3. 2" Jet Hose Valve
4. 11/2" By-pass Valve
5. 1" Wash Up Line
Figure 1-51: Mixing Tree Assembly
When performing ground mixing, the 2" main valve is opened (and closed) to control the
total volume of water to be jetted to the mixing bowl. The 2" jet hose valve is always
wide-open to supply water, and provide the jetting power to ascend up the riser hose
into the mix slurry tub, to the mixing bowl. The 11/2" by-pass valve is adjusted to change
the density of the slurry in the mixing bowl. The 1" wash up line is used to maintain
(clean) the equipment after the job is completed.

Unit 1
1.2.9 High Pressure Pumping System

The function of the high pressure pumping system is to pressurize the slurry coming
from the averaging tank or slurry tub, or the displacement fluid from the displacement
tank and then to push the fluid down hole. This system is composed of a 4" Coriolis
mass flow meter, a centrifugal pressurizer pump, twin high pressure Triplex pumps, an
“H” style discharge manifold, and their related controls.
1.2.9.1 Pressurizer Centrifugal Pump

The pressurizer centrifugal pump (Figure 1-52) is driven by a Sauer Danfoss hydraulic
motor that is powered by a Sauer Sundstrand hydraulic pump. The pump receives fluid
from either the averaging tank, or the displacement tank, and then discharges the fluid
to the high pressure Triplex pumps. In the case of a recirculation pump failure, the
pressurizer pump can also circulate slurry from the mix tank to the mix head. Sanjel’s
SCM units are equipped with two Gardner Denver 2045 LX centrifugal pumps. One is
called the pressurizer pump (below) and the other is called the recirculation pump. The
6x5 means an outlet diameter of 5" by an inlet diameter of 6".
Figure 1-52: Pressurizer Centrifugal Pump

Unit 1
1.2.9.2 4" Coriolis Mass Flow Meter and 4" Down Hole Pump Boost
Pressure Transducer
The 4" Coriolis mass flow meter (Figure 1-53) is installed, in the discharge line from the
averaging tank, to capture and record the density, rate and temperature of the fluids
being pumped to the Triplex pumps. The readings of the flow meter are displayed on
the HMI screen and the 4" E&H transmitter (Figure 1-54).
The 4" down hole pump boost pressure transducer (Figure 1-55) measures the boost
pressure to the high pressure pumps. The measuring range is 0 – 160 psi. This
transducer is located at the outlet of the 4" Coriolis flow meter.
Figure 1-53: 4" Coriolis Mass Flow Meter Figure 1-54: 4" E&H Transmitter (with local display)
Figure 1-55: 4" Down hole Pump Boost Pressure Transducer

Unit 1
1.2.9.3 High Pressure Triplex Pumps

The Gardner Denver twin high pressure Triplex pumps (Figure 1-56) are horizontal,
single-acting horsepower pumps, with 600 maximum brake horsepower, located at the
rear of the SCM units. The two pumps have a 6" stroke length with a plunger diameter
of 31/2" on the road side and 41/2" on the curb side. Each pump consists of a fluid end
and a power end. The fluid end is where the slurry gets pressurized by the pushing of
the three plungers. The power end is connected to the drive line, through which the
power from the engine is transferred to the plungers.
Figure 1-56: High Pressure Triplex Pumps (road side and curb side)

Unit 1
1.2.9.4 Discharge Manifold

The discharge manifold (Figure 1-57) connects the pressurized fluids discharged from
the Triplex pumps to the wellhead. The discharge manifold of the unit forms an “H”
shape, so it is also called the “H” style discharge manifold.
Figure 1-57: Discharge Manifold (road side)
1.2.10 Air System

There are two air systems equipped on the SCM skid. The CAT engine air system
supplies air to the air starters to start the CAT engine and the two Detroit engines. The
Detroit engine air system provides compressed air to the Triplex pump plungers’ oiler
system (to pressurize oil being injected into the plungers), to the air actuators (to
operate the actuators), to the control console (to enable the master water valve control),
and to the Vortec air conditioner (to operate the air conditioner).

Unit 1
1.2.11 Operation and Display System

1.2.11.1 Control System
The control system for the SCM is called the MARK IV with AT (MARK IV with
Automated Technology). The operator enters the cement blend data that the system
uses to calculate the set-points for water and bulk cement delivery. The hydraulic
actuators control the mix water control valve, and bulk cement control valve, to achieve
the set-points. Numerous process variables are monitored, and the valves are
continually adjusted, to maintain tight control over the process.
The following are included as standard Mark IV AT features:
• Automatic density control
• Automatic mix water control
• Surge tank weight indication
• Pre-job system check
• Real time data storage
o Density and pump rate
o Total volume pumped
o Slurry temperature
o Triplex pump discharge pressure and several process piping pressures
• Store up to 20 cement slurry designs
• Slurry rate and density trims
• Download data through an industrial Ethernet connector
• Electronic over pressure protection

Unit 1
The core of the control system is the programmable logic controller (PLC). The PLC is
essentially a computer that runs a custom program, which analyzes the process
variables and electrical inputs, performs calculations and generates outputs. The
outputs are used to control the process, as well as provide the operator visually with the
process status and variable values.
The interface to the PLC is a Human Machine Interface (HMI). The HMI is a 15" touch
screen display that is also a computer running on Windows CE. It provides the operator
with a visual interface of the process and the ability to input data and execute functions
related to the process.
1.2.11.2 Data Acquisition

The SCM unit uses the Field Data Acquisition System (FDAS) as the data acquisition
system to receive data from the PLC. The job data is recorded and enables the operator
to produce a graph on location for the customer. Numerous process variables are also
recorded to the data card located in the HMI. This data can be used to analyze the job,
in the event there are concerns.

Unit 1
1.2.11.3 Operator Control Console

The SCM unit control console houses a variety of engine, hydraulic, pneumatic and
process parameters, as well as the unit control switches. It is also equipped with a
Vortec air conditioner unit to keep the upper control console cool in hot weather. It
allows the operator to control the unit’s engines, transmissions, centrifugal pumps, a
series of valves, and the hydraulic system. The job parameters displayed by the gauges
on the control console include pressures, temperatures, and fuel levels for different
equipment. Figure 1-58 shows the layout of the upper and lower control consoles.
Figure 1-58: Upper and Lower Control Consoles

Unit 1
Figure 1-59 to Figure 1-63 show the upper and lower control consoles components.
Figure 1-59: Components of the Upper Control Console

1. Curb Side Electronic Engine Display
2. Curb Side Transmission Alarm Lamp
3. Curb Side Transmission Lock-up Lamp
4. Curb Side Transmission Shift Pad
5. Curb Side Engine STOP/RUN/START Switch
6. Curb Side Engine Fuel Prime Switch
7. Curb Side Engine Diagnostic Alarm
8. Curb Side Engine Stop Indicator
9. Curb Side Pump Rate Monitor (Backup)
10. Curb Side Pump Low Lube Pressure Alarm
11. Curb Side Engine Throttle
12. Road Side Electronic Engine Display
13. Road Side Transmission Alarm Lamp
14. Road Side Transmission Lock-up Lamp
15. Road Side Transmission Shift Pad
16. Road Side Engine STOP/RUN/START Switch
17. Road Side Engine Fuel Prime Switch
18. Road Side Engine Diagnostic Alarm
19. Road Side Engine Stop Indicator
20. Road Side Pump Rate Monitor (Backup)
21. Road Side Pump Low Lube Pressure Alarm
22. Road Side Engine Throttle
23. Electronic Hydraulics Engine Display
24. Hydraulics Engine Idle Speed HIGH/LOW Switch
25. Hydraulics Engine STOP/RUN/START Switch
26. Hydraulics Engine Diagnostic Alarm
27. Hydraulics Engine Stop Indicator
28. Emergency Shutdown Button (Air Kill Switch)
29. Master Power Switch

Unit 1
Figure 1-60: Components of the Upper Control Console (cont’d)
30. Instrument Power Switch

31. Work Lights Switch
32. Cement Valve AUTO/MANUAL Switch
33. Cement Valve Manual Control
34. Mix Water Valve Manual Control
35. Mix Water Valve AUTO/MANUAL Switch
36. Master Water Valve AUTO/MANUAL Switch
37. Master Water Valve OPEN/CLOSE Switch
38. High Pressure Return Valve OPEN/CLOSE Switch
39. Unit HMI Screen

Unit 1
The function of each toggle switch assembled on the upper control console is described
below (Figure 1-61).
Figure 1-61: Toggle Switches on the Upper Control Console

Master Power – Enables all panel power.
Instrument Power – Turns on the PLC, HMI, instrumentation and DC components.
Work Lights – Operates the relays in the DC junction box that power the work lights.
Cement Valve AUTO/MAN – Selects the source for the cement valve hydraulic driver
board command signal, which can be the PLC or the cement valve control potentiometer.
Cement Valve Control – The cement valve control potentiometer can be used to operate
the cement valve. In order to use this potentiometer, the cement valve switch must be in
“MAN” mode. It sends a command signal to the cement valve hydraulic driver board.
There is a dead band at each end of the pot because the valve does not use 360 degrees
of rotation.
Mix Water Valve Control – The mix water valve control potentiometer can be used to
operate the mix water valve. In order to use this potentiometer the mix water valve switch
must be in “MAN” mode. It sends a command signal to the mix water hydraulic driver
board. There is a dead band at each end of the pot because the valve does not use 360
degrees of rotation.
Mix Water Valve AUTO/MAN – Selects the source for the mix water hydraulic driver
board command signal, which can be the PLC or the mix water valve control
potentiometer.
Master Water Valve AUTO/MAN – Selects the source for the valve control signal, which
can be the PLC or the master water valve OPEN/CLOSE switch.
Master Water Valve OPEN/CLOSE – Allows the operator to manually open or close the
master water valve. The master water valve AUTO/MAN switch must be in “MAN” mode
for this switch to work.
High Pressure Return Valve OPEN/CLOSE – This valve controls an electro-hydraulic
valve that opens and closes the high pressure return valve. This valve is used to bleed off
high pressure or create a pumping path back to the displacement tanks. There is a
restriction in the hydraulic line, to limit the speed at which the valve will open or close.

Unit 1
Figure 1-62: Components of the Lower Control Console

1. Curb Side Transmission Pressure Gauge
2. Curb Side Transmission Temperature Gauge
3. Curb Side Triplex Pump Lube Pressure Gauge
4. Curb Side Triplex Pump Lube Temperature Gauge
5. Recirculation Pump Main Pressure Gauge
6. Recirculation Pump Speed Control
7. Curb Side Mix Water/Transfer Pump Main Pressure Gauge
8. Curb Side Mix Water/Transfer Pump Speed Control
9. Road Side Transmission Pressure Gauge
10. Road Side Transmission Temperature Gauge
11. Road Side Triplex Pump Lube Pressure Gauge
12. Road Side Triplex Pump Lube Temperature Gauge
13. Down hole/Pressurizer Pump Main Pressure Gauge
14. Down hole/Pressurizer Pump Speed Control
15. Road Side Mix Water/Transfer Pump Main Pressure Gauge
16. Road Side Mix Water/Transfer Pump Speed Control
17. Sauer Hydraulic Pump Pressure Gauge
18. Cessna Hydraulic Pump Pressure Gauge
19. Road Side Engine Fuel Level Gauge
20. Hydraulics Engine Fuel Level Gauge
21. Curb Side Engine Fuel Level Gauge
22. Horn Button
23. Hydraulic Temperature Gauge
24. Air Pressure Gauge
25. Curb Side Triplex Pump Martin Decker Down hole Pressure Gauge
26. Road Side Triplex Pump Martin Decker Down hole Pressure Gauge

Unit 1
Figure 1-63: Components of the Lower Control Console (cont’d)

27. Averaging Tank Isolation Valve Switch
28. X-over Valve Switch
29. Displacement Side Pressurizer Pump Isolation Valve Switch
30. Road Side Triplex Pump Isolation Valve Switch
31. Curb Side Triplex Pump Isolation Valve Switch
32. Curb Side Mix Water Pump Isolation Valve
33. Road Side Displacement Tank Isolation Valve Switch
34. Curb Side Displacement Tank Isolation Valve Switch
Figure 1-64 shows the location of the Vortec air conditioner unit. It is mounted on the
right hand side of the upper control console.
Figure 1-64: Vortec Air Conditioner

Unit 1
1.3 Safety Precaution
Caution
Risk of moderate equipment damage or minor personal injury
Good safety practices are critical when starting and operating the unit.
Keep the following safety precautions in mind when performing a cement job:
• Keep away from all rotating machinery and pinch points.
• Avoid skin contact with the hot surfaces on engine.
• Do not smoke around the well area.
• Make sure to wear all the proper Personal Protective Equipment (P.P.E.)
including: steel-toed boots, hard hats, safety glasses, coveralls, gloves, or any
protective equipment required.
• If a hydraulic leak occurs, stop the unit immediately. Do not operate the unit, until
the leak is fixed.
• After each cement job has been completed, flush the mixing system immediately
and ensure that the flow meters are clean and free of dirt.
• Disassemble the bulk cement control valve from the mix head after each
cementing job and flush out the inside of the head; clean the vacuum breakers.
• Do not clean the bulk cement control valve with water. Avoid water inside of the
valve.

Unit 1
1.4 Pre-job Preparation

The pre-job preparation involves spotting and inspecting the skid, rigging in, setting the
automation system, and simulating the recipe.
1.4.1 Spotting and Inspecting the SCM Skid

1.4.1.1 Spotting the SCM Skid
The SCM skid should be spotted at a proper location, so that the necessary fluids can
be transported freely between the well and the unit. If a “P” tank is used to supply the
bulk cement, spot the unit to the “P” tank for a desired location. When spotting the unit,
there should be a minimum 30 meters (100 ft) between the unit and the wellhead.
Sometimes the bulk units will be used, instead of the “P” tank, to supply the bulk cement
to the SCM skid on location. When the bulk unit gets to the lease, spot the bulk unit to
the SCM skid for a desired position.
1.4.1.2 Inspecting the SCM Skid

The operators of a commercial unit must inspect it (prior to operating it) at the beginning
of each day and (after operating it) at the end of each day. These inspections ensure
that the unit will be working properly and reliably during any job. The following items
should be done when inspecting the skid:
• Check all the fluid levels, including the engine oil, coolant, hydraulic oil, lube oil,
and plunger oil.
• Check all the batteries and connections.
• Check all the fan belts and alternator belts.
• Check for any leaks.

Unit 1
• Check the drive lines.
• Check the fuel tanks. All the fuel tanks should be full.
• Check the drip pans on the primary skid and ensure they are not full.
• Power the unit up. Check all the displays.
• Air the unit up from the rig. Check for any air leaks.
• Run the CAT C9 engine and the Detroit engines and check for any abnormities.
• Engage all the centrifugal pumps and check for any abnormities.
• Function test all the air and hydraulic actuated valves. Ensure the water and bulk
control valves function from “fully open” to “fully closed” without any interference.
• Check the condition of the pressure relief valves, installed on the high pressure
Triplex pumps, with the pumps turning over.
• Grease the four centrifugal pumps.
• Visually inspect the metering valve of the surge tank, to make sure there is no
cement build-up.
• Inspect the rubber boots of the fluidizers for wear. If wear is detected, replace the
boots.
• Reset/preset the load cell of the surge tank.
• Function test all the centrifugal pumps, and preset the actuated valves to the
desired position, before initiating water.
• Preset the water valves to the desired position for mixing and taking on water.
• Close all the drain valves of the mix water pumps, recirculation pump, and
pressurizer pump.

Unit 1
1.4.2 Rigging In
As soon as the pre-job inspection has been finished, the operator starts rigging in.
Follow the procedures below to set up the SCM unit and connect the unit with other
associated equipment.
1.4.2.1 Connecting the Unit with the Water Sources

The unit needs to be connected with water sources in order to obtain the water supply.
There are three connections on the road side that can be used to connect to the drilling
rig, or water truck, to get water. The three connections are shown in Figure 1-65.
Figure 1-65: Water Connections

Unit 1
1.4.2.2 Laying out the Treating Iron and Connecting the Unit to the
Wellhead
The treating iron is always connected to the discharge iron on the road side. Before
laying out the treating iron, check with the supervisor to see if the client has requested a
particular layout to the wellhead, and if a pump-out tee and valve are required. When
laying out the treating iron to the wellhead, the wings on the treating iron should face
towards the SCM unit. Oil the unions before joining each piece. Tighten each
connection properly (generally 4 – 5 hits with the hammer). The treating iron layout and
connections are:
• The number and configuration of iron differs from job to job, but there is a
standard configuration from the discharge of the Triplex pump down to ground
level called the “dog-leg”, which consists of three swivel joints (Chicksans) and
one pup joint.
NOTE: The type of layout of treating iron shown in Figure 1-66 is different than
the “dog-leg” described above; however, it is still applicable to the jobs.
Figure 1-66: Type of Layout of Treating Iron

Unit 1
• Iron should be laid out in a box shape to prevent it from breaking during jacking
(the recoil reaction of equipment, particularly treating iron, due to sudden
changes in pressure or Triplex pump “cavitations”).
• Slings must be placed, at rear of the unit, from the discharge valve to the ground
(including all the swivel joints).
1.4.2.3 Connecting the Surge Tank to the P Tank/Bulk Unit

To supply bulk cement to the mixing system of the skid, either “P” tanks or bulk units will
be used. At the same time, the dust bag should be installed on the dust collector and
the fluidizers should be connected to the air line (Figure 1-67).
Figure 1-67: Dust Bag, Fluidizers and Air Line

Unit 1
To connect a “P” tank to the surge tank, perform the following:
• Connect the cement loading line of the surge tank and the product line of the “P”
tank via a 4" bulk hose (Figure 1-68). If two tanks are to be used, a “Y” cam lock
must be installed to make the connection.
Figure 1-68: Bulk Hose Connecting Surge Tank and P Figure 1-69: 3" Air Hose of P Tank
Tank
• Connect the 3" air hose, on the “P” tank, to a blower that is carried by another
unit (Figure 1-69). The unit with the blower should be located at a convenient
spot, and not interfere with the operation of other equipment.
To connect a bulk unit to the surge tank, perform the following:
• Connect the cement loading line of the surge tank and the product line of the bulk
unit via a 4" bulk hose. A 45° cam lock can be used for proper orientation of the
hose.
NOTE: The bulk hose should be free from tight curves, or other potential bridge points,
to ensure constant flow of bulk to the surge tank.

Unit 1
1.4.2.4 Connecting the Mix Head to the Surge Tank for High
Energy Mixing Jobs
Connect the cement transfer line from the master bulk shut-off valve, of the bulk cement
control valve, to the metering valve of the surge tank (Figure 1-70).
Figure 1-70: Bulk Cement Transfer Line Connecting Mix Head to Surge Tank

Unit 1
1.4.2.5 Setting up the Unit for Ground Mixing Jobs

To set up the unit for ground mixing jobs, the mixing bowl and the mix slurry tub should
be connected with the unit. The dust bag should be installed on the dust collector and
the fluidizer should be connected to the air line. Refer to Figure 1-67.
To connect the mixing tree to the mixing bowl, perform the following:
• Connect the 2" jet hose valve of the mixing tree with the 2" water line of the
mixing bowl via a 2" water hose (Figure 1-71 and Figure 1-72).
• Connect the 11/2" bypass valve of the mixing tree with the 11/2" bypass water line
of the mixing bowl via a 11/2" water hose (Figure 1-71 and Figure 1-72).
Figure 1-71: Connecting Mixing Tree to Mixing Figure 1-72: Connecting Mixing Tree to Mixing
Bowl Bowl (cont’d)

Unit 1
To set up the mix slurry tub, perform the following:
• Remove the mix slurry tub from the iron skid and mount the tub on the curb side
of the primary skid (Figure 1-73).
• Attach the 4" suction line to the pressurizer pump along with a 2" recirculation
line (Figure 1-73).
• Connect the mix slurry tub to the mixing bowl via a 4" riser hose (Figure 1-73 and
Figure 1-74).
Figure 1-73: Mix Slurry Tub Connection Figure 1-74: Connecting Mix Bowl and Mix
Slurry Tub via 4" Riser Hose

Unit 1
1.4.3 Setting the Automation System

After the rigging in has been completed, the operator starts setting the automation
system. Follow the procedures below.
1.4.3.1 Inputting the Recipe in the PLC Program

1. Use the touch screen to select the desired field to change.
2. Once the field is selected, use the number pad provided to input the information.
3. Once the information is input, press “ENTER”.
4. Repeat steps 1 through 3 until the recipe is updated.
5. Once the recipe is updated, press “SAVE”. A confirmation screen will come up at
this time. If you want to overwrite the current recipe, press “YES”.
6. In order for the program to update a stage, press “NEXT STAGE” and then press
“PREVIOUS STAGE”.
7. Select the pump that will be used to bring on the mix water.
1.4.3.2 Setting the Centrifugal Pumps (rpm)

1. Rev-up the hydraulic power pack to high idle (1800 rpm).
2. Set the centrifugal pumps’ revolutions to the optimum number – mix water pump
(2100 rpm); Recirculation pump (minimum 1500 rpm).
3. For the operation of the pressurizer pump, the minimum rpm is set to 1000. The
rpm may need to be increased during the job, to the desired back pressure on
the 4" Coriolis flow meter.

Unit 1
1.4.3.3 Presetting the Recirculation Valves to Hold Back Pressure

on the 2" Coriolis Flow Meter
1. Set the 3" recirculation line shut-off valve. Close two notches, if required, to
achieve 20 psi back pressure on the 2" Coriolis flow meter. The valve is located
just below the “Y horn” of the recirculation line (Figure 1-75).
2. The Venturi bean (fixed choke) on the 2" recirculation side should have the
desired back pressure (17 – 24 psi).
Figure 1-75: 3" Recirculation Line Shut-off Valve

Unit 1
1.4.4 Simulating the Recipe

Before each job, the operator should simulate the recipe to ensure both the actual bulk
delivery, and the bulk delivery set-point, are within the proper range. Follow the
procedure below to simulate the recipe:
1. Properly place the recipe for the job on the PLC screen.
2. Make sure that the program mode is selected in the mixing function screen.
3. Touch either the mixing water, or the cement, to bring up a pop-up screen.
4. Enter the values for the rate and the density, and touch their correlated
simulation buttons.
NOTE: If the simulation is running, the buttons will appear yellow, and the
simulation will be seen on the mixing water and the cement screens.
5. Press “Start Mixing”.
6. Examine the functions of the bulk cement control valve and the mix water control
valve. Ensure there are no erratic and irregular movements of both valves.
7. Compare the actual bulk delivery and the bulk delivery set-point, making sure the
values are within range.
8. Associate the correlation explained in step 5, with the one explained in step 6,
and make a decision if the PLC is working properly for either of them.
NOTE: Make sure that both simulations are turned off before starting the job.

Unit 1
1.5 On-job Procedures

After the pre-job preparation is all finished, attend an operational and safety meeting
with all the personnel on location. Get a radio from the supervisor, after the safety
meeting. Using the radio, the operator is able to communicate with other crew regarding
the progress of the job.
1.5.1 Checking the Instrumentation, Bulk Cement Control

Valve, and Centrifugal Pumps
Before initiating the mixing process, check the instrumentation, bulk cement control
valve, and centrifugal pumps to make sure all functions are properly working. Use the
“Process Variables” screen to view all the parameters.
1.5.2 Bulk Unit/P Tank Operation

The bulk unit or “P” tank operator must always be in communication, with the SCM
operator, to ensure proper procedures are followed and that the SCM operator is fully
aware of the bulk status.
1.5.2.1 Bulk Unit Valve Operation

To position the valves, perform the following:
1. Check and make sure the cyclone supply valve (Figure 1-76) is closed, at all
times.
2. Air up the bulk unit, to a maximum of 40 psi, and maintain this constant pressure
for the proper pneumatic flow of bulk cement to the SCM unit.
3. Turn the canvas valves (Figure 1-77) to ¾ open to ensure proper aerating of
cement.

Unit 1
Figure 1-76: Cyclone Supply Valve
Figure 1-77: Valves

Unit 1
4. Place the top air valve (Figure 1-77) to ½ open for constant flow of bulk.
5. Check and make sure the purge valve (Figure 1-77 and Figure 1-78) is closed, at
all times during the job, unless bridging occurs.
6. To reduce bridging effects and ensure proper constant bulk flow, slowly open the
pod valve (Figure 1-78) to fully open, so that the desirable mixture of air and bulk
flow to the SCM unit can be acquired. Keep the pod valve at fully open, until
switching the pods is required.
Figure 1-78: Pod Valve and Purge Valve

Unit 1
To switch the pods, perform the following:
1. When there is approximately one ton of cement left in the pod, switch pods for
smooth operation of bulk cement flow. Another indication that a pod is getting
close to empty is the excessive amount of air found coming from the 4" vent line
on the SCM unit (Figure 1-79).
NOTE: The bulk unit operator should let the SCM operator know when there is
only one ton of bulk cement left, to ensure that the proper slurry density is
maintained.
Figure 1-79: 4" Vent Line
2. When switching the pods, fully open the pod valve on the new pod and close the
pod valve halfway on the pod that is almost empty. An indication that the pod is
empty is that the air pressure will fall below 14 psi.
3. Fully close the first pod, when it is empty.
NOTE: Close attention is required to ensure that the empty pod is not left open,
thereby, allowing the pneumatic transfer of air to escape.

Unit 1
To clear the bridging, perform the following:
1. When bridging occurs, that means the bulk cement has stopped being delivered
to the SCM unit, due to insufficient pneumatic transfer. To remove the bridging,
close the pod valve and open the purge valve to allow air to push bridged off bulk
to the SCM unit.
2. If this does not sufficiently push the bulk to the SCM unit then properly disengage
the PTO to the blower. Take off and clear the 8' bulk hose.
NOTE: The PTO must be disengaged to the blower. Ensure that all pressure is
bled from the plumbing before removing the 8' bulk hose.
1.5.2.2 P Tank Operation

To position the valves, perform the following:
1. Air up the “P” tank to maximum 15 psi and maintain, at all times, the proper flow
of bulk cement to the SCM unit.
2. Turn the canvas air valve (Figure 1-80) to ¾ open to ensure proper aerating of
the cement.
3. Check, and make sure, that the purge valve (Figure 1-80) stays closed, at all
times, during the job unless bridging occurs.
4. To reduce the possibility of bridging and ensure proper constant bulk flow, slowly
open the tank valve (Figure 1-81) to fully open, so that the desirable mixture of
air and bulk flow to the SCM unit can be acquired. Keep the pod valve fully open
until switching tanks is required.

Unit 1
Figure 1-80: Canvas Valve and Purge Valve
Figure 1-81: Tank Valve

Unit 1
To switch the tanks, perform the following:
1. Switch to a different tank when the tank being used is empty. An indication that
the “P” tank is getting empty is an excessive amount of air coming from the 4"
vent line (Figure 1-79) on the SCM unit. A reduction in air pressure from the “P”
tank also occurs, at this time.
2. To switch to a different “P” tank, completely open the tank valve (on the new
tank) and close the tank valve (on the empty tank). Ensure that continuous air
flow is maintained, so that no bridging of the bulk cement occurs.
NOTE: The PTO must be disengaged to the blower. Ensure that all pressure is bled
from the plumbing before removing the 8' bulk hose.

Unit 1
1.5.3 Starting the Mixing Process

To start the mixing process, perform the following:
1. Flip the “MASTER WATER”, “MIX WATER VALVE”, and “CEMENT VALVE”
switches, located on the upper control console, to the “AUTO” position. See
Figure 1-82.
Figure 1-82: Valve Switches
2. With the mix water pumps’, the recirculation pump’s, and pressurizer pump’s revs
already preset, and once the curb side Triplex pump is rolling, and the circulation
is acquired in the well, initiate the road side Triplex pump.
NOTE: This scenario is out of the road side displacement tank with the curb side
isolated.
3. Once there is 2 m3 (12.6 bbl) of pre-flush left to pump, in the road side of the
displacement tank, press the “START MIXING” button on the HMI screen.

Unit 1
4. After the “START MIXING” button has been pressed, the mix water rate will
increase. The cement control will not open until the mix water rate is 100 liter/min
(25 gpm). After the cement control valve opens, with the increasing of the bulk
cement delivery, the slurry density will be increasing to the set-point. Refer to
Section 1.6.2.1.10.1.1 Start Mixing/Pause Conditions for more details.
5. Increase the bulk cement delivery so that the density of the slurry increases (as
quickly as possible).
6. After all rates are reading properly, watch the density of the 2" Coriolis flow
meter. Make sure that the bulk control valve is responding properly to the density
changes. Also, check the recirculation pressure on the “process variables”
screen and verify that it is reading 20 psi. If there is not enough back pressure on
the meter, the density will read lower than what the actual slurry density is. To
increase the pressure, adjust the 3" recirculation line shut-off valve two notches
(Figure 1-75) to increase the back pressure to approximately 20 psi. Ensure the
flow is still maintained through the meter.
7. With the valves being set, and the automation working properly, observe the
averaging tank level and adjust the rate trim to raise or lower the slurry height in
the tank.
8. When all the processes are functioning properly, stand back and watch. Make
sure that the bulk control valve is reacting properly to the density changes.
9. When there is the predetermined pre-flush pumped, and sufficient slurry in the
averaging tank, switch from the displacement tanks to the mix tank and
averaging tank.
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10. Always open and then close the valves. Make sure the valves are given enough
time to function before operating another valve.
NOTE: Switching the valves too quickly will cause the pumps to suck air and
jack.
1.5.4 When Slurry is Finished Mixing

When the slurry is finished mixing, perform the following:
1. Flip the mix water valve to the “MANUAL” position (see Figure 1-82 for the
location of the “AUTO/MANUAL” switch) and close the bypass water. Keep the
slurry weight as consistent as possible. Make sure that the density does not get
too high. Additional mix water may be needed.
2. Inform the bulk unit operator to “shut in” the product line. If the slurry weight is
declining to low, then flip the master water valve to the “CLOSE” position (see
Figure 1-83 for the location of the “OPEN/CLOSE” switch).
Figure 1-83: Master Water Valve OPEN/CLOSE Switch
3. Purge the product line.

Unit 1
4. Flip the master water valve to the “CLOSE” position, if it is still in the “OPEN”
position.
5. Once the bulk cement product line is purged, turn off the recirculation pump.
6. Flip the “X-OVER” switch (Figure 1-84) to open the mix tank to the pressurizer
pump.
7. When the mix tank, and averaging tank, are just about to suck air, shut down
pumping.
Figure 1-84: X-OVER Valve “OPEN/CLOSE” Switch
NOTE: Make sure there is constant communication, at all times, between the SCM unit
operator and the bulk unit operator. The bulk unit operator should let the SCM unit
operator know when the cement level in the pod is getting low. The indications include:
excessive air coming from the 4" vent line (Figure 1-79) on the SCM unit, a decline in
pressure on the bulk unit, or the actual bulk delivery on the HMI screen is declining
below the bulk delivery set-point.

Unit 1
1.5.5 Switching from Lead to Tail

To switch from lead to tail, perform the following:
1. Once the lead is finished and the bulk unit operator has purged out the bulk line,
switch from the averaging tank to the mix tank by opening the “X-OVER” valve
(Figure 1-84) and turning the “Averaging Tank Isolation Valve” switch to “CLOSE”
(Figure 1-85).
Figure 1-85: Averaging Tank Isolation Valve “OPEN/CLOSE” Switch
2. Turn off the recirculation pump to allow the mix tank to drain at a quicker rate.
3. Once the mix tank is empty, switch back to the averaging tank and slow down the
Triplex pump rate.
4. Make sure that the “MIX WATER VALVE” and “MASTER WATER” switches are
in the “AUTO” position and press the “NEXT STAGE” button. Make sure to turn
the recirculation pump to 1600 rpm.
5. Once the mix water is flowing, initiate the bulk cement.

Unit 1
6. When the slurry level in the averaging tank is getting low and the tail slurry is at
weight, open the “X-OVER” valve and close the “AVERAGING TANK
ISOLATION VALVE”. Change the weight to the proper slurry density.
7. Pump out of the mix tank until the slurry is flowing over the weir and filling up the
averaging tank.
8. When the averaging tank is full enough so that the down hole pump will not suck
air, switch back from the mix tank to the averaging tank by closing the “X-OVER”
valve and opening the “AVERAGING TANK ISOLATION VALVE”.
9. Pump the tail slurry.
1.5.6 Carrying on Mixing Process in Manual Control

To carry on the mixing process, in manual control, perform the following:
1. Flip the “MASTER WATER”, “MIX WATER VALVE”, and “CEMENT VALVE”
switches to the “MANUAL” position.
2. Set the mix water to the desired rate.
3. Adjust the density of the slurry with the bulk control valve. Make minor
movements, as reaction to the changes can be very drastic.
4. Once the valve is in the “Sweet Spot”, usually only minor adjustments will be
needed.

Unit 1
1.6 HMI Program Operation (U.S. Units)

1.6.1 Initial Operation
The initial operation steps are as follows:
1. Turn on the Master Power Switch.
2. Turn on the Instrumentation Power Switch. This switch turns on the PLC, HMI,
instrumentation and DC components. The HMI automatically boots up to the
previous settings and information. This would be either US or Metric units, and
also be the recipe data that had been previously saved.
3. Double check to see if all the information is entered correctly.
4. Simulate the cement recipe to ensure the recipe provided will give the
appropriate results.
5. Make sure that the simulation mode is turned off, immediately following this
check.

Unit 1
1.6.2 HMI Screens

1.6.2.1 Main Screen
Figure 1-86 shows the main screen display.
Figure 1-86: Main Screen
The main screen contains the following fields:
• Mix Water Control with Master • Stage Information
Water Valve Status Indicator • Centrifugal Pump rpm
• Cement Control • Stage Adjustment
• Discharge Pressure with Over • Cement Recipe Data
Pressure Trip Point • Function Buttons
• Message Box • Flex Area

Unit 1
The function of each field listed previously is described in the following subsections:
1.6.2.1.1 Mix Water Control
The mix water control circuit consist of two paths. When the
master water valve is opened, it supplies water directly to the
mix head. The flow rate to the mix head is approximately 66
gallons per minute.
It also supplies water to the recirculation loop through a
hydraulically actuated mix water control valve. This valve adds
up to 317 gallons per minute of water. This means that a mix
water rate of approximately 383 gallons per minute can be
Figure 1-87: Mix Water achieved.

Control Field
The mix water control field (Figure 1-87):
• Controls the mix water valve.
• Calculates the mix water rate set-point for desired mixing rate.
• Shows the actual rate of mix water through the magnetic flow meter.

Unit 1
It also contains the following:
• Bar graphs that indicate loop status, control output and valve feedback
o LE (Load Error) displays load error between rate set-point and actual rate
▪ Plus/minus 5% – Green, Plus/minus 5-7% – Yellow, Plus/minus 7-
10% – Red
o VP (Valve Position) displays the valve position (0 – 100 % of valve travel)
▪ Blue bar indicates the actual valve position
▪ Pink bar indicates the PLC command
• Master Water Valve Status Indicator
o Green – Open
o Yellow – Fault in valve – Not opened/Not closed
o Red – Closed
• Square background flashing “Warning” shows the water rate is too low
Pressing the bar graphs opens the Control Valve Calibration screen (Figure 1-88) in the
Flex Screen. This screen contains calibration parameters for the mix water valve.
Detailed characteristics, and settings, are accessed via the Tuning Screen.
Figure 1-88: Control Valve Calibration Screen

Unit 1
1.6.2.1.2 Cement Control
The cement control field (Figure 1-89) displays the density
set-point and the measured density, in the mixing side of the
process. Control of the cement valve is based on the bulk
delivery rate and the set-point. A bulk delivery rate is
automatically calculated using the mix water rate set-point, the
actual density, and the density change rate.
Figure 1-89: Cement

Control Field
It also has:
• Bar Graphs
o LE (Load Error) displays the load error between density set-point and
actual density.
▪ Plus/minus 5% – Green, Plus/minus 5-7% – Yellow, Plus/minus 7-
10% – Red
o VP (Valve position) displays the valve position.
▪ 0 – 100 % of valve travel
▪ Blue bar indicates the actual valve position
▪ Pink bar indicates the PLC command
• Background flashing “Warning” shows the density is too high

Unit 1
Pressing the bar graphs opens the Control Valve Calibration screen (Figure 1-90) in the
Flex Screen. This screen contains calibration parameters for the cement valve control.
Detailed characteristics and settings are accessed via the Tuning Screen.
Figure 1-90: Mix Water/Cement Valve Calibration Screen

Unit 1
1.6.2.1.3 Discharge Pressure
The discharge (treating) pressure field (Figure 1-91):
• Displays pressures in digital formats.
• Displays the “Over Pressure Trip Points”.
Figure 1-91: Discharge Pressure

Field
Pressing the numerical value, for each pressure, opens detailed screens (Figure 1-92
and Figure 1-93) in the Flex area. To change the “Over Pressure Trip Point”, press on
the current set-point and the number pad will appear for entering the new over pressure
set-point. Press “Esc” if you do not want to change the value.
NOTE: When the over pressure set-point is exceeded, the throttle will go to low idle and
the transmission will shift to neutral for the associated engine, transmission or pump.
The over pressure trip point field will flash red, when active. The actual pressure must
be lower than the over pressure trip point, to be able to reset the system. Before doing
this, press the throttle in (to reset to low idle). The transmission should always be shifted
from neutral to 1st at a low idle rpm. After the system is reset, resume the normal
operations.

Unit 1
The screens below (Figure 1-92 and Figure 1-93 ) allow you to do the following:
• Calibrate the electronic pressure transducers
• Adjust the upper limit on the analog gauge
• Apply dampening to the raw signal
• Reset the “Over Pressure Trip”
Figure 1-92: Treating Pressure Road Side Screen
Figure 1-93: Treating Pressure Curb Side Screen

Unit 1
1.6.2.1.4 Message Box
This box (Figure 1-94) displays error or warning messages from the control system. The
messages only display for a few seconds and then go into the message log.
Figure 1-94: Message Box
1.6.2.1.5 Stage Information
The stage information field (Figure 1-95) shows
the following data about the job:
• Down hole Rate
• Stage Total
• Job Total
• Down hole Density – 4" Coriolis

Figure 1-95: Stage Information Field
• Bulk Delivery Set-point
• Bulk Delivery – Actual (calculated)
• Surge Can (Tank)
NOTE 1: The Zero Stage Total button is only for
zeroing the stage total value.
NOTE 2: Click on “SURGE CAN” to open the
surge can set-up screen in the Flex area.

Unit 1
1.6.2.1.6 Surge Can (Tank) Weight Indicator
The surge can weight indicator (Figure 1-96) provides a weight and tare function for the
vessel. The hydraulic load cell is positioned under one leg of the vessel and measures
50% of the total weight.
Figure 1-96: Surge Can Weight Indicator Screen

The surge can weight indicator screen fields are:
• Tare
o The tare function provides a method of zeroing the weight of the vessel.
Any product added to the vessel will be weighed and displayed.
• Default
o If you have tared the vessel mistakenly, you can return to the default,
which will remove the tare offset and will once again display the weight of
the vessel.
• Load Cell Max

Unit 1
o This is the measurement rating of the load cell in kilograms. It is based on
the manufacturer’s specification sheet.
• Factor
o The weight measured under the one leg represents 50% of the total
weight. The factor multiplies the weight by 2 to display the actual weight
measured.
1.6.2.1.7 Pump (RPM’S)
The pump RPM’S field (Figure 1-97)
displays the rpm values for the four
centrifugal pumps. If the backgrounds are

Figure 1-97: Pump RPM’S Field
green, the revs are at the recommended
values. If the backgrounds are red, the
revs are too high. If the backgrounds are
yellow, the revs are too low.

Unit 1
1.6.2.1.8 Stage Adjustment
The stage adjustment field (Figure 1-98) contains
the Rate Trim and Density Trim.
Figure 1-98: Stage Adjustment Field
The stage adjustment field shows the following:
• Rate Trim
o Initially set to the programmed rate in the current recipe stage. It is for use
during the job for adjusting the mixing rate. The down hole rate is
manually controlled using the gears (rpm) or each pump.
• Density Trim
o Initially set to the programmed density in the current recipe stage. It is
used during mixing to adjust for the difference between the mud (or
pressurized scales) and the density reading.

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1.6.2.1.9 Cement Recipe Data
This section (Figure 1-99) contains the input
boxes for the recipe data needed for the
different cement blends for the job.
Figure 1-99: Cement Recipe Data Fields
It includes the following input boxes:
• Rate – Mixing rate of slurry
• Density – Desired density of slurry

Figure 1-100: Enter Key
• Yield – Yield of slurry
• Water Req. – Mix water of slurry
• Sack Weight – Net weight per sack of dry bulk cement.
1.6.2.1.9.1 How to Change the Recipe Data
To change the Recipe Data, press the variable you want change. The screen is a touch
screen. Once the box is selected, a number pad (Figure 1-101) will appear on the
screen. This will allow you to change the data in the input boxes. Once the data in the
input box is changed, press the “ENTER” key (Figure 1-100) and the number pad will
disappear. It will reappear every time that a variable is selected. When the new recipe
has been entered, and is correct, then press the “SAVE” button in the middle of the
bottom of the recipe box.

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A message will appear in the message window indicating that the data has been saved.
If the job has only one type of slurry, then input the recipe into the program. To do this
either a) press the “SAVE” button again and press “YES” to overwrite the data again, or
b) press the “NEXT STAGE” button on the top right corner of the screen once.
Let the 2nd recipe come up and then press the “PREVIOUS STAGE” button just below
the “NEXT STAGE” button. This inputs the data into the program by making it disregard
the old recipe and retrieve the new recipe.
Figure 1-101: Main Screen with Input Number Pad

Unit 1
When there is a 2nd recipe, just press “NEXT STAGE” button on the bottom of the recipe
input box and it will read “STAGE 2” on the top of the recipe box. Enter the new recipe
for the 2nd slurry by following the same procedures as for the 1st slurry. The only thing
that will be noticed with the program is that when you press the “SAVE” button and
overwrite the previous recipe, the program automatically changes to the most current
saved stage.
So when saving the 2nd recipe, and before starting the job, make sure that on the top
right hand corner of the screen, it reads “STAGE 1” or the proper stage is needed. If the
incorrect stage is selected, press the “PREVIOUS STAGE” button or “NEXT STAGE”
button to select the desired stage. When you press the “NEXT STAGE” or “PREVIOUS
STAGE” buttons, on the upper right hand side of the screen, the recipe box on the
bottom right automatically changes to correspond to the stage selected.

Unit 1
1.6.2.1.10 Function Buttons
The function buttons field (Figure 1-102) contains nine function
buttons.
• Start Mixing/Pause
• (Going to) Next Stage
• (Going to) Previous Stage
• System Diagnostic
• System Tuning
• Screen Lock
• Mixing Functions
• Process Variables
• Trend Graphs
NOTE: Also displayed is the version number of the software as well
as the data logging status.
Figure 1-102:
Function Buttons
Field

Unit 1
The function of each button is explained below.
1.6.2.1.10.1 Start Mixing/Pause Button
This function starts mixing the slurry based on the current stage information. When
pressed, the mix water pump must be over 2000 rpm and the recirculation pump must
be over 1500 rpm. The bulk control, mix water and master water valves must be set to
“automatic” on the toggle switches on the operator panel. If they are not, a message
will appear in the message box and mixing will not start. If all the parameters are met,
and mixing starts, the button will turn green in color. Initially, to pause the process,
press the button again and it will close the water and bulk valves.
NOTE: When you engage the “Start Mixing” function after the pause has been pressed,
the program does not go to the previous position. It goes to the calculated positions and
the water valve slowly opens to the calculated position.
1.6.2.1.10.1.1 Start Mixing/Pause Conditions Summary
There are conditions that must be met for the following:
• Mixing Function
o Mix water valve “AUTO/MAN” switch set to “AUTO”
o Cement valve “AUTO/MAN” switch set to “AUTO”
o Master water valve switch in “AUTO” or “MAN” but valve must be open
o Mix water centrifugal pump operating at 2200 rpm (minimum allowable is
1200)
o Recirculation centrifugal pump operating at 1600 rpm (minimum allowable
is 1200)
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o If any “simulation” is active (density or rate), the above conditions are
overridden and the system will go into the mixing mode. This is because
the simulated values are typically used for testing.
• Automatic Corrective Actions
o With the system in “AUTO” and mixing, if the mix water rate drops below
50 liter/min (12.5 US gpm), the water valve area flashes.
▪ If the condition lasts more than 3 seconds, the cement valve will
close.
▪ If the system is in “MAN”, the cement valve will not close as it is
assumed the operator requires this low flow rate.
o After “Start Mixing” is active, the cement valve will not open until the mix
water rate is 100 liter/min (25 gpm US) or higher.
• Alarms/Notifications
o If the recirculation density is 200 kg/m3 (1.7 lb/gal) higher than the
set-point, the cement valve area on the HMI screen flashes.
o During mixing, if the cement valve is 100% open and the density is 30
kg/m3 (0.25 lb/gal) lower than the set-point, the bulker symbol on the
“Process Variables” page flashes (orange/grey).
o If the recirculation pressure is less than 20 psi, the value flashes.
o If the down hole Triplex pump’s boost pressure is less than 30 psi, the
value flashes.

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o The Coriolis meter symbols on the “Process Variables” page (Figure
1-107) are color coded according to the amplitude of the excitation current
signal.
▪ Green (0 – 18 ma)
▪ Orange (18 – 50 ma)
▪ Red (50 – 94 ma)
▪ Red Flash (94 – 100 ma)
• The centrifugal pump symbols are color-coded dependent on the rpm. See
“Process Variables” details for more information.
1.6.2.1.10.1.2 Next Stage and Previous Stage Buttons
These buttons change the stage recipe that is read by the program. The stage recipe
that is being read is shown on the top of the stage information area. Also, the “Cement
Recipe Data” changes to correspond to the stage read by the program.

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1.6.2.1.10.1.3 System Diagnostic Button
Pressing this button opens the System Diagnostic screen (Figure 1-103), which assists
with troubleshooting problems. This screen displays raw input, and output, signals from
the system. From this screen the operator can also change units or access the
“archiving data” function.
Caution
These functions should only be accessed by qualified personnel. Incorrect usage could result in
data loss or equipment malfunction.
Figure 1-103: System Diagnostic Screen

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1.6.2.1.10.1.4 System Tuning Button
This button brings up the screens used for system tuning. There is a system tuning
page for each of the control loops – water and cement (Figure 1-104 and Figure 1-105).
This area is for an electronic technician to view process response characteristics, while
making changes to the loop tuning settings.
Warning
Risk of substantial equipment damage or serious personal injury
The tuning variables should only be modified by qualified personnel. Minor changes to the
variables can have major effects on the control characteristics.
Figure 1-104: Mix Water Loop Control Screen

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Figure 1-105: Bulk Cement Valve Loop Control Screen
1.6.2.1.10.1.5 Screen Lock Button
This button is pressed when you need to clean the screen. It will produce a blank
screen with a bar graph that acts as a count down timer. This allows the operator to
clean the screen without activating any functions.
NOTE: When this function is used it will disable the screen for 10 seconds.

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1.6.2.1.10.1.6 Mixing Functions Button
This button opens the “Mixing Functions” screen (Figure 1-106) in the Flex area. The
screen contains items that determine how some pre-mixing functions will be controlled.
It contains three buttons and four drop boxes which are:
• “Start/Stop Water” Button
• “Start Cement” Button
• “Reset Job” Button
• “Water Valve Initial Position” Drop Box
• “Cement Valve Initial Position” Drop Box
• “Down Hole Rate” Drop Box
• “Control Reference” Drop Box
Figure 1-106: Mixing Functions Screen

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These features are designed for mixing an initial batch of slurry to weight before
engaging the “Start Mixing” function. With the start tub level set at 80%, the program
would calculate the required mix water needed to have the initial batch of slurry
occupying 80% of the mix tank. The calculations are based on the data entered in the
selected stage. See below for the functions of the buttons and boxes.
“Start/Stop Water” Button – This function opens the master water valve, and the mix
water valve, fully until the required mix water (REQ) matches the actual mix water
(ACT). Once the actual mix water matches the required mix water, the valves close and
a checkmark appears on the left side of the “Start/Stop Water” button.
“Start Cement” Button – Once the system verifies that the required mix water has
been delivered to the mixing tank; it allows the operator to activate the “Start Cement”
button. At this point, the operator would be circulating the mix side at the specified rpm.
When the “Start Cement” function is activated, the bulk cement valve travels to 60%
open. It remains there until the density in the mixing tank equals the programmed
density set-point. Once the density is reached, it would close the valve or the operator
would press “START MIXING” and the program would take over.
“Reset Job” Button – This button resets the program for a new job, puts the program
back to stage 1, and resets all the totals to zero.

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“Water Valve Initial Position” and “Cement Valve Initial Position” Drop Boxes –
Either of the two valves can be initially set to open, to a calculated position, based on
cement blend parameters. The other method is to have the valve initially go to a
manually entered position. This manual setting is adjusted by entering the desired
percentage position in the water or bulk cement control valve position box.
“Down Hole Rate” Drop Box – The down hole rate drop box has two different options
– “Mass” and “Pumps”. This is the down hole rate that is displayed on the “Stage
Information” area of the screen. This also affects the “totalizer” with how it calculates the
total pumped. “Mass” is the 4" Coriolis mass flow meter and “Pumps” is the combined
rates of the Triplex pumps. Most often, this is set to “Mass” to read the actual flow of
fluid to the pumps. This helps the operator notice if the pumps are jacking, or partially
bridging off, by the difference in flow to the pump rate. The only time that “Pumps”
would need to be selected is if the fluid is very aerated that the Coriolis does not read
properly or if the operators are pumping through the short suction and no fluid is flowing
through the Coriolis.
“Control Reference” Drop Box – This is specifically for the mixing rate. The two
choices are “Program” and “Pump” rates. “Program” rate is the rate set by the recipe or
is changed with the rate trim. “Pump” rate is the mixing rate corresponding to the rate
that is being pumped down hole. The best way to start mixing is in the “Program” rate,
because when pumping the pre-flush the operator may need to slow down the pumps
for the mixing system to build-up enough slurry in the averaging tank (to start pumping)
or to reach the proper level in the tank.

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1.6.2.1.10.1.7 Process Variables
Pressing this button opens the “Process Variables” screen (Figure 1-107). This screen
contains all the pertinent information for the mixing system and the high pressure
pumping system in a flow diagram (as to the unit).
Figure 1-107: Process Variables Screen
This screen contains the following information:
• Master Water Valve Position
o Green – Open
o Yellow – Not open/Not closed/Stuck in the middle
o Red – Closed

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• Magnetic Flow Meter Rate (gal/min)
• Mix Water Control Valve Position (%)
• Cement Control Valve Position (%)
• Mix Water Centrifugal Pump RPM - Curb and Roads
o White 0 – 1200 RPM
o Yellow 1201 – 2000 RPM
o Green 2001 – 2300 RPM
o Red 2301 – 5000 RPM
• Recirc Pump RPM
o Background Color
▪ White 0 – 1200 RPM
▪ Yellow 1201 – 1500 RPM
▪ Green 1501 – 1700 RPM
▪ Red 1701 – 5000 RPM
• Pre-charge or Pressurizer Pump RPM
o White 0 – 500 RPM
o Yellow 501 – 1000 RPM
o Green 1001 – 1400 RPM
o Red 1401 – 5000 RPM
• Auxiliary Rates and Pressure (psi)
• Triplex Pump Rates (bbl/min)

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• 2" Coriolis
o Density (lb/gal)
o Rate (bbl/min)
o Temperature (Fahrenheit)
o Pressure (psi)
• 4" Coriolis
o Density (lb/gal)
o Rate (bbl/min)
o Temperature (Fahrenheit)
• Process Pressures
o Mix Water Line Pressure at Mix Head
▪ 0 – 160 psi
o Recirc Line Pressure at Mix Head
▪ 0 – 160 psi
o High Pressure Triplex Pump Boost Pressure

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Pressing the “Calibration Data” button opens the “Calibration Data” screen (Figure
1-108). This screen allows you to enter in the calibration factors for:
• High pressure down hole pumps
• RPM for centrifugals
• Auxiliary inputs on side of unit
Figure 1-108: Calibration Data Screen

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Pressing the “Auxiliary Pressure Data” button opens the “Auxiliary Pressure Data”
screen (Figure 1-109). This screen allows you to enter in ranges for process pressure
transducers as well as a dampening factor.
• Use “Zero” function to offset readings at zero pressure.
• If “Zero” function is used (when the line has pressure), “Default” can be used to
return the transducer to factory defaults.
o 4 – 20 ma = 0 – 160 psi
Figure 1-109: Auxiliary Pressure Data Screen

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Pressing the “Aux Press Calib” button opens up the “Auxiliary Pressure” faceplate
(Figure 1-110). This faceplate is used to setup, and calibrate, the auxiliary pressure
transducer, and dampen the raw pressure signal, if it is required.
• “Zero” function is used to correct measured value at zero psi.
• “Span” function is used to calibrate the transducer to full scale.
• If either of the previous functions are used incorrectly, use the “Default Values”
function to return to the factory setting
o 4 – 20 ma = 0 – 15000 psi
Figure 1-110: Auxiliary Pressure Faceplate

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A condensed screen (Figure 1-111) containing the two Coriolis flow meters’ main values
can be viewed by pressing the middle of the “Process Variables” screen. The screen
can be hidden again by pressing in the same place.
Figure 1-111: Condensed Screen with Coriolis Flow Meters Main Values

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1.6.2.1.10.1.8 Trend Graphs
Pressing this button opens up the options available for viewing during the job (Figure
1-112). These options are:
• Job Data – Rate, Pressures, Density, Bulk Delivery, Bulk Delivery Set-point
• Density – Recirc Density, DH Density
• Rates – Mix Water Rate, 2" Coriolis Rate, Down Hole Rate
• Process Pressure – Mix Head Water Pressure, Mix Head Recirculation Pressure,
2" Coriolis Pressure, 4" Coriolis Pressure
• RPM’s – Centrifugal Pump RPM’s

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Figure 1-112: Main Screen with Trend Graphs Select Options
The data viewed in Figure 1-113 to Figure 1-117 is a 15 minute history of the job. The
data is stored on a memory card in the HMI. It can be retrieved, if necessary, for
detailed job analysis.

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Figure 1-113: Trend Graph 1 – Job Data
Figure 1-114: Trend Graph 2 – Density

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Figure 1-115: Trend Graph 3 – Rates
Figure 1-116: Trend Graph 4 – Process Pressure
Figure 1-117: Trend Graph 5 – RPM’s
1.7 Post-job Procedures

After the cementing job has completed, the operator starts a series of post-job activities,
these including rigging out, cleaning up the SCM high energy mixing system, washing
the high pressure Triplex pumps, washing up the ground mixing system, greasing the
unit, and doing a walk-around inspection.

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1.7.1 Rigging out

Once the pumping job has been completed, the crew starts rig out. To rig out:
• Disconnect the water line between the drilling rig and the SCM unit.
• Disconnect the water line from the water truck to the SCM unit.
• Disconnect the bulk hose from the bulk unit to the surge tank. If the “P” tank is
used, disconnect the bulk hose from the “P” tank to the surge tank and
disconnect the air hose from the blower.
NOTE: Ensure that all air is bled off from the bulk system, prior to disconnecting
the hoses.
• For high energy mixing jobs, disconnect the bulk hose between the mix head and
the surge tank.
• For ground mixing jobs,
o Disconnect the 11/2" and 2" water hoses between the mixing tree and the
mixing bowl.
o Disconnect the 4" riser hose between the mix slurry tub and the mixing
bowl.
o Disconnect the 2" recirculation line, and the 4" suction line, from the
primary skid to the mix slurry tub.
o Dismount the mix slurry tub from the primary skid and place it back on the
iron skid.
• Disconnect the treatment line from the well head equipment.

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• Connect a vacuum truck to the end of the treatment line, to suck out all the slurry
remaining in the Triplex pumps, via a 3" hose.
• After the Triplex pumps have been vacuumed, rig out the treatment line.
1.7.2 Cleaning up the High Energy Mixing System

It is very important to clean up the mixing system, after each job. Without a thorough
clean up, cement can build-up rapidly around various areas of the mixing system. Given
time, this build-up can cause serious restrictions in the slurry, and dry cement, flow. It
can also result in the slurry being mixed too slowly or it can cause the whole mixing
system to stop functioning.
Once the cementing-mixing process has completed, immediately clean up the unit
following the procedure below. This ensures that the unit will perform properly on the
next job. The clean up steps are:
1. Turn the “MIX WATER VALVE” and “MASTER WATER” switches from the
“AUTO” position to the “MANUAL” position.
2. Turn the mix water valve and the bulk cement valve to the “Close”.
3. Close the 2" mix water valve to the mix head. This ensures that all the water is
supplied to the wash up valve, when the master water valve is opened. Open the
master water valve.
4. Open the wash up valve as desired.
NOTE: To use the wash up valve, the master water valve must be open.

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5. Close the 2" mix head water line shut-off valve to the mix head. This ensures that
all the water is supplied to the wash up valve. To use the wash up valve, the
master water valve must be open.
6. If possible, rinse down the mix and averaging tanks while they are still warm and
the fluid on the walls is not dried. This speeds up the wash up.
7. Open the lid of the cyclonic chamber and wash it off. Also, wash under the 180°
lip on the mix tank.
8. Hammer loose the union, for the mix head, and tilt it back.
9. Rinse down the bulk cement sleeve.
10. Remove the bulk cement sleeve and wash off the bottom of the jets.
11. With the sleeve removed, check the jets to ensure that they are not plugged off
with debris. Also, check the condition of the mix water diffusion plate and make
sure it is not damaged.
12. Inspect the o-rings and ensure that they are not damaged or cut.
13. Wash the inside of the mix head.
14. Drain both the mix tank and averaging tank, and rinse out the bottoms.
15. Isolate the averaging tank, by closing the “AVERAGING TANK ISOLATION
VALVE”, so that no fluid will come back through the drain and close the
averaging recirculation line.
16. Open the automated “WATER CONTROL VALVE” to flush the recirculation lines.
This will also fill up the mix tank.
17. Once the mix tank is half full, turn on the recirculation pump.

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18. Fully open, and close, the 3" recirculation line shut-off valve to flush thoroughly.
19. With the recirculation pump on, open and close the 4" isolation manual valve to
ensure there is no cement build-up (Figure 1-118).
Figure 1-118: 4" Isolation Manual Valve
20. Shut off the recirculation pump. Open the “X-OVER VALVE”.
21. Open the recirculation line to the averaging tank, and once flowing, open the
“AVERAGING TANK ISOLATION VALVE”.
22. The recirculation of the averaging tank may need to be flushed, a few times until
it is clean.
23. Once the mix tank and averaging tank are clean, drain the remaining water.
24. At the end of the job, hammer off the suction caps to ensure there is no slurry
debris. This will make certain that there are no restrictions or problems for the
next job.
25. Open all the valves and drain ports.

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1.7.3 Washing the High Pressure Triplex Pumps

Follow the steps below to wash the high pressure Triplex pumps:
1. Close the discharge valves.
2. Shift the transmission to the 5th gear. Flush back to the displacement tank.
3. Open the displacement side pressurizer pump isolation valve (see Figure 1-119
for the location of the switch) and the high pressure return valve (see Figure
1-120 for the location of the switch).

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Figure 1-119: Displacement Side Pressurizer Pump Isolation Valve Switch
Figure 1-120: High Pressure Return Valve Switch
4. Turn on the pressurizer pump. Turn on one of the Triplex pumps, returning back
to the curb side displacement tank.
5. Open the short suction valve (Figure 1-121 and Figure 1-122) for 2 to 3 seconds
and close. Repeat 6 to 8 times, ensuring that the valve is free of debris.

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Figure 1-121: Short Suction Valve and 4" Suction Figure 1-122: Short Suction Valve and 4" Suction
Caps (on road side) Caps (on curb side)
6. Repeat steps 2 and 3 with the second Triplex pump.
7. Drain all the tanks to a vacuum truck or back to a pit.
8. Hammer off all the 4" suction caps (Figure 1-121 and Figure 1-122) and push the
valves of the Triplex pumps to drain all water from the pumps.
1.7.4 Washing up the Ground Mixing System

Follow the steps below to wash up the ground mixing system:
1. Wash the outside of the mixing bowl and the hopper.
2. Take off the hopper and clean up the mixing bowl.

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NOTE: Make sure the 2" water line and 11/2" bypass water line are cleaned, to
free all cement slurry debris.
3. Run the 2" water line to clean all the debris up to the riser hose and into the mix
slurry tub.
4. Wash the mix slurry tub. Make sure the inside of the mix slurry tub lip, and
suction, is washed. Ensure that the mix slurry tub is cleaned outside and inside.
5. Suck out the rest of water through the pressurizer pump and hammer off the 4"
cap to drain the rest of water from the tub (Figure 1-123).
Figure 1-123: 4" Cap on Mix Slurry Tub
1.7.5 Greasing the Unit

After the unit is cleaned up and drained of the remaining fluid, grease the four
centrifugal pumps. To grease the centrifugal pumps, pump 3 to 4 shots of grease while
the pumps are rotating.
There are some valves that need to be greased including:

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• High pressure return valve
• 2x2 plug valves on the discharge iron
• Hydraulically actuated mix water valve
• Neutron valves on the mixing tree (if the ground mixing is used)
o 2" jet hose valve
o 11/2" bypass valve
o 1" wash up line valve
For the greasing procedure of the plug valves, refer to Section 2.10.1.2.1 Plug Valve.
Follow the procedure below to grease the neutron valves:
1. In the “open” position, pump 2 to 3 shots of grease.
2. Close, and open, the valve two times.
3. Repeat steps 1 and 2 once again.
1.7.6 Doing a Walk-around Inspection

Before leaving the lease, do a walk-around inspection of the unit to ensure that:
• All the items that came off the unit go back onto the unit.
• All the pins are in place and the equipment is secure.
• All the suction and discharge ports are capped.

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• The main power is disengaged.
• All the valves and drain ports are open.
• All the hammers are inspected for cracks in the handles or other aspects that
could make them break.
• All the swivel joints have been greased (this should be done weekly).
• The unit is clean inside and outside before it is handed over to the next crew.
NOTE: If any problems are found that need to be resolved by the mechanics, report the
problems to them quickly. The mechanics can then inspect the unit, prior to the next
job.

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2.0 SCM W/MK IV AT INTERNATIONAL

SKID MAINTENANCE
2.1 Objectives
The objectives specify what you should know and the tasks you should be able to
perform by the end of the unit.
Upon completion of the unit you will be able to:
• Identify the requirements for conducting routine maintenance.
• Perform routine maintenance correctly and properly.
2.2 Introduction
SCM W/MK IV AT (abbreviated as SCM) International skids are all constructed at the
Sanjel fabrication shop. These skids are operated and maintained by a supervisor and
an operator. All SCM units have been designed to operate with high efficiency and high
durability. It is important that these units are maintained following a simple maintenance
schedule, so they will continue to operate effectively for many years.
In this section, first, Sanjel’s routine maintenance schedule and general maintenance
requirements for the SCM skid will be introduced. Then the unit will be broken down into
a series of single components to be described in terms of their maintenance.

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2.3 Maintenance Interval Schedule

Sanjel’s regular maintenance elements for the SCM units consist of 250 hour
inspection, monthly maintenance, quarterly maintenance, and annual maintenance.
2.3.1 250 Hour Service Inspection

A 250 hour service inspection must be performed by the crew on the unit, with a
licensed mechanic’s help, if required. This inspection report must be turned in to the
maintenance personnel and a copy should be left in the unit. Refer to Sanjel’s “250
Hour Vehicle Inspection Report” to conduct the inspection (Table 2-1 to Table 2-3).
NOTE 1: The “250 Hour Vehicle Inspection Report” sheets contain references to
vehicle (tractor/trailer) equipment. This vehicular information is included because there
may be tractors or trailers used to transport the SCM skid, at some future date.
NOTE 2: The “250 Hour Vehicle Inspection Report” sheets are provided here as
examples only. These sheets should not be used as the actual checklist forms, unless
there are no other options. In cases where there are no proper forms available, make
copies of the sheets provided here (you may have to resize the pages to fill them out).
After copying, ensure that the original pages are put back into the manual.
2.3.2 Monthly Maintenance

The monthly maintenance must be performed by the crew on the unit, assisted by a
licensed mechanic. When performing the monthly maintenance, fill out Sanjel’s “Monthly
Maintenance Log” each time work is done. This log must be turned in to the
maintenance personnel and a copy should be left in the unit. See Table 2-4 for an
example of the “Monthly Maintenance Log”.

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Table 2-1: 250 Hour Vehicle Inspection Report (Part 1)

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Table 2-4: Monthly Maintenance Log

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2.3.3 Quarterly Maintenance

A major equipment inspection must be performed at regular intervals, not exceeding
three months or 50,000 km (32,000 miles) on the unit. The inspection is carried out by a
licensed mechanic with help from the operator and supervisor. The mechanic is
responsible to insure that the inspection is done properly. The mechanic, in consultation
with the camp management, determines what course of action is taken on items
requiring major repairs. Follow Sanjel’s “Quarterly Inspection Report” sheet to perform
the maintenance. The sheet should be handed in to the maintenance personnel once
the work is done. Refer to Table 2-5 to Table 2-8 for examples of the “Quarterly
Inspection Report” sheets.
NOTE 1: The “Quarterly Inspection Report” sheets contain references to vehicle
(tractor/trailer) equipment. This vehicular information is included because there may be
tractors or trailers used to transport the SCM skid, at some future date.
NOTE 2: The “Quarterly Inspection Report” sheets are provided here as examples
only. These sheets should not be used as the actual checklist forms, unless there are
no other options. In cases where there are no proper forms available, make copies of
the sheets provided here (you may have to resize the pages to fill them out). After
copying, ensure that the original pages are put back into the manual.
2.3.4 Annual Maintenance

The annual maintenance is to be performed by a mechanic with the help of the
operator, if needed. The “Quarterly Inspection Report” sheet is also used as the annual
maintenance sheet.

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Table 2-5: Quarterly Inspection Report (Part 1)

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2.4 Commissioning the Skid

This section provides examples of the checklists (forms) used to commission the SCM
skid. Refer to
Table 2-9 to Table 2-34 for examples of the “Commissioning Document” sheets (26
pages).
NOTE: The checklists provided in this section are examples only. Please refer to the
Sanjel SCM Commissioning Document, which resides on Sanjel’s Intranet website, for
the proper checklists (along with a number of other forms available for download).

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Table 2-9: Commissioning Document (Page 1)

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2.5 General Maintenance Requirements

Every piece of equipment starts to wear out as soon as it is put to work. Some type of
maintenance is always required. With regular inspection and efficient maintenance, the
equipment will always be reliable.
Regular lubrication and inspection of the parts of a unit is the most cost effective
method of obtaining safe and reliable unit operation. Sanjel has developed a scheduled
maintenance program for all units, ensuring that every unit operates properly when
called upon, thereby reducing unit downtime.
2.5.1 Major Equipment Inspections

The major equipment inspection tasks are as follows:
• The crew on the unit must perform a 250 hour service, assisted by a mechanic if
necessary.
• A major equipment inspection must be performed at regular intervals every three
months or at 50,000 km (32,000 miles) on all units. A mechanic performs the
inspection, with assistance from the driver, operator, and supervisor. The
mechanic ensures the inspection is done properly and determines, after
consultation with camp management, the appropriate course of action on items
requiring major repairs.
• A work order (Table 2-35) is completed for every inspection, detailing actions
taken on major repairs. The maintenance department keeps the work order as a
record.

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Table 2-35: Work Order

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The maintenance department also ensures the inspection is properly performed and
takes follow up action on rejected items. The maintenance department updates the
maintenance log book and wall chart, and keeps the documents in the unit's file.
Modifying units is not acceptable, unless absolutely necessary for job completion.
Modification requirements are:
• Modifications made to the vehicle must be properly fixed and the vehicle
restored to its original state when returned to the shop.
• All permanent modifications must be authorized through the maintenance,
engineering, and operation departments. Modifications that enhance or simplify
duties will be reviewed and applied to all units in the fleet, if approved.
2.5.2 Service and Grease

The unit must be greased twice per week.
2.5.3 Oil Analysis

All large engines are to be on an Oil Analysis program. The purpose of oil analysis is to
gain information about the condition of the oil itself, or the condition of the component
from which the oil was removed. This information can then be used to reduce
unscheduled equipment downtime, determine oil change intervals and increase
equipment or component life.
Engine oils are to be sampled and changed every 250 hours +/- 10%. The shop
mechanic co-ordinates the program and supervises taking the samples. An approved
sampling device should be installed on all the engines. Dates and hours (or miles) are
tracked on the reference board.

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The "oil added box" is the total oil added between oil changes, not the amount of oil
added at the oil change. When completing the unit number, add suffixes.
NOTE: If more than 3.785L (1 gallon) of oil is added between oil changes, report this to
the maintenance department.
2.5.4 Obtaining an Oil Sample

Follow the procedure below to obtain an oil sample:
1. Attach the oil drain pipe from the oil pan to the oil drain pan.
2. Allow the oil to flow out of the oil drain pipe for one minute to permit the oil to
clear the drain pipe of any debris or oil left from other trucks.
3. While oil is still flowing, take the oil sample directly from the flowing hose, not
from the drain pan.
Key Action Items

3 All units must be greased twice per week.
2.5.5 Lubrication Change Period

Refer to Table 2-37: Lubrication Sheet to determine what types of lubricant should be
chosen when performing lubrication changes.
2.5.5.1 Hydraulics – Oil and Filters

The maintenance tasks are as follows:
• Change the oil filters once per year. If changing for regular maintenance be sure
to cut open the filters to see if any metal is present. This could possibly tell of a
failure starting.

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• Change the hydraulic oil once every other year. Filter the oil with the filter cart
opposite the oil change year.
• Inspect the oil and filters for contaminants, at the year when the oil is changed.
• Table 2-36 gives an example to specify the years of the oil and filters changes.
Table 2-36: Example of the Hydraulic Oil and Filters Change Schedule
2008 2009 2010 2011 2012

Inspect oil and filters for Inspect oil and filters for
contaminants. contaminants.
Change
New filters Change filters. Change filters. Change filters.
filters.
New oil Filter oil. Change oil. Filter oil. Change oil.
2.5.5.2 Engine – Oil and Filters

• Sample oil, and change oil and filters every 250 hours.
• Change fuel filters every 250 hours.
2.5.5.3 Transmission – Oil and Filters

• Change oil once per year with ATF Petro Canada – Semi Synthetic oil. Refer to
Section 2.7.1 Transmission Maintenance for proper refill level.
• Change the filter once per year.
2.5.5.4 Triplex Pump – Lube Oil and Lube Tank Oil Filter
The maintenance task is as follows:
• Change the lube oil and lube tank oil filters once per year. Cut open the oil filters
to see what contaminants are in the filters.

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Table 2-37: Lubrication Sheet

Unit 2
There are certain components on the SCM skid unit that require routine inspection and
maintenance. These equipment components and assemblies will be described in the
following order:
• Detroit Diesel Engines
• Transmissions
• Drive Lines
• High Pressure Triplex Pump
• Iron
• Recirculation Pump and Pressurizer Pump
• Mix Water Pumps
• High Energy Mixing System
• Hydraulic System
• Plumbing System
• Pressure Relief Valves
• Skid Structural Frame
• Lifting and Transporting the Skid
• Equipment Pressure Testing
• SCM Skid Troubleshooting
• Top 10 Maintenance Items

Unit 2
2.6 Detroit Diesel Engines

Sanjel’s SCM skids are equipped with two Detroit Diesel Series 60 engines. These
engines are located at the front of the primary skid. Refer to Figure 2-1 and Figure 2-2
for the road side and curb side views of the engines. In the following subsections, the
engine components are divided into the fuel system, oil system, air system, cooling
system, and electrical system to be discussed in terms of their maintenance.
1. Exhaust
2. Air Cleaner
Canister
3. Radiator
4. Air Kill Reset
Lever
5. Air
Compressor
6. Coolant
Inhibitor
Element
7. Primary Fuel
Filter
8. Secondary
Fuel Filter
9. Oil Filters
10. Oil Filler Cap
11. Oil Dipstick
12. Oil Pan
13. Air Starter
14. Oil Drain
Plug
Figure 2-1: Detroit Diesel Engine (road side view)

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15. Fuel Tank

16. Fuel Filler Cap
17. Primer Pump
Figure 2-2: Detroit Diesel Engine (curb side view)
2.6.1 Fuel System

The fuel system supplies diesel fuel that is consumed by the engines. The two fuel
tanks are located below the two engines (see Figure 2-3 and Figure 2-4 for the major
components of the fuel tanks). Each engine is equipped with primary and secondary
fuel filters. The primary filter or fuel/water separator removes large contaminations from
the fuel. The secondary filter removes the smaller particles.

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1. Fuel Cap
2. Fuel Return Line
3. Fuel Suction
Lines
4. Fuel Level
Sensor
5. Fuel Vent Hose
6. Fuel Primer
Pump
7. Fuel Tank Drain
Plug (not
showing)
Figure 2-3: Detroit Engine Fuel Tank (road side)
Figure 2-4: Detroit Engine Fuel Tank (curb side)

Unit 2
2.6.1.1 Fuel System Maintenance

The fuel system maintenance tasks are as follows:
• Inspect the fuel lines, for fray and physical damage, daily.
Warning
Fuel is highly flammable. Always follow proper safety procedures when refueling the unit.
Always shut off the engines during refueling.
• Always fill the fuel tanks after each job. Filling the fuel tanks minimizes moisture
build-up on the tank walls.
• During fuel refills, inspect the fuel cap gasket for a proper seal.
• There are two types of fuel caps (Figure 2-5). Always replace the existing fuel
cap with the same type.
o A (Non-Vented) – does not have a white diaphragm to allow fumes to
escape.
o B (Vented) – has a white diaphragm to allow fumes to escape.
Figure 2-5: Two Types of Fuel Caps

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• Change the primary fuel filter and secondary fuel filter at the 250 hour service.
The Detroit engines are equipped with spin-on primary and secondary fuel filters.
Follow the steps below to replace the filters.
Figure 2-6: Primary Fuel Filter and Secondary Fuel Filter
Caution
Engine exhaust is poisonous. Always operate the engine in well-ventilated area to avoid injury
from inhaling engine exhausted air.
The steps to replace the fuel filters are as follows:
1. Shut down the engine and allow it to cool.
2. When the engine reaches the ambient temperature and is cool to touch,
place a container under the filter.

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3. If there is a fuel shutoff valve installed on the discharge side of the
secondary fuel filter, turn the handle on the shutoff valve to the “Close”
position.
NOTE: Fill the replacement filters with fuel and have them ready to install
immediately. This prevents possible siphoning and fuel system aeration.
4. Remove the primary and secondary fuel filters using a band type of filter
wrench.
5. If the new replacement filters were not previously filled, fill them with clean
diesel fuel and coat the gaskets lightly with the fuel.
6. Thread the new filters onto the adaptor inserts until the gaskets make full
contact with the adaptor head and no side movement is seen.
NOTE: Do not over tighten the filters. Over tightening the filters may
fracture and distort the adaptors.
7. Tighten the filters an additional one-half turn by hand, or as indicated on
the filters.
8. Turn the handle on the shutoff valve to the “Open” position.
Warning
Engine exhaust is poisonous. Always operate the engine in a well-ventilated area to avoid
injury from inhaling engine exhaust.
9. Start the engine and check for any leaks. Shut down the engine and fix
any leaks, when the engine is off.

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NOTE: Never use the starting motor and fuel pump to prime the fuel
filters. Excessive use of both, to prime the fuel system, will result in
damage to the starter, fuel pump and injector.
10. Mark down the date of change along with the operator’s initials on the
filters.
2.6.2 Oil System

The oil system supplies lubrication oil to the internal moving parts of the engine. It
cleans, inhibits corrosion, and cools the engine by carrying heat away from the moving
parts.
2.6.2.1 Oil System Maintenance
Warning
Hot oil and components can cause personal injury. Do not allow hot oil or hot components to
contact the skin.
Warning
To avoid injury from slipping and falling, clean up any spilled oil immediately.

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The oil system maintenance tasks are as follows:
• Check the engine oil level, daily. See Figure 2-7 and Figure 2-8 for the locations
of the engine oil filler cap and dipstick. Perform this action when the engine is
stopped and the equipment is on level ground. If the engine has just been
stopped and is warm, wait about 20 minutes to allow the oil to return back to the
oil pan before checking. Maintain the oil level within the satisfactory range on the
dipstick (Figure 2-9). Add the proper grade of oil, if necessary.
Figure 2-7: Engine Oil Filler Cap and Dipstick Figure 2-8: Engine Oil Filler Cap and Dipstick (curb
(road side) side)
Figure 2-9: Oil Level Gauge

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• Visually check for oil leaks around the oil filters and the external oil lines (daily).
• All diesel engines must be on an oil analysis program. Refer to Section 2.5.3 Oil
Analysis for oil analysis information.
• The engine oil must be sampled and changed at the 250 hour service. Refer to
Section 2.5.4 Obtaining an Oil Sample for the oil change information.
• Change the oil filters (Figure 2-10) at the 250 hour service. Follow the steps
below to change the oil filters.
Figure 2-10: Oil Filters
Warning
Immediately clean up any spilled liquids to avoid injury from slipping and falling.

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The steps to change the oil filters are as follows:
1. Place a container under the engine oil pan, remove the drain plug and
drain the engine oil. Replace the drain plug and tighten it securely.
2. Remove and discard the used oil filters.
3. Clean the filter gasket and the contact surface of the adaptor head.
4. Have the new filters filled with engine oil and lightly apply the same oil to
the filter gaskets.
5. Start the new filters on the adaptor head and tighten by hand until the
gaskets touch the adaptor head. Tighten the filters an additional two thirds
of a turn by hand, or as indicated on the filter.
NOTE: Do not over tighten. Over tightening the filter may fracture and
distort the filter adaptor.
6. Fill the oil (as needed) to bring the oil level within the satisfactory range
on the dipstick (Figure 2-11).
7. Start and run the engine for a short period of time and check for any leaks.
Then shut down the engine and fix the leaks.
Warning
Engine exhaust is poisonous. Always operate the engine in a well-ventilated area to avoid
injury from inhaling engine exhaust.

Unit 2
Figure 2-11: Satisfactory Oil Level Range
8. After all the leaks have been corrected, shut down the engine and wait
approximately 20 minutes to allow the oil to return back to the engine oil
pan, from various parts of the engine. Check the oil level again. Add oil, as
needed.
2.6.3 Air System

The air system of the Detroit engines supplies air to the air actuators, plunger packing
oiler system, the control console to enable the master water valve, and the Vortec air
conditioner. Refer to Figure 2-12 for a simplified diagram of the Detroit engine air
system.
Vortec Air
Conditioner
Figure 2-12: Simplified Diagram of Air System
Routine maintenance needs to be performed for the air cleaner, air kill button and air kill
reset lever, air compressor, air dryer, air lubricator, and air tank. The entire air system
should be inspected for leaks, daily.

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2.6.3.1 Air Cleaner

The air cleaner cleans and silences the air, which is consumed by the engine during
running. It sits on the top the engine compartment (Figure 2-13).
Figure 2-13: Air Cleaner (road side)
2.6.3.1.1 Air Cleaner Maintenance
Caution
Never service the air cleaner element with the engine running since this will allow dirt to enter
the engine.

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The air cleaner maintenance tasks are as follows:
• The Detroit engine has one air cleaner element. The air cleaner element should
be checked at the 250 hour service. Inspect the element with a trouble light by
inserting the light into the element and scanning all the way around. If the light
penetrates the element, the element is still good. If not, the element needs to be
replaced.
NOTE 1: This is important especially when the engine is operated under severe
dust conditions.
NOTE 2: Cleaning or reusing air cleaner elements are not recommended.
• Mark the installation date and operator’s name on the air cleaner canister.
• Check the gaskets for deterioration and replace, if necessary.
2.6.3.2 Air Kill Button and Air Kill Reset Lever

The Detroit Series 60 engines are equipped with air kill functionality. The air kill is used
for runaway engines, which are caused when flammable gas enters the engine (i.e.,
methane, sour gas, propane). The air kill button (Figure 2-14) of the Detroit engines is
located on the upper control console on the operator’s platform. It is a red button
labeled as “Emergency Shutdown” at the right bottom corner of the control console. The
air kill reset lever (Figure 2-15) is mounted in the air intake line of the engine.

Unit 2
Figure 2-14: Air Kill Button (Emergency Shutdown)
Figure 2-15: Air Kill Reset Lever (open – handle vertical)
2.6.3.2.1 Air Kill Reset Lever Maintenance
• Function test the air kill reset lever before each job and at the 250 hour service
(Figure 2-15). Check it with the engine at a dead idle, NOT at high rpm, to ensure
the gates will cut off the air supply. Do the test using the air kill button on the
upper control console.

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• Move the handle back from the closed position (handle at 45°) to the opened
position (handle at 90°) and feel for smoothness of operation, or any other
obstructions, and listen for an audible clicking sound as it moves back into place
(Figure 2-15).
Key Action Items

3 Check the air kill reset lever daily and at the 250 hour service.
2.6.3.3 Air Compressor

The air compressor receives cooled air from the radiator and compresses it into high
pressure air. It pumps the air into the air tank (reservoir). It is located on the engine’s left
side above the middle of the compartment. See Figure 2-16 for the major components
of the air compressor.
1. Discharge
Line
2. Governor
3. Coolant Line
4. Oil Line
Figure 2-16: Air Compressor

Unit 2
The governor (Figure 2-16) controls the air compressor and starts or stops the air
compressor from pumping air. When the air tank pressure rises to the “cut-out”
pressure, the governor stops the compressor from pumping air. However, the
compressor runs constantly in the event of an air leak.
2.6.3.3.1 Air Compressor Maintenance
Danger
Risk of extreme equipment damage, severe personal injury or possible death
Never work on or repair compressor system when the engine is in operation.
Do not disconnect the high pressure air line unless the air tank has been drained.
Warning
The compressor may be hot to touch after several hours of operation.
The air compressor maintenance tasks are as follows:
• Inspect the air intake, oil suction and return lines, and coolant suction and return
hoses for tight connections and general condition. Tighten the connections, and
replace the lines and hoses, as needed.
• Always listen for air leaks.
• If any oil is present during the draining of the air tank or slow air build-up occurs,
this may be an indication of a failing compressor.

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2.6.3.4 Air Dryer

The air dryer (Figure 2-17) collects and removes any air system contaminants (in liquid
and vapor form) before the air is collected by the air tank. It is located between the two
Allison transmissions. The air dryer of the SCM skids is manufactured by Bendix.
Figure 2-17: Air Dryer

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2.6.3.4.1 Air Dryer Maintenance
Warning
Always shut off the engines prior to servicing the air dryer.
The air dryer maintenance tasks are as follows:
• Always monitor the following during the air dryer operation.
o If oil is present in the air system when draining the air tanks, check the air
dryer. The presence of oil in the air dryer will render the dryer ineffective.
o If the air dryer is continuously blowing off, check oil contaminants in the air
system.
o If there are white milky deposits on the exhaust of the air dryer, this may
be the result of water and oil mixing in the dryer. Notify the maintenance
department.
• Change the Bendix air dryer with a mechanic’s assistance once a year.
Key Action Items

3 Change the air dryer yearly, in the Autumn, and monitor its performance
regularly.

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2.6.3.5 Air Lubricator

The air lubricator (Figure 2-18) is connected to the inlet side of the air tank to inject
lubrication into the air system. This injection helps reduce friction between the sliding
surfaces, thus increasing the cycling speed of the components and reducing wear. It is
located between the two Allison transmissions.
Figure 2-18: Air Lubricator
2.6.3.5.1 Air Lubricator Maintenance
• Check the lubrication oil level in the air lubricator, at the 250 hour service.
• Top up the lubricator, when needed.

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2.6.3.6 Air Tank

The air tank (Figure 2-19) receives and stores compressed air from the air compressor,
and provides compressed air to the plunger packing oiler system, the air actuators, the
control console, and the Vortec air conditioner unit. It sits between the two fuel tanks of
the Detroit engines.
Figure 2-19: Air Tank Figure 2-20: Air Tank Drain Valve
2.6.3.6.1 Air Tank Maintenance
• The air tanks must be drained of moisture and sediment, daily (after each job).
See Figure 2-20 for the location of the drain valve. There are three reasons for
draining the air tanks daily.
1. To remove contaminants inside the air tanks.
2. To remove trapped moisture from the cooling compressed air.
3. To inspect for oil. If oil is detected in the tanks, it indicates the air
compressor seals are failing and must be replaced.
Key Action Items

3 Drain the air tank of moisture and sediment daily.

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2.6.4 Cooling System

The cooling system (Figure 2-21 and Figure 2-22) regulates the engines’ temperatures
through radiators. There are coolers attached to the radiators to cool the pressurized
air, engine oil, and diesel fuel.
Figure 2-21: Detroit Engine Radiator (road side) Figure 2-22: Detroit Engine Radiator (curb side)
2.6.4.1 Cooling System Maintenance

• Inspect the cooling system for leaks, daily. Watch for an accumulation of coolant
when the engine is running and when it is stopped.
• Replace hoses that are cracked or soft.
• Check the coolant level daily by checking the sight glass (Figure 2-23). Add
coolant, as needed. Do not overfill. Do a Cold Check and a Hot Check.

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o Cold Check
▪ Ensure that all coolant plugs at the bottom of the radiator, and on
the radiator outlet pipe, are secure and tight.
▪ Check the coolant level. The cooling system is correctly filled when
the coolant level reaches the middle of the sight glass on the
radiator.
o Hot Check
▪ Start and run the engine for about five minutes at a moderate
speed.
Warning
Hot coolant can cause serious burns. Never remove the filler cap when the engine is under the
operating temperature. To open the radiator filler cap, stop the engine and wait until the
cooling system is cool. Wear adequate protective clothing (face shield, rubber gloves, apron,
and boots). Slowly loosen the filler cap in order to relieve the pressure.
▪ With the coolant temperature above 50°C (122°F), recheck the
coolant level.
▪ Add coolant, if required.

Unit 2
Figure 2-23: Cooling System Filler Cap and Sight Glass
• Change the coolant inhibitor elements every 500 hours (Figure 2-24 and Figure
2-25).
Figure 2-24: Coolant Inhibitor Element (road side) Figure 2-25: Coolant Inhibitor Element (curb
side)

Unit 2
2.6.5 Electrical System

The Detroit engines’ alternators charge the batteries used to provide power to the
electrical system of the skid. There are two alternators (Figure 2-29), two batteries
(Figure 2-26 shows the locations of the two battery boxes), three power switches
(Figure 2-27 and Figure 2-28), and the necessary wiring.
Figure 2-26: Battery Boxes Figure 2-27: Curb Side Battery Switches
Figure 2-28: Road Side Battery Switch

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The main skid power switch (Figure 2-27) on the curb side battery box and the night
switch (Figure 2-28) on the road side battery box are used to connect/disconnect the
batteries with the electrical system. If the road side engine fails, turn on the road/curb
side battery isolation switch (Figure 2-27) so that the curb side engine can charge the
batteries on the road side, and vice versa.
2.6.5.1 Electrical System Maintenance

• Check the tension of the alternator belt, daily, (Figure 2-29) and adjust when
necessary. Inspect the condition of the belt.
Figure 2-29: Alternator
• Check the battery connections at the 250 hour service.
• Clean the batteries (connections and cables) at the 250 hour service.
• Inspect the alternator for loose connections and ensure proper battery charging,
yearly.

Unit 2
2.6.6 Miscellaneous maintenance

Miscellaneous maintenance is as follows:
• The engine mounting bolts, and the condition of the mounting pads, should be
checked at the 250 hour service. Tighten or repair, when required.
2.7 Transmissions
Sanjel’s SCM skids are equipped with two Allison 4700 transmissions. These
transmissions (Figure 2-30) are located underneath the displacement tank, one on the
road side and the other one on the curb side. They transfer power from the engines, to
the drive lines, allowing the operator to select the proper gear to run the high pressure
Triplex pumps.
1. Oil Fill Plug

2. Oil Drain Plug (not
showing)
Figure 2-30: Allison 4700 Transmission

Unit 2
2.7.1 Transmission Maintenance

• Determine the transmission fluid level by performing a COLD CHECK and a HOT
CHECK. The fluid level should be inspected, daily. Report an abnormal fluid level
to the maintenance personnel.
o Cold Check – The purpose of the Cold Check is to determine if the
transmissions contain enough fluid, to be operated safely, until a Hot
Check can be made.
▪ A cold check may be made after the initial start-up and the
presence of the transmission oil has been proven (the sump fluid
temperature is typically 16°C - 50°C [60°F - 120°F] at this point).
Remove the dipstick and examine the fluid level. If the fluid on the
dipstick is within the COLD CHECK band, the level is suitable. If the
fluid level is not within this band, add or drain fluid as needed to
bring the level within the COLD CHECK band.
o Hot Check
▪ The hot check is performed as soon as the normal operating
temperature (70°C - 93°C [160°F - 200°F]) is achieved. Because
the fluid level increases with the temperature rising, the
transmission fluid must be hot in order to obtain an accurate check.
Remove the dipstick and examine the fluid level. The safety
operating level should be within the HOT RUN band on the dipstick.

Unit 2
If the fluid level is not within this band, add or drain fluid (as
needed) to bring the level within the HOT RUN band.
NOTE: Make sure the results of each fluid level check are
consistent. Determine the level more than once and, if readings are
not consistent, check the transmission breather to see if it is clean
and not clogged. If readings are still not consistent, report this to
the maintenance department.
• Change the transmission oil once per year with ATF Petro-Canada – Semi
synthetic.
NOTE: It is extremely important that the transmission oil is kept clean. The fluid
must be carried in clean containers to avoid foreign material entering the
transmission.
• When changing the transmission oil, check the drain plug (Figure 2-31) for filings
and give these filings to a mechanic or a manager for inspection.
Figure 2-31: Transmission Fluid Drain Plug Location
• Change the oil filter once per year.

Unit 2
2.8 Drive Lines

The drive lines are round cylindrical shafts that mount between the Allison
transmissions and the Triplex pumps. They provide the torque to the power ends of the
Triplex pumps. The skid is equipped with two drive lines. One is on the road side, the
other one is on the curb side. See Figure 2-32 and Figure 2-33.
Figure 2-32: Drive Line (road side) Figure 2-33: Drive Line (curb side)
2.8.1 Drive Lines Maintenance
Danger
Rotating drive shafts are dangerous. You can snag clothes, skin, hair, or hands. Never use a
pipe wrench on the drive shaft, always use a strap wrench.
• Before lubricating the drive lines, visually inspect all input and end-fitting retaining
nuts, u-joints, caps, and bolts for any gaps.

Unit 2
o Rotate and feel for any excessive looseness (Figure 2-34).
o Grasp the end fittings (yokes) and attempt to move vertically and
horizontally (Figure 2-35).
Figure 2-34: Rotating Drive Lines Figure 2-35: Moving Drive Lines (vertically and
horizontally)
Figure 2-36: Greasing the Cross Lube Fitting
• Add grease to the CROSS lube fitting (nipples) until lubricant exits at the
universal bearings (Figure 2-36 and Figure 2-37).

Unit 2
Figure 2-37: Greasing the Cross Lube Fitting (cont’d)
• Grease the slip yoke until grease exits the yoke plug (may require several
squirts). Cover the pressure relief hole while continuing to lubricate the yoke.
NOTE: Covering the pressure relief hole allows lubrication to the back of the
yoke.
• Replace the grease nipple, if it does not take or hold the grease.
• Wipe off the excess grease.
• Use a trouble light, if available, to inspect the grease points.
Key Action Items

3 Grease the slip yoke until grease exits from the yoke plug.
3 Prior to lubrication, physically grasp the yoke and test for looseness.
3 Replace the grease nipple, if it does not take or hold the grease.

Unit 2
2.9 High Pressure Triplex Pumps

Sanjel’s SCM skids are equipped with two Gardner Denver compact pumps with the
stroke length in 6" and plunger diameter in 31/2" on the road side and 41/2" on the curb
side. These twin Triplex pumps are horizontal, single-acting horsepower pumps located
beneath the operator’s platform.
To maintain the Triplex pumps, service the following:
• Plunger Packing Oiler System
• Power End Lube System
• Valves, Springs, and Keepers
• Repacking the Triplex Pump

Unit 2
2.9.1 Plungers Packing Oiler System

The plungers packing oiler system (Figure 2-38 to Figure 2-43) is a pneumatically
pressurized system that injects oil into the plungers’ packing as they operate. The two
pressure regulated oiler tanks (Figure 2-38 and Figure 2-39) are mounted beside the
right side of the control console on the operator’s platform. They have pressure hoses
attached, through which oil is supplied to the plunger stuffing boxes.
1. Air Pressure
Gauge
2. Air Pressure
Regulator
3. Air Lines
4. Pneumatic
Pumps
5. Needle Valves
6. Oil Lines
7. Filler/Breather
Cap
8. Ball Valve
Figure 2-38: Oiler Tank (top view)

Unit 2
9. Bleed Valves
10. Sight Glasses
Figure 2-39: Oiler Tanks Subassemblies
11. Check Valves
Figure 2-40: Oiler Tank Hoses and Valves to Plungers Housing (road
side)

Unit 2
Figure 2-41: Oiler Tank Hoses and Valves to Plungers Housing (road
side)
12. Plunger Oil

Holding Tanks
13. Plunger Oil
Holding Tank
Drain Valves
Figure 2-42: Oiler Tanks Reservoir (road side)

Unit 2
Figure 2-43: Oiler Tanks Reservoir (curb side)

Unit 2
2.9.1.1 Plungers Packing Oiler System Maintenance
Warning
Prior to any maintenance on the oiler, release all pressure in the tank by opening the bleed
valves (# 9 in Figure 2-39).
• Measure the pressures and inspect the oil lines for obvious signs of leaks, or
wear, daily.
• Check the oil level in the oiler tanks during the pre-job inspection. Fill up the
oilers with Greenpatch Oil to the blue mark on the sight glasses (Figure 2-44), if
needed. If the oil level is low during a job, use any engine oil or a suitable
substitute to complete the job.
NOTE: If a substitute is used as an emergency lubricant, the system oil must be
changed right after the job has completed.
• Drain the plunger oiler tanks reservoirs (Figure 2-42 and Figure 2-43), daily.
Figure 2-44: Oiler Tank Blue Marks

Unit 2
2.9.2 Triplex Pump Power End Lube System

The power end lube system lubricates the drive gears and crank shaft for the Triplex
pump at a rate of 60 to 80 psi. During operations, the pressure can be a maximum of
150 psi. Consult with the maintenance department for proper operating requirements.
NOTE: If the psi drops below 10 psi, contact the dispatch.
Figure 2-45 to Figure 2-51 show the major components of the lube system. All units
have two 100 gallon lube tanks.
1. Lube Tank below

Allison
Transmission (road
side)
Figure 2-45: Lube Tank (road side)
2. Lube Tank below

Allison
Transmission (curb
side)
Figure 2-46: Lube Tank (curb side)

Unit 2
3. Lube Tank Filler

Cap/Breather Cap
4. Lube Tank Sight
Glass
Figure 2-47: Lube Tank Components
5. Lube Pressure
Gauge (on Triplex
pumps)
6. Lube Swivel (on
Triplex pumps)
Figure 2-48: Lube Tank Gauge and Swivel (road side)
Figure 2-49: Lube Tank Gauge and Swivel (curb side)

Unit 2
7. Lube Tank Oil

Filters
Figure 2-50: Lube Tank Oil Filters
8. Lube Tank PTO

9. Lube Pump
Figure 2-51: Lube Tank PTO and Pump

Unit 2
2.9.2.1 Triplex Pump Power End Lube System Maintenance

• Check the pressure and oil lines for obvious signs of leaks and wear daily.
• Top up the lube tank with EP 220 lubricants.
NOTE: If engine oil is used as an emergency lubricant, the system oil must be
changed back to EP 220 once the job has completed.
• Each lube tank is equipped with a sight glass (Figure 2-47). Fill the lube tank until
the oil level reaches the blue mark on the sight glass.
• Change the lube tank oil filter, once a year.
• Change the lube oil and thoroughly clean the lube oil reservoir once a year.
• Clean or replace the breather cap at the 250 hour service.
• Check the lube oil and filter element supplies needed for frequent maintenance.
• Check all pressure, vacuum and temperature gauges and replace any defects.
• Check the lube system light device to make sure it is working.
• Clean the lube system suction strainer, quarterly.

Unit 2
2.9.3 Valves, Springs, and Keepers

The valves control the flow direction in the Triplex pump. They are located on the
suction, and discharge ends, of the Triplex pump and use springs to close the valves.
The valve of the Gardner Denver high pressure pump is shown in Figure 2-52. The
keeper holds the valve and spring in place.
1. Valve
2. Valve Insert
3. Spring
4. Keeper
Figure 2-52: Valve, Spring and Keeper
2.9.3.1 Valves, Springs, and Keepers Maintenance

• Inspect the seals regularly to ensure the seals are working and to prevent
pumping problems.
• Remove the three springs (Figure 2-53) and compare height differences on a flat
surface. If there is a height difference between the springs, change the springs.

Unit 2
Figure 2-53: Spring
• Visually inspect the valve inserts for wear and surface condition. Run fingers over
the mating surface where the insert sits, and feel for surface roughness and
irregularities.
• When replacing the rubbers on the valves, ensure the mating surfaces are clean
and the rubbers are flush against the mating plate to create a perfect seal. This
prevents fluid from entering the gap and separating the seal from the seat.
Key Action Items

3 Ensure the rubbers and valve mating surfaces are flush.
3 Remove the springs and compare height differences. Replace with
new springs, if necessary.

Unit 2
2.9.4 Repacking the Triplex Pumps

Periodically, the Triplex plunger seals must be repacked. The average packing life is
approximately eight months. If less than eight months, advise maintenance. Figure 2-54
illustrates the fluid cylinder assembly. Refer to the SCM unit Parts Manual for proper
materials for the repacking. Supplies such as the o-rings, seals, packing, valves, seats,
and maintenance tools should be checked periodically to allow for frequent
maintenance.

Unit 2
Figure 2-54: Fluid Cylinder Assembly

Unit 2
2.9.4.1 Removing Plungers and Packing 1

The steps to remove the plungers and packing are as follows:
1. Remove the suction cover (Figure 2-55) with tools provided for the pumps.
2. Loosen the specific stuffing box.
3. Remove the plungers (Figure 2-55) through the front of the fluid end.
4. Remove the stuffing box and the stuffing box adapter.
5. Before repacking the pumps, check the plungers and packing brass for excessive
wear, nicks or burrs. Also, clean, grease, and inspect the packing bore in the
stuffing box.
Figure 2-55: Triplex Pump Plungers and Packing Components
1
Courtesy of Gardner Denver Compact Pump Service Manual.

Unit 2
6. Install the packing, and brass, into the stuffing box with the packing lips facing
the front of the fluid end. See Figure 2-56 and Figure 2-57 for the correct packing
sequence.
NOTE: The current Sanjel Corporation packing configurations (or components)
may change. Check with the maintenance department for the proper packing ring
seal components.
1. Wiper Ring
2. Lantern Ring
3. Peek Adapter
4. Double Stack
Pressure Ring
5. Header Ring
6. Adapter (with
back-up rings
and o-rings)
Figure 2-56: Order of Packing Rings for Triplex Pumps

Unit 2
1. Lantern Ring
2. Double Stack
Pressure Ring
3. Single Stack
Pressure Ring
4. Header Ring
5. Adaptor
6. O-Ring
7. Back-up Ring
8. Back-up Ring
9. O-Ring
Figure 2-57: Packing Assembly for 31/2" and 41/2" Pumps
7. Install the stuffing box and hand-tighten. Slide the plunger through the suction
cover bore and packing.
8. Tighten the plunger in the crosshead (350 to 400 ft-lbs). Tighten the stuffing box.
9. Replace the suction covers with new seals, if necessary, and install the suction
covers.
10. Connect the plunger oiler lines to the packing nuts (Figure 2-58) and make sure
oil is going into the packing bore.
Figure 2-58: Plungers Oiler Lines and Packing Nuts

11. Adjust the packing nuts, as needed, after the pump is running.

Unit 2
2.9.4.1.1 Plungers and Packing Maintenance
• The key to long lasting packing is to ensure the packing rings and spacers are
clean prior to packing the pump.
• New packing is ordered through A.R. Thomson Group.
• The packing directions and order of seals are very important.
• When removing the plungers, always use a strap wrench on the pump shaft to
rotate the Triplex. Do not load the plungers into the Triplex pump with any tool
other than the plunger loading tool.

Unit 2
2.9.5 Triplex Pump Troubleshooting

Table 2-38 gives some Triplex pump troubleshooting tips.
Table 2-38: Triplex Pump Troubleshooting
Observation Reason Solution
High Oil Contaminated Oil Change Oil

Pressure
Relief Valve Maladjusted Check and Reset
Oil Filter Clogged Change Filter Cartridge
Restrictions in Passageways Clean Passageways
Erroneous Gauge Reading Recalibrate or Replace Gauge
High Oil Heat Exchanger Malfunction Clean Tubes and Shell

Temperature
Regulate Coolant Rate
Improper Bearing Adjustment Check and Adjust Clearances
Improper Crosshead
Adjustment
Low Discharge Worn or Fluid Cut Valve

Replace Valve Assembly
Pressure Assembly
Valve Propped Open Remove Propping Agent
Improper Filling Remove Restrictions from Suction Line
Increase Level of Fluid Supply
Increase Charging Pump Speed
Decrease Pump Speed
Prime Fluid Chambers
Fluid Slippage Replace Piston/Liner or Plunger/Pack
Low Suction Low Head Increase Level of Fluid Supply

Unit 2

Pressure
Charging Pump Capacity Increase Charging Pump Speed
Retarded Fluid Flow Remove Restriction from Suction Line
Fluid Knock or Air Entering Suction Line Repair Suction Line

Hammer
Air Entering Charging Pump Tighten or Replace Shaft Packing/Seal
Air Entering Suction Stabilizer Repair and Re-balance
Air/Gas in Pumped Fluid Impose Vacuum on Supply Tank
Allow More Setting Time
Reduce Pump Speed
Adjust Suction Stabilizer
Same as Low Discharge Same as Low Discharge Pressure

Pressure
Discharge Line Discharge Pulsation Dampener Repair and Recharge or Replace

Vibration
Unsupported Discharge Line Provide Supports or Hangers
Refer to Low Discharge Refer to Low Discharge Pressure

Pressure
Refer to Low Suction Pressure Refer to Low Suction Pressure
Refer to Fluid Knock or Refer to Fluid Knock or Hammer

Hammer
Oil Seal Worn Sealing Lip Replace Seal

Leakage
Damaged Sealing Lip Replace Seal
O.D. Not Seated Clean/Polish Bore of Oil Seal Housing
Foreign Material at Seal Point Clean & Polish Shaft
Clean/Polish or Replace Shaft Sleeve

Unit 2
Pressure in Crankcase Clean or Replace Air Breather
Low Oil Low Oil Level Check & Add Oil if Necessary
Pressure
High Oil Temperature Refer to High Oil Temperature
Contaminated Lubricant
Change Oil
Relief Valve Maladjusted Check and Reset
Leakage in Piping System Repair All Leaks
Choke Washers Misplaced Check Installation Directions

Oil Pump Worn
Repair or Replace Oil Pump
Clogged Suction Screen Clean Screen and Change Oil
Worn Oil Pressure Ring Replace Ring & Housing
Short Valve Abrasives in Fluid Filter Pumped Product

Life
Large Particles in Fluid Screen Pumped Product
Valve Not Seating Broken Valve Spring – Replace
Worn Valve Guide – Replace
Worn Valve/Seat – Replace
Pump Not Filling Refer to Low Suction Pressure
Pulsation Dampener Repair or Replace

Malfunction
Corrosion Treat Pumped Fluid
Short Plunger/ Abrasives in Fluid Filter Pumped Product & Flush Fluid
Packing Life Friction Wear Lubricate with Rock Drill Oil
Do not Over-tighten Adjustable Packing

Unit 2
Use Ceramic Plungers if Fluid is Clean
Check Stuffing Box Alignment
Check Gland Alignment
Check Plunger Alignment
Check Packing for Foreign Particles
Replace Stuffing Box Bushing
Replace Packing Follower
Replace Lantern Ring
Use Recommended Packing
Key Action Items

3 Prior to placing new packing, ensure all components are clean.
3 All packing is ordered from A.R. Thompson Group.
3 Packing report must be completed each month.

Unit 2
2.10 Iron
The intention of the iron maintenance is to ensure that all critical components, in all
services, perform safely during high pressure operations. The iron maintenance
involves routine and annual maintenance. Properly maintaining the iron carried by the
iron skid is one of the responsibilities of the operator. For the details regarding how to
conduct the iron maintenance, refer to “Sanjel’s Treating Equipment Inspector’s
Handbook” in the “Maintenance Manual”. The annual maintenance, inspection, and
pressure testing are currently conducted by a certified iron inspection facility.
2.10.1 Routine Maintenance

Routine maintenance consists of the following sections:
• Visual Inspection
• Specific Iron
2.10.1.1 Visual Inspection

As part of the iron maintenance, the operator of any unit should take care to visually
inspect the iron on a regular basis to examine for signs of cracks, washout, corrosion,
and damaged rubber inserts. Repair the iron that is not working properly, if possible. If
there are any damages that affect the performance of the iron, and the operator cannot
fix them, report this to the maintenance department.

Unit 2
2.10.1.2 Specific Iron

2.10.1.2.1 Plug Valves
See Figure 2-59 and Figure 2-60 for an example of 2x1 and 2x2 plug valves.
Figure 2-59: 2x1 Plug Valve Figure 2-60: 2x2 Plug Valve
• Prior to use, the plug valves should be inspected for proper operation. Make sure
that the valves are free of contamination and should actuate from the opened to
the closed position freely.
• After each use, the bore of the plug valves should be sprayed with a light oil or
equivalent corrosion inhibitor. Replace any damaged grease fittings to prevent
leaks and to allow proper greasing of the valve.
• The plug valves are required to be greased by the operators after each use on
the job site. Follow the steps below to grease the valves.
o Use a 21 MPa (3,000 psi) high pressure grease gun to grease the valve,
in the opened position, until grease can be seen.
o Rotate the valve to the closed position to open and pump a little more
grease into the valve while it is in the opened position.
o Repeat steps 1 and 2 twice.

Unit 2
o If the valve is in line, grease the valve a moderate amount until the
maximum grease pressure is reached during greasing, then rotate the
valve and re-grease it.
2.10.1.2.2 Swages
See Figure 2-61 for examples of the swages.
Figure 2-61: Swages
• Before each use, clean the threads with a wire brush and apply lubricant on the
threads of the swages to prevent rust. Inspect for any thread damage.
NOTE: Do not use the swage, if it is damaged.

Unit 2
2.10.1.2.3 Swivel Joints
Swivel joints are also called “Chicksans”. See Figure 2-62 and Figure 2-63 for examples
of two way swivel joints and three way swivel joints.
Figure 2-62: Two-way Swivel Joint Figure 2-63: Three-way Swivel Joint
• Each week, at a minimum, the swivel joints are to be greased by the operators.
• Before greasing, check all swivel joints to make sure that they can swivel without
much effort. If a swivel joint is hard to swivel, grease it. If a swivel joint cannot
swivel, and greasing does not solve the problem, flag it unusable and send it to a
certified repair facility.
• While greasing, they must be rotated to ensure proper application to all bearing
races. Do not over grease. Once grease is seen outside the dust seal on the
entire rotation, greasing is complete. Over greasing may cause the dust seal to
be extruded out. Clean off the excess grease and replace the slotted screw.
Ensure that the dust seal is in place so contamination cannot occur from the
outside.

Unit 2
2.10.1.2.4 Unions
See Figure 2-64 and Figure 2-65 for an example of Weco wings and Weco threads.
Figure 2-64: Weco Wing (103 MPa/15,000 psi Figure 2-65: Weco Thread (103 MPa/15,000 psi
CWP) CWP)
• Replace the rubber seals, if they are cracked or missing.
Warning
Remind any third party onlookers to keep clear, as bits of metal may break off when
hammering.
• Oil the unions before hammering them together.
• Before using the hammer, ensure the wedge on the hammer is secure and the
handle has not dried out (otherwise there is a danger of the hammer head
coming off or breaking).

Unit 2
• The threads should be visually checked for nicks or spurs after each job. If any
are observed, send the iron to a certified repair facility for repair or replacement.
If threads are in good condition, spray WD-40 (or equivalents) to prevent them
from rusting.
• Constant hammering on the wings, to tighten them, wears them to a point. They
are ground on an annual basis, but may require periodic grinding to flatten them.
Change any wings that cannot be ground to a square, with the following steps.
o Remove segments
o Replace wing half
o Reassemble
• Before each use, clean threads with a wire brush and apply lubricant on the
threads to prevent rust. Inspect for any thread damage.
• The folded metal should be ground to repair the wing on the union (Figure 2-66).
If the wing is completely pounded to a point, it should be replaced.
Figure 2-66: Wing

NOTE: Rotate the iron so the wings wear equally and ensure all iron is maintained on a
daily basis.

Unit 2
2.10.2 Annual Maintenance

The annual maintenance of the iron includes: assembly/disassembly, pressure testing,
thickness inspection, MPI (Magnetic Particle Inspection), banding, repair (if required),
and recertification. It is currently performed by a certified maintenance facility. An
inspection report is acquired from the facility after the annual maintenance has been
completed and kept by the maintenance personnel in Sanjel as a record.

Unit 2
2.11 Recirculation Pump and Pressurizer

Pump
The SCM skids are equipped with two Gardner Denver 2045 LX centrifugal pumps. One
acts as the recirculation pump. The other acts as the pressurizer pump (also called pre-
charge, boost pump, or down hole pump).
Both the recirculation pump and the pressurizer pump are located under the averaging
tank. One is on the road side and the other one is on the curb side. The recirculation
pump is used for slurry recirculation from the averaging tank to the mix tank. The
pressurizer pump is used for pushing slurry into the high pressure Triplex pumps.

Unit 2
2.11.1 Recirculation Pump and Pressurizer Maintenance

• After each job, open the drain valve to drain the remaining liquid out of the pump.
NOTE: Remember to close the drain valve before the next job.
Figure 2-67: Drain Valve of Recirculation Pump Figure 2-68: Drain Valve of Pressurizer Pump
Figure 2-69: Recirculation Pump Grease Points Figure 2-70: Pressurizer Pump Grease Points
• Grease the packing grease points (Figure 2-69 and Figure 2-70), daily, during
mixing operations.
• Grease the bearing housing grease points (Figure 2-69 and Figure 2-70), weekly.

Unit 2
2.11.1.1 Testing the Pressurizer and Recirculation Pumps

Sanjel has a pressure gauge (Figure 2-71) to diagnose the condition of the recirculation
and pressurizer pumps.
Figure 2-71: Pressure Gauge for Pumps with Pump Adaptor
To test the pressurizer pump and recirculation pump, follow the steps below:
1. To pressure test the recirculation pump, attach the pressure gauge to the 4"
recirculation discharge end of the recirculation pump (Figure 2-72). To pressure
test the pressurizer pump, attach the pressure gauge to the 4" pressurizer
discharge end of the pressurizer pump (Figure 2-73).

Unit 2
Figure 2-72: 4" Recirculation Discharge End (road side)
Figure 2-73: 4" Pressurizer Discharge End (curb side)
2. Close the return and discharge valves.
3. Turn on the recirculation or pressurizer pump and record the pressure reading.
4. Open the return valve and circulate water back to the displacement tank using
only the recirculation or pressurizer pump.

Unit 2
5. Once the water circulation back to the displacement tank has been established,
record the pressure. Circulating to the tanks using only the recirculation or
pressurizer pump should read at 25 psi; the dead head reading should be 50 psi.
NOTE: The performance of the pressurizer and recirculation pumps should be
monitored on a daily basis through the use of the electronic pressure transducers
located in the process piping. The deviation from expected pressures can be an
indication of the pressurizer and recirculation pumps beginning to wear out.
2.11.1.2 Packing Procedure for the Pumps 2

See Figure 2-74 for the pump packing assembly.
Figure 2-74: Pump Packing Assembly
2
Courtesy of the Gardner Denver 2045 LX Centrifugal Pump Maintenance Manual and Parts List.

Unit 2
Follow the procedure below to pack the pump:
1. Remove all the worn packing rings from the stuffing box and clean them
thoroughly.
2. Check all the bearings as per the manufacturer’s specifications and replace
them, if necessary.
3. Check the shaft and replace it, if necessary.
4. Lubricate the two primary seal rings. Install and seat each seal ring separately,
with all the seal lips facing toward the impeller. Stagger the splits at the 12
o’clock and the 3 o’clock positions so that there is no direct leakage path
established.
5. Lubricate and install the two-piece plastic lantern ring.
6. Lubricate the two secondary seal rings. Install and seat each seal ring separately
and again stagger the splits.
a. The first secondary seal ring of this series must be installed with the lips
facing away from the impeller with splits at the 6 o’clock position. The
reverse position of this seal will prevent air from being drawn through the
gland, and thus causing the loss of prime.
b. The second secondary seal ring of this series must be installed with the
seal lips facing toward the impeller, and with the split at the 9 o’clock
position.
7. Lubricate, install, and seat the split compression packing ring with the split at the
12 o’clock position.

Unit 2
8. To properly preload this combination set, bottom out the flat side of the gland
against the face of the stuffing box.
2.12 Mix Water Pumps

The two mix water pumps are located below the operator’s platform. One is on the road
side and the other one is on the curb side. The mix water pumps are used to pressurize
the water before it fills the displacement tank, feeds the high pressure mixing head or
the mixing tree. The mix water pumps are powered by the hydraulic system. Sanjel’s
skid units are equipped with two 3x2 Mission centrifugal pumps.

Unit 2
2.12.1 Mix Water Pump Maintenance

• Grease the packing grease point daily and the bearing lubrication points, weekly
(Figure 2-75 and Figure 2-76).
Figure 2-75: Lubrication Points for the Mix Water Pump (road side)
Figure 2-76: Lubrication Points for the Mix Water Pump (curb side)

Unit 2
• Drain water from the pump volute after each job. Leave the drain valve open
(Figure 2-77 and Figure 2-78) until the next cementing job.
Figure 2-77: Drain Valve of Mix Water Pump (road side)
Figure 2-78: Drain Valve of Mix Water Pump (curb side)

Unit 2
2.12.1.1 Testing the Mix Water Pumps

Sanjel uses a pressure gauge (Figure 2-71) to diagnose the condition of the mix water
pumps. To test the mix water pumps, follow the steps below:
1. Stop the Detroit engines. Attach the pressure gauge to the 4" mix discharge end
(Figure 2-79 and Figure 2-80).
2. Turn on the unit and dead head the water flow by closing the master water valve.
3. Record the pressure reading.
NOTE: The dead head pressure should be 200 to 250 psi.
Warning
Do not leave the mixing water pump dead headed for long periods of time, as the pump will
heat the fluid and the pump housing will become very hot.
4. Reopen all the valves and record the pressure reading.
NOTE: The open range pressure should be 175 to 200 psi.
Figure 2-79: 4" Mix Discharge End (road side) Figure 2-80: 4" Mix Discharge End (curb side)

Unit 2
2.12.1.2 Disassembly of Packing

The mission pumps should be repacked when the pump packing leaks excessively.
Follow the procedure below to disassembly the pump:
1. Remove the gland bolt assembly by loosening the gland bolt retaining nuts.
2. Remove the rope packing (six) with a pick.
3. Add three to four squirts of grease. Watch for grease exiting the packing gland.
4. Add only two to three pieces at a time, between repacking intervals. If this occurs
more than twice, all the packing in the pump should be replaced.
2.12.1.3 Reassembly of Packing

Follow the procedure below to reassemble the pump:
1. Cut the new packing to the desired lengths.
2. Grease all the packing ropes and insert pieces into the packing housing
staggering the cut end (i.e., cut end up is inserted first, cut end down is inserted
second) to eliminate any leaks along the cut packing.
3. Place the packing gland in position and swing the gland bolts in place.
4. Tighten the gland lightly against the packing using the gland bolt nuts.
NOTE: Tighten the gland against the packing “finger tight” only. If the packing is over
tightened, it may be burned when the pump is started.

Unit 2
2.13 High Energy Mixing System

There are some conditions that could cause problems in mixing. For example, if the
mixing system is not thoroughly cleaned after each job, cement can build-up around
various components of the unit. As a result, the build-up can cause serious restraints in
the slurry and dry cement. It can also cause the slurry to be mixed too slowly or even
cause the mixing system to stop functioning completely.
To prevent these problems from occurring, the following components should be properly
maintained:
• Bulk Cement Control Valve
• Mix Head Assembly
2.13.1 Bulk Cement Control Valve

The bulk cement control valve (Figure 2-81) seats on the top of the mix head. When
performing maintenance on the valve, remove it from the mix head first.
Figure 2-81: Bulk Cement Control Valve Figure 2-82: Union and Hinge Bolts

Unit 2
To remove the valve, take the following steps:
1. Hammer loose the union (see Figure 2-82 for the location of the union).
2. Unfasten the bolts of the hinge (see Figure 2-82 for the location of the hinge
bolts).
3. Lift the bulk cement control valve off the mix head.
If cement build-up is detected on any component of the bulk cement control valve, then
clean the build-up immediately.
After the bulk cement control valve is removed, do the following checks:
• Push the vacuum breakers (x3) in and out to make sure it is working properly.
• Check the vacuum breaker seats for cement build-up and any damage. If the
vacuum breaker will not seat properly, then replace it.
NOTE: It is crucial that the vacuum breakers work properly.
• Check the bulk cement control valve for free valve movement and cement
build-up.
• Make sure the bulk cement control valve can be rotated smoothly. Grease the
control valve before every job. If the valve is hard to rotate, there may be cement
build-up between the plug and control valve body. Take the following steps.
o Remove the plug by loosening the clamp on top of the valve body.
o Remove the actuators, and plug, out of the valve body.
o With the actuators and plug removed, clean all cement build-up, then
grease and reassemble the valve. While the control valve is disassembled,
remove all cement build-up from the control valve body.

Unit 2
o When the bulk cement control valve is removed, check the mix head
throat for cement build-up and clean it completely.
NOTE: While the bulk control valve is disassembled, remove all cement build-up
from the control valve body by chipping it off. Do not clean any cement build-up
in the bulk cement control valve using water. Water left inside of the valve will
mix with the dry cement creating a blockage or a closed valve condition.
2.13.1.1 Bulk Cement Control Valve Cleaning Procedure

Follow the steps below to clean the bulk cement control valve:
1. Remove the vacuum breakers.
2. Remove the Allen bolts on the clamp on top of the bulk control valve (Figure 2-83
and Figure 2-84). Remove the clamp (Figure 2-83).
Figure 2-83: Allen Bolt Removal Figure 2-84: Allen Bolt Removal (cont’d)
3. Pull up the top portion of the valve attached to the actuator (Figure 2-85).

Unit 2
Figure 2-85: Valve Removal (top portion)
4. When the valve shutter is free, inspect the gap between the shutter and the top
(Figure 2-86).
Figure 2-86: Valve Shutter
5. Clean out any cement that is in the gap.
6. Inspect the inside of the bulk cement valve (Figure 2-87).
7. To clean out any cement that is caked on, use a buffing wheel.

Unit 2
Figure 2-87: Inside the Bulk Cement Valve (top view)
8. Remove the plates, starting with the one opposite to the bulk inlet (Figure 2-88).
Figure 2-88: Plate Removal
9. Buff the plates clean, using a buffing wheel.
10. Buff up the inside of the head and clean the vacuum breaker ports.
11. Once all is clean, reassemble the head.
12. When reinstalling the top, make sure the guide pin lines up to the guide hole
(Figure 2-89).

Unit 2
Figure 2-89: Guide Pin
2.13.1.2 Greasing the Bulk Cement Control Valve

• There is only one nipple on the head for greasing (Figure 2-90). Grease the bulk
cement control valve before every job.
• When greasing the actuated shutter shaft, work the shutter to ensure the grease
is properly spread around.
• To work the shutter you may operate it using the hydraulics, or bypass the
hydraulics and operate the valve manually (using a bar).
NOTE 1: Greasing the shaft keeps cement out and keeps the valve from freezing.
NOTE 2: After reassembly, make sure that the bulk control valve is fully closed when
the indication pin (Figure 2-90) is lined up with “0” and make sure it is fully open when
the indicator pin is lined up with 10. Recalibration of the electronics may also be
required.

Unit 2
Figure 2-90: Bulk Cement Control Valve Grease Nipple
2.13.2 Mix Head Assembly

The mix head assembly consists of several high-tolerance parts. If certain parts are
worn or damaged, performance will be affected. The following maintenance should be
performed for the mix head assembly:
• Inspect and clean the bulk cement sleeve and water diffusion plate after each
job.
• Wash up the 3" Magnetic flow meter and 2" Coriolis flow meter, after each job.
• Perform an extra check of the top and bottom of the mix chamber, below the
water diffusion plate, for cement build-up. If build-up is observed, clean up the
mix chamber.
• Ensure the holes in the water diffusion plate are free of debris.
• Inspect the curved surface inside the cyclonic mixing chamber for cement build-
up after each job. Clean it up, if necessary.
• Perform an annual thickness test for the mix chamber, especially the elbow
directly below the mix head.

Unit 2
2.14 Hydraulic System

The hydraulic system is driven by a Caterpillar C9 Industrial engine. This engine
distributes power to the hydraulic pumps via a multi-pad Funk gearbox. Routine
maintenance for the hydraulic tank, the CAT C9 engine, and the Funk gearbox need to
be regularly performed.
2.14.1 Hydraulic Tank
Warning
Never attempt to perform work on the hydraulic system when it has operated for some time.
Hot hydraulic oil can cause severe burns.
• The oil level in the hydraulic tank (Figure 2-91) should be checked, daily, and
filled up to the blue mark on the sight glass (Figure 2-92) when the engine is off
to allow room for the hydraulic oil to expand.

Unit 2
Figure 2-91: Hydraulic Tank Sight Glass and Drain Figure 2-92: Close-up View of Sight Glass
Valve
Figure 2-93: Hydraulic Filter and Filler Cap

Unit 2
• The hydraulic oil filters must be changed once per year. Loosen the bolts (Figure
2-93) indicated by the arrows to access the oil filter. If oil is hot, wait until it has
cooled down.
• The hydraulic oil must be changed once every other year. Filter the oil with the
filter cart opposite the oil change year.
• Inspect the oil and filters for contaminants, at the year when the oil is changed.
• Refer to Table 2-36 for an example in terms of the hydraulic oil and filters change
schedule.
• Liquid Teflon sealant should be used on hydraulic line pipe threads. All fittings
should be tight.
• Tiny dust particles are harmful to a hydraulic system. Every effort should be
made to prevent contaminants from entering the system.
• Change the charge filters (Figure 2-94) once every year.
• Change the main filters/high pressure filters (Figure 2-95) once every year.
• The hoses and other components should be checked for leaks and wear daily,
especially at contact areas.
• Repairs to the system should only be made using the proper hoses and fittings.

Unit 2
Figure 2-94: Hydraulic Pump Charge Filters
Figure 2-95: Hydraulic Pump Main Filters

Unit 2
2.14.2 Caterpillar C9 Engine

The Caterpillar C9 engine is located at the rear of the primary skid. Refer to Figure 2-96
and Figure 2-97 for the engine’s right and left side views. In the following subsections,
the engine components are divided into the air system, electrical system, cooling
system, fuel system and fuel lines, and oil system to be discussed in terms of their
maintenance.
Figure 2-96: Caterpillar Engine (right side view)
1. Air Inlet Canister 9. Gauge Panel

2. Air Inlet Pipe 10. Engine Oil Dipstick
3. Valve Cover 11. Engine Oil Filter
4. Turbocharger 12. Oil Drain Plug (not showing)
5. Exhaust Manifold 13. Engine Oil Pan
6. Radiator 14. Alternator
7. Primary Fuel Filter 15. Alternator Belts
8. Secondary Fuel Filter 16. Hydraulic Cooler Lines

Unit 2
Figure 2-97: Caterpillar Engine (left side view)
17. Air Compressor 19. Air Dryer

18. Air Kill Reset Lever 20. Air Starter

Unit 2
2.14.2.1 Air System

The air system of the CAT C9 engine supplies air to the CAT engine air starter and the
two air starters of the Detroit engines to start the three engines. See Figure 2-98 for a
simplified diagram of the CAT engine air system.
Figure 2-98: Simplified Diagram of Air System
Routine maintenance needs to be performed for the air cleaner, air kill button and air kill
reset lever, air compressor, air dryer, and air tank. The entire air system should be
inspected for leaks daily.
2.14.2.1.1 Air Cleaner
The air cleaner filters and silences the air, which is consumed by the engine during
running. It sits inside the air inlet canister (Figure 2-99). The CAT engine is equipped
with a dual element air cleaner, which contains a primary air filter (Figure 2-100) and a
secondary air filter (Figure 2-101).
Figure 2-99: Air Inlet Canister

Unit 2
Figure 2-100: Primary Air Filter Figure 2-101: Secondary Air Filter
2.14.2.1.1.1 Air Cleaner Maintenance
Caution
Never service the air cleaner elements with the engine running since this will allow dirt to enter
the engine.
• The air filters should be checked at the 250 hour service. Inspect the filters with a
trouble light by inserting the light into the filter and scanning all the way around. If
light penetrates the filter, the filter is still good. If not, replace the filter.
NOTE: This is especially important when the engine is operated under severe
dust conditions.
• Ensure the lid-attaching latches are tightened, to ensure a proper seal between
the lid and the canister, after the air filters are in place.
• The CAT C9 engine air cleaners are equipped with two air filters. Ensure both air
filters are changed at the service.
• Mark the installation date and operator’s name on the air cleaner canister.

Unit 2
2.14.2.1.2 Air Kill Button and Air Kill Reset Lever
The CAT C9 engine is equipped with air kill functionality. The air kill is used for runaway
engines, which are caused when flammable gas (i.e., methane, sour gas, or propane)
enters the engine. The air kill button (Figure 2-102) of the CAT engine is located on the
upper control console on the operator’s operation platform.
It is a red button labeled as “Emergency Shutdown” at the right bottom corner of the
control console. Another air kill button (Figure 2-103) can be found on the engine gauge
panel mounted on the engine compartment. The air kill reset lever is located at the top
of the engine’s left side (see Figure 2-97).
Figure 2-102: Air Kill Button (Emergency Shutdown on upper control console)

Unit 2
Figure 2-103: Air Kill Button on CAT Engine
2.14.2.1.2.1 Air Kill Maintenance
• Function test the air kill reset lever during the pre-job inspection. Check it with the
engine at a dead idle, NOT at high rpm, to ensure the gates will cut off the air
supply. Test using both air kill buttons on the upper control console and the
gauge panel mounted on the CAT engine.
• Move the handle back from the closed position (handle at 45°, see Figure 2-104)
to the opened position (handle at 90°) and feel for smoothness of operation or
any other obstruction, and listen for an audible clicking sound as it moves back
into place (handle vertical).

Unit 2
Figure 2-104: Air Kill Closed (handle at 45°)
Key Action Items

3 Check the air kill reset lever at every pre-job inspection and at the 250
hour service.
2.14.2.1.3 Air Compressor
The air compressor (Figure 2-105) is the source of air for the two air starters of the two
Detroit engines and one air starter of the CAT engine. Its function is to gather air from
the radiator and compress it into high pressure air. It is located on the engine’s left side
above the middle of the compartment.
The air compressor pumps air into the air tank (reservoir). The governor controls the air
compressor and starts or stops the air compressor from pumping air. When the air tank
pressure rises to the “cut-out” pressure, the governor stops the compressor from
pumping air. However, the compressor runs constantly in the event of an air leak.

Unit 2
1. Coolant Line
2. Air Intake
3. Coolant Line
4. Governor
Line
5. Oil Feed Line
Figure 2-105: Air Compressor
2.14.2.1.3.1 Air Compressor Maintenance
Danger
Never work on the compressor system when the engine is in operation.
Do not disconnect the high pressure air line unless the air tank has been drained.
Warning
The compressor may be too hot to touch after several hours of operation.

Unit 2
• Inspect the air intake, hydraulic oil suction and return lines, coolant suction and
return hoses (for tight connections) and overall general condition. Tighten the
connections and replace the lines and hoses, as needed.
• Always listen for air leaks.
• If any oil is present during the draining of the air tank or slow air build-up occurs,
this may be an indication of a failing compressor.
2.14.2.1.4 Air Dryer
The air dryer (Figure 2-106) collects and removes any air system contaminants (in liquid
and vapor form) before the air enters the air tank, and provides clean and dry air to the
air system. It is located on the engine’s left side beside the Funk gearbox. The air dryers,
for the SCM skid, are manufactured by Bendix.
Figure 2-106: Air Dryer

Unit 2
2.14.2.1.4.1 Air Dryer Maintenance
Warning
Always shut off engines prior to servicing the air dryer.
• Always monitor the following during the air dryer operation.
o If oil is present in the air system, when draining the air tanks, check the air
dryer. The presence of oil in the air dryer will render the air dryer
ineffective.
o If the air dryer is continuously blowing off, check oil contaminants in the air
system.
o If ice builds up in the exhaust (bottom) of the air dryer, check the heating
unit inside the dryer. It may be malfunctioning.
o If there are white milky deposits on the exhaust of the air dryer, this may
be the result of water and oil mixing in the dryer. Notify the maintenance
department.
• Change the Bendix air dryer with a mechanic’s assistance once a year.
Key Action Items

3 Change the air dryer yearly, in the Autumn, and monitor its performance
regularly.

Unit 2
2.14.2.1.5 Air Tank
The air tank receives and stores compressed air from the compressor, then it supplies
the air to the air starters for all three engines. It is mounted on the hydraulic skid next to
the CAT C9 engine (Figure 2-107).
Figure 2-107: Air Tank
2.14.2.1.5.1 Air Tank Maintenance
• The air tank must be drained of moisture and sediment daily (after each job). See
Figure 2-108 for the location of the drain valve. There are three reasons for
draining the air tanks daily:
1. To remove contaminants inside the air tanks.
2. To remove trapped moisture from the cooling compressed air.
3. To inspect for oil. If oil is detected in the tanks, it indicates the air
compressor seals are failing and must be replaced.

Unit 2
Figure 2-108: Air Tank Drain Valve
Key Action Items

3 Drain the air tank of moisture and sediment daily.

Unit 2
2.14.2.2 Electrical System

The engine’s alternator charges the battery used to provide power to the electrical
system of the SCM skid. There is an alternator (Figure 2-109), a battery (see Figure
2-110 for the battery box), a night switch (Figure 2-110), and the necessary wiring. The
night switch on the battery box is used to connect/disconnect the battery with the
electrical system of the skid (Figure 2-110).
Figure 2-109: Alternator and Alternator Belt

Unit 2
Figure 2-110: Hydraulic Skid Battery Box and Night Switch
2.14.2.2.1 Electrical System Maintenance
• Check the tension of the alternator belt daily and adjust when necessary. Inspect
the condition of the belt.
• Check the battery connections at the 250 hour service.
• Clean the batteries (connections and cables) at the 250 hour service.
• Inspect the alternator for loose connections and ensure proper battery charging
yearly.

Unit 2
2.14.2.3 Cooling System

The cooling system (Figure 2-111) regulates the engine’s temperature.
Figure 2-111: Cooling System
2.14.2.3.1 Cooling System Maintenance
• Inspect the cooling system for leaks daily.
• Replace hoses that are cracked or soft.
• Check the coolant level in the radiator daily (when the engine is stopped and
cool). Follow the steps below.

Unit 2
Warning
Hot coolant can cause serious burns. Never remove the filler cap when the engine is under the
operating temperature. To open the radiator filler cap, stop the engine and wait until the
cooling system is cool. Slowly loosen the filler cap in order to relieve the pressure.
o Remove the cooling system filler cap (Figure 2-112) slowly to relieve
pressure.
Figure 2-112: Cooling System Filler Cap (located on the top of the
coolant tank)
o Maintain the coolant level within 13 mm (0.5 inch) of the bottom of the filler
cap.
o Clean the cooling system filler cap and check the condition of the filler cap
gaskets. Replace the cap, if the gaskets are damaged.
o Reinstall the cooling system filler cap.

Unit 2
2.14.2.4 Fuel System and Fuel Lines

The fuel system supplies diesel fuel that is consumed by the CAT engine. The fuel tank
is located below the engine compartment. See Figure 2-113 and Figure 2-114 for the
major components of the fuel tank.
1. Fuel Cap
2. Fuel
Return
Line
Figure 2-113: CAT Engine Fuel Tank

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3. Fuel Suction
Line
4. Fuel Level
Sensor
5. Fuel Vent
Hose
Figure 2-114: CAT Engine Fuel Tank Fuel Lines
2.14.2.4.1 Fuel System and Fuel Lines Maintenance
The maintenance tasks are as follows.
• Inspect the fuel lines for fray and physical damage daily.
• Check for fuel leaks at all engine-mounted fuel lines and connections daily.
Warning
Fuel is highly flammable. Always follow proper safety procedures when refueling the unit.
Always shut off the engines during refueling.
• Always fill the fuel tank after each job. Filling the fuel tank minimizes moisture
build-up on the tank walls.
• During fuel refills, inspect the fuel cap gasket for a proper seal.

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• There are two types of fuel caps (Figure 2-115). Always replace the existing fuel
cap with the same type.
o A (Non-Vented) – does not have a white diaphragm to allow fumes to
escape.
o B (Vented) – has a white diaphragm to allow fumes to escape.
Figure 2-115: Two Types of Fuel Caps
Figure 2-116: Primary Fuel Filter/Water

Separator
• Monitor the bowl of the primary fuel filter/water separator (Figure 2-116) daily for
signs of water. If water is observed, drain the water from the bowl.

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• Change the primary fuel filter at the 250 hour service. Follow the steps below.
o Close the main fuel supply valve.
o Remove the fuel filter element from the mounting base with the bowl
attached.
o Dispose of the fuel in the filter element.
o Remove the O-ring from the gland of the bowl. Clean the following
components.
▪ Bowl
▪ O-ring. Inspect the O-ring for damage or deterioration. Replace it, if
necessary.
▪ Mounting base
o Lubricate the O-ring with clean diesel fuel.
o Install the bowl on a new element. Tighten the bowl by hand. Do not use a
tool to tighten the bowl.
o Lubricate the top seal of the element with clean diesel fuel. The element
may be filled with fuel, at this time. Install the new element on the
mounting base. Tighten the element by hand.
o Open the main fuel supply line.
o Start the engine and check for leaks. Run the engine for one minute. Stop
the engine and check for leaks again.

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o Mark down the date of change along with the operator’s initials on the
filter.

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• Replace the secondary fuel filter (Figure 2-117) at the 250 hour service. Follow
the steps below to prime the fuel system and to change the secondary fuel filter.
Figure 2-117: Secondary Fuel Filter and Fuel Primer Pump
o Stop the engine. Turn the ignition switch off or disconnect the battery.
Shut off the fuel supply valve (if equipped).
o Remove and discard the used filter.
o Clean the gasket sealing surface of the fuel filter base. Ensure that all of
the old gaskets are removed.
o Apply clean diesel fuel to the new fuel filter gasket.
o Install the new fuel filter. Spin the fuel filter onto the fuel filter base until the
gasket contacts the base. Use the rotation index marks on the filters as a
guide for proper tightening. Tighten the filter for an additional full turn (360
degrees) by hand.

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NOTE: Do not over tighten the filter.
filter.
o Open the fuel priming pump and operate the fuel priming pump until a
strong pressure is detected. This procedure will require a number of
strokes. Lock the fuel priming pump, when complete.
o Promptly start the engine. If the engine runs rough, continue to operate
the engine at low idle. Do not raise the engine speed above idle, until the
engine operates smoothly.
NOTE: If the engine does not start, open the fuel priming pump and repeat
the previous two steps, in order to start the engine.
• During a filter change, match the new filter type and manufacturer with the old
filter. Ensure the old filter gasket is not left on the filter mount.
o Fill the new filter with fresh diesel fuel to prevent an air lock in the fuel
system.
o If an air lock occurs in the fuel system,
▪ Remove both filters and check the fuel level. Top it off, if necessary,
and replace the filters.
▪ Unscrew the fuel primer and pump until resistance is felt. Replace
the fuel primer and start the engine.
NOTE: Do not add fuel conditioner without consulting the maintenance
department.
Unit 2
2.14.2.5 Oil System

The oil system supplies lubrication oil to the internal moving parts of the engine. It
cleans, inhibits corrosion, and cools the engine by carrying heat away from the moving
parts.
2.14.2.5.1 Oil System Maintenance
Warning
Hot oil and components can cause burns. Do not allow hot oil or hot components to contact
the skin.
• Check the engine oil level, daily, using the engine oil dipstick (Figure 2-118).
Perform this action only when the engine is stopped. Maintain the oil level
between the “ADD” mark and the “FULL” mark on the oil level gauge (Figure
2-119). Clean the oil filler cap (Figure 2-120), if necessary.
Figure 2-118: Engine Oil Dipstick

Unit 2
Figure 2-119: Oil Level Gauge
Figure 2-120: Engine Oil Filler Cap
• All diesel engines must be on an oil analysis program. Refer to Section 2.5.3 Oil
Analysis for oil analysis information.
• The engine oil must be sampled and changed at the 250 hour service. Refer to
Section 2.5.4 Obtaining an Oil Sample for the oil change information.
• Change the oil filter (Figure 2-121), at the 250 hour service. Follow the steps
below.
NOTE: Only use oil filters recommended by Caterpillar when changing the oil
filter.

Unit 2
o Remove the oil filter with a 185 – 3630 Strap Wrench.
o Clean the sealing surface of the filter mounting base. Make sure that the
entire old oil filter gasket is removed.
o Coat the new oil filter gasket with clean engine oil.
NOTE: Do not fill oil filters with oil before installing them. This oil would not
be filtered and could be contaminated. Contaminated oil can cause
accelerated wear to the engine components.
Figure 2-121: Oil Filter
o Install the oil filter. Tighten the oil filter until the oil filter gasket contacts the
base. Tighten the oil filter by hand according to the instructions on the oil
filter. NOTE: Do not over tighten.
filter.

Unit 2
2.14.3 Funk Gearbox

The Funk gearbox (Figure 2-122) provides the torque to drive the hydraulic pumps.
Figure 2-122: Funk Gearbox
2.14.3.1 Funk Gearbox Maintenance

• Check the gearbox oil level daily. Add oil, if necessary. See Figure 2-123 for the
location of the dipstick. See Figure 2-123 for the location of the filler cap.
• Change the oil every 1000 hours with Synthetic 50W. See Figure 2-124 for the
location of the drain plug.

Unit 2
1. Dipstick
2. Filler Cap/Vent Cap
3. Drain Plug
Figure 2-123: Funk Gearbox (mounted on CAT Engine)
Figure 2-124: Funk Gearbox (not mounted)

Unit 2
2.14.4 Key Hydraulic Notes

The key hydraulic information to note is as follows:
• For full operation of the hydraulic pumps, the CAT engine should be operating at
a minimum of 2000 rpm. Sanjel systems are designed to operate at a maximum
of 2400 rpm.
• Pinch the rate to adjust the density and flow using valves, instead of idling down
the CAT engine; otherwise, the hydraulics may slow down.
• Do not adjust the pressure relief valves on the hydraulic system. This will heat
the hydraulic fluid and cause pump failure.
• Do not add dyes to the hydraulic oil.
• Do not use silicone on hydraulic systems.
• If a hydraulic failure occurs, shut down the CAT engine immediately.
• Cleanliness is key to maintaining the hydraulic system.
NOTE: The most common failure of the hydraulic system is leakage from the rubbing of
hydraulic lines. The friction weakens the hydraulic lines.

Unit 2
2.14.5 Hydraulic System Component Specifications

Table 2-39 gives the hydraulic system component specifications.
Table 2-39: Hydraulic System Components Specifications
Component Specifications
1. Sauer Sundstrand Series 90 Hydraulic Maximum Pressure – 5000 psi

Pump (for recirculation pump and
Maximum Speed – 2400 rpm
pressurizer pumps)
2. Sauer Sundstrand Series 90 Hydraulic Maximum Pressure – 5000 psi

Pump (for mix water pumps)
3. Sauer Danfoss Hydraulic Motor (for Delivers 47.5 hp at 2400 rpm

recirculation pump and pressurizer
Maximum Pressure – 5000 psi
pumps)
4. Cessna Hydraulic Pump (for bulk cement Maximum Pressure – 3000 psi
control valve actuator, mix water control
valve actuator, and high pressure return
line control valve actuator)
5. Char-Lynn Hydraulic Motor (for mix tank Delivers 10 hp at 200 rpm

agitation paddle)
6. Sundstrand Hydraulic Pump (for five Maximum Pressure – 3000 psi

agitation paddle motors)
7. Sauer Sundstrand Series 90 Hydraulic Delivers 30 hp at 2400 rpm

Motor (for mix water pump)
8. Char-Lynn Hydraulic Motor (for Delivers 10 hp at 200 rpm

averaging tank agitation paddles)
9. Char-Lynn Hydraulic Motor (for Delivers 10 hp at 200 rpm

displacement tank agitation paddles)
10. Main Filter Maximum Flow Rate – 60 gpm
11. Charge Filter (for recirculation, Maximum Flow Rate – 20 gpm

pressurizer, and mix water pumps)

Unit 2
Component Specifications
12. Hydraulic Pressure on Pressurizer Circuit Maximum Pressure – 1400 psi

with Water
13. Hydraulic Pressure on Pressurizer Circuit Maximum Pressure – 2200 psi
with Slurry
14. Hydraulic Pressure on Recirculation Maximum Pressure – 1400 psi

Pump Circuit with Water
15. Hydraulic Pressure on Recirculation Maximum Pressure – 2200 psi
Pump Circuit with Slurry
16. Hydraulic Pressure on Mix Water Pump Maximum Pressure – 3000 psi
17. Speed of Mix Water Motor 2400 rpm
18. Speed of Pressurizer Motor 1600 rpm
19. Speed of Recirculation Motor 1600 rpm
20. Speed of Agitation Paddle Motor 200 rpm
21. Mix Water Pump Output 1.2 cm3 – 100 psi
22. Pressurizer Pump Output 3 cm3 + 100 psi
23. Recirculation Pump Output 3 cm3 + 100 psi
24. Hydraulic Tank Capacity – 200 gallons

Unit 2
2.15 Plumbing System

The plumbing system is an integral part of the mixing system, high pressure pumping
system, and fluid displacement system. It is used for the conveyance of fluids including
water, slurry, and drilling mud. The main components of the system are a series of
pipes, valves with air actuators, and valves with hydraulic actuators. The configuration
of the plumbing system of the SCM skids is shown in Figure 2-125.
Figure 2-125: Schematic of Plumbing System

Unit 2
The plumbing system has a total of eleven air actuators, as shown in Figure 2-126.
Figure 2-126: Exploded Schematic of Piping System
1. Curb Side Displacement Tank Control Valve Air Actuator

2. Road Side Displacement Tank Control Valve Air Actuator
3. Curb Side Displacement Tank Suction Valve Air Actuator
4. Road Side Displacement Tank Suction Valve Air Actuator
5. Curb Side Triplex Pump Isolation Valve Air Actuator
6. Road Side Triplex Pump Isolation Valve Air Actuator
7. Master Water Valve Air Actuator
8. Averaging Tank Isolation Valve Air Actuator
9. Displacement Side Pressurizer Pump Isolation Valve Air Actuator
10. X-over Valve Air Actuator
11. Curb Side Mix Water Pump Bypass Valve

Unit 2
2.15.1 Plumbing System Maintenance

• Perform a weekly check of the valve air actuators (open and close) and ensure
they work properly. The yellow indicator on each air actuator shows if the air
actuator is functioning well. The two diagnosis switches of the curb side and road
side displacement tank suction valve air actuators are mounted on the rear of the
displacement tank (Figure 2-127). The diagnosis switch of the master water valve
air actuator is located on the upper control console and the other diagnosis
switches are located on the lower control console at the operator’s platform
(Figure 2-128).
Figure 2-127: Diagnosis Switches on Displacement Tank

Unit 2
Figure 2-128: Diagnosis Switches on Lower Control Console
• Inspect the pipes and joints for any leaks, daily. Identify the causes of leaks.
Disassemble and reassemble the pipes, if needed.
• Perform an annual thickness test for all the pipes.

Unit 2
2.16 Pressure Relief Valves

The pressure relief valves are designed to protect personnel and equipment from being
injured by an accidental explosion. The skid is equipped with four pressure relief valves.
There are two 2" SPM pressure relief valves installed on the discharge ends of the
Triplex pumps (Figure 2-129 and Figure 2-130) and one 1" Baird pressure relief valve
installed on the surge tank (Figure 2-131). Ensuring these valves operate to
specification is very important.
Figure 2-129: 2" SPM Pressure Relief Valve (road Figure 2-130: 2" SPM Pressure Relief Valve (curb
side) side)
Figure 2-131: 1" Baird Pressure Relief Valve

Unit 2
The configurations of the 1" and 2" pressure relief valves are illustrated in Figure 2-132
and Figure 2-133, respectively.
Figure 2-132: 1" Baird Pressure Relief Valve – 70 MPa (10,000

psi)

Unit 2
1. Valve Body
2. Spider
3. Adjusting Screw
4. Keeper
5. Cap
6. Disk Spring
7. Ball and Seat
8. Lock Nut
9. Cap Seal
10. Keep Seal
11. Seat Seal
12. Wing Nut
13. Ring Segment
14. Retainer Ring
15. Set Screw
16. Drive Screw
17. Label
18. Ring Seal
Figure 2-133: 2" SPM Pressure Relief Valve – 103 MPa (15,000 psi)
2.16.1 Pressure Relief Valves Maintenance

Regularly scheduled pressure relief valve maintenance is required. The maintenance
tasks are as follows:
• Relief valves should be tested, on a weekly basis, and the test results recorded
in the unit maintenance manual. Recommended test dates are during crew
changes days (refer to Section 2.19 Equipment Pressure Testing).
• If the relief valve function tests show a different pressure than what is tagged,
remove the adjustment cap, adjust and retest the relief valve. Retag the valve
with the appropriate bypass pressure.

Unit 2
• All tests should be completed, and the pressure logged, using the chart recorder.
• If slurry is pumped through the valve prior to regular service intervals, the valves
should be disassembled, cleaned, and inspected for any sign of cement
accumulation, wear, or fatigue.
NOTE: Do not use the supplied lithium grease on the pressure relief valve spring. This
grease will freeze, depending on the climate of the job location.
Table 2-40: Unit Specifications for Pressure Relief Valve Configurations
Configuration
Seat ID
Operating OD
Setting Range (mm/
# of Spring Ball Bearing OD
Unit # (MPa/psi) Type (MPa/psi) Springs Configuration inch) (mm/inch)
0-103/
35/5000 SPM 16 2x2 19/0.75 35/1.375
924501 0-15,000
924502
2-10/ 13
7/1000 Baird 18 1x1 19/0.75 23 /16/0.9375
300-1,500
• Regular relief valve maintenance consists of disassembly, inspection,
reassembly, adjustment of relief valve to unit specification, bench testing with the
Haskell pressure pump to confirm pressure setting and tagging the valve to
indicate its setting.
• Instructions for unit disassembly and reassembly are listed, for both the 1" Baird
and 2" SPM pressure relief valves, next.

Unit 2
2.16.1.1 Disassembly
Warning
Ensure there is no pressure on the valve.
The disassembly steps are:
1. Back off the locking nut and loosen the adjusting screw.
2. Loosen the valve cap.
3. Loosen the wing union and remove the valve from the discharge line tee or pump
fluid head.
4. Place the valve in a vise. Remove the valve adjusting screw, lock nut, and valve
cap. Once the valve cap is off, pull the keeper assembly out of the valve body
and remove the Bellville springs.
5. Remove the ball bearing from the valve seat.
6. Clean the Bellville springs, keeper, ball bearing, seat, and the inside of valve
body. Visually inspect the condition of each piece for signs of wear and/or
fatigue.
7. Use a flashlight to visually inspect the condition of the ball seat inside the valve
body.
8. Replace any components showing signs of wear or fatigue.
9. When removing the seat,

Unit 2
a. Baird - Place the valve in a vise and remove the seat frame from the body of
the valve. Once the seat frame has been removed, the seat can be removed
by tapping the seat from the top of the valve down and out of the bottom of
the valve (using a hammer and punch).
b. SPM - Turn the valve upside down after removing the ball and keeper. Use a
punch to tap the seat up and out the top of the valve.
2.16.1.2 Reassembly
The reassembly steps are:
1. Before replacing the seat, clean the seat area and apply grease liberally (refer to
Table 2-40: Unit Specifications for Pressure Relief Valve Configurations). Ensure
the seat is in place by tapping it gently with the same hammer and punch used
when removing the seat. The seat on the Baird valve is inserted from the bottom;
while the seats on the SPM valves are inserted from the top. Ensure the seat
faces the correct way; the chamfered edge should face the ball bearing.
2. On the Baird valve, apply Loctite 567 Thread Sealant to the seat frame thread,
and then screw the thread into the bottom of the valve body. This is the high
pressure side of the valve, and should be tightened with a 48" pipe wrench into
the male WECO thread half.
3. Lubricate the new ball bearing with grease and insert it into the valve seat.
4. Lubricate the keeper assembly with grease and place the greased springs onto
the keeper assembly in the correct configuration (refer to Table 2-40: Unit
Specifications for Pressure Relief Valve Configurations).

Unit 2
5. Place the keeper assembly into the valve body and on top of the ball bearing.
6. Using an anti-seize compound, lubricate the threads of the valve cap, thread the
cap on, and tighten.
7. Using an anti-seize compound, lubricate the threads of the adjusting screw and
lock nut. Tighten the adjusting screw until contact is made with the Bellville spring
stack.
8. The unit should now be tight at every thread seal, except for the adjusting screw
and lock nut.

Unit 2
The wiring of an adjustment screw cover, over the top of the adjustment screw and lock
nut, provide a visual indication of when, and at what pressure, the relieve valve was last
adjusted (Figure 2-134 and Figure 2-135). It also indicates whether the valve has been
tampered with since last being tagged.
Figure 2-134: 1" Baird Pressure Relief Valve Figure 2-135: Close Up of 1" Baird Pressure
(shown with wired and tagged adjustment screw Relief Valve
cover in place)

Unit 2
The materials used to tag the 1" Baird pressure relief valves (Figure 2-136) are ordered
through the Sanjel Procurement Department.
Modified
2" Brass Tag Adjustment Screw
3
/32" Cable
with Sleeve Adjustment
Screw Cover
Figure 2-136: 1" Baird Pressure Relief Valve (with tagging materials)
The SPM pressure relief valves are equipped with an adjustment screw cover and only
require the addition of a Sanjel tag (Figure 2-137).
Figure 2-137: 2" SPM Pressure Relief Valve (with Sanjel 2" Brass
Tag)

Unit 2
To effectively communicate the pressure relief valve’s date of adjustment, a company
wide standard method for labeling is used. Brass tags are labeled on one side with iron
stamps. Refer to Figure 2-138 for the standard labels.
Figure 2-138: Standard Pressure Relief Labels (Metric on the left

and Imperial on the right)
2.16.1.3 Adjustment Screw Modification

The adjustment screws for the 1" Baird pressure relief valves must be modified to
accommodate the adjustment screw cap. This involves drilling a 1/8" hole completely
through the side of the nut part of the adjustment screw (Figure 2-139).
1/8” drilled
hole
Figure 2-139: 1" Baird Adjustment Screw Modification

Unit 2
Table 2-41: Relationship between Working Pressure Rating, Spring Number & Orientation, and
Bore Seat Internal Diameter
ALUMINUM WORKING VOLUME SPRING SEAT INLET CAP
BRONZE PRESSURE (GPM) AT ARRANGEMENT BORE AND COLOR
31G S.S. OR RANGE 25% OVER AND NUMBER OUTLET CODE
MONEL SET
PRESSURE
762 7601-2-LLP 25 - 400# 3-100 Thin 1x1 19 11/8” 2” NPT White
Table 2-42: 2" SPM Pressure Relief Valve Configurations

INLET (LOW PRESS) PRESSURE INT. END SERVICE TEMP.
DISCHARGE RANGE NSCWP RANGE
2” – 1502 M 2” LPTL 0-15,000 15,000 Standard -30°C-110°C
Table 2-43: 1" Baird Pressure Relief Valve Configurations

ALUMINUM WORKING VOLUME SPRING SEAT INLET CAP
BRONZE 316 PRESSURE (GPM) SET ARRANGEMENT BORE AND COLOR
S.S. OR RANGE PRESSURE AND NUMBER OUTLET CODE
MONEL
761 7601-1-LP 300-1000# 25-100 Reg 1x1 18 ¾” 1” NPT Yellow
Key Action Items

3 Pressure relief valves must be tested weekly. All test results are
recorded in the unit maintenance manual. The recommended test
dates are crew change days (refer to Section 2.19 Equipment Pressure
Testing).

Unit 2
2.17 Skid Structural Frame Maintenance

• Visually check the mounting bolts for rust, weekly. Replace with Grade 8 bolts, if
needed.
• Check the structural frame for cracks, at the 250 hour service.
• Check the tightness of the mounting bolts, at the 250 hour service. Tighten the
bolts, if necessary.
2.18 Lifting and Transporting the Skid

Once the SCM skid finishes the cementing jobs on one job site, it needs to be
transported to the next job site. When transporting the skid on shore, a winch truck can
be used. When transporting the skid to an offshore drilling rig, via a ship, sometimes the
skid will be disassembled and cranes will be used to lift each piece of the skid onto the
ship.
Warning
To avoid damage to the crash guards, never use any part of the crash guards as a lifting point.
NOTE: Before lifting and transporting the main skid, make sure the mix tank, averaging
tank, and displacement tank are all empty.

Unit 2
2.18.1 Lifting and Transporting the Main Skid using a

Winch Truck
To transport the main skid using a winch truck, first, tighten the winching cable around
the end rolls of the cross member, and the cross member itself, at the engine end of the
secondary skid (Figure 2-140 and Figure 2-141). Then, winch the skid with the winching
cable to a proper position where the skid can seat on the deck of the winch truck
securely (Figure 2-142).
Figure 2-140: Tightening Winching Cable around Lifting Lugs and Cross Member

Unit 2
Figure 2-141: Tightening Winching Cable around Lifting Lugs and Cross Member (cont’d)
Figure 2-142: Lifting and Transporting the Skid using a Winch Truck

Unit 2
2.18.2 Lifting and Transporting the Iron Skid using a

Winch Truck
Warning
The surge tank load cell safety pin must be locked, prior to lifting and traveling, and then
removed before the job starts.
The cement heads must be secured with chains, on the storage domes, prior to lifting and
traveling.
All iron must be locked on the racks prior to lifting and traveling.
To transport the iron skid using a winch truck, first, tighten the winching cable around
the end rolls of the cross member and the cross member itself at the surge tank end of
the skid. Then, winch the skid with the winching cable to a proper position where the
skid can seat on the deck of the winch truck securely.
2.18.3 Lifting the Main Skid using Cranes (with the Skid
Assembled)
Depending on the number of available cranes, and the lifting capacity of each crane, to
lift the skid as a whole unit, the following will be discussed:
• Four point lifting using two cranes
• Four point lifting using one crane

Unit 2
2.18.3.1 Four Point Lifting using Two Cranes
Caution
The lifting slings that are attached to the end rolls of the secondary skid must be vertical to
prevent the slings from contacting and damaging the crash guards of the primary skid. Spreader
bars must be installed to keep the slings vertical.
To lift the entire skid using two cranes, two 125 ton cranes are recommended. The four
lifting points, that are connected to the lifting slings, are the four end rolls of the two
cross members of the secondary skid (Figure 2-143).
Figure 2-143: Four Point Lifting using Two Cranes

Unit 2
2.18.3.2 Four Point Lifting using One Crane
Caution
The lifting slings that are attached to the secondary skid must be vertical to prevent the slings
from contacting and damaging the crash guards of the primary skid. Spreader bars must be
installed to keep the slings vertical.
To lift the entire skid using one crane, a 200 ton crane is recommended. The four lifting
points that are connected to the lifting slings are the four end rolls of the two cross
members of the secondary skid (Figure 2-144).
Figure 2-144: Four Point Lifting using One Crane

Unit 2
2.18.4 Lifting the Main Skid using Cranes (with the Skid
Disassembled)
When carrying or transporting the skid, via a ship, sometimes the skid needs to be
disassembled to allow the ship to accommodate the skid. One situation is that the
secondary skid will be removed from the primary skid. Then, the primary skid will be
lifted as one unit and placed on the ship by one crane or two cranes. The other situation
is that the primary skid will be disassembled into three parts: the engine skid, the pump
skid, and the hydraulic skid (after the secondary skid has been removed). In this case,
each single skid will be lifted and placed on the ship by one crane.
2.18.4.1 Eight Point Lifting using One Crane (with the Secondary
Skid Removed)
Before lifting the primary skid, using one crane, follow the procedure below to remove
the secondary skid from the primary skid, and set up the primary skid for lifting.
1. Unbolt all the Grade 8 bolts, and washers, fastening the secondary skid to the
primary skid. NOTE: Sanjel requires using Grade 8 bolts for fastening the skids
together. Refer to Table 2-44 for the specifications of the Grade 8 bolts.
Table 2-44: Tightening Torque Guide for Grade 8 Bolts
SAE Grade 8 – Coarse Thread

Size Clamp Load Plain Plated
1-8" (1.000") 54,525 lbs 909 ft-lbs 682 ft-lbs
2. Fold all the ladders and remove any tools and loose equipment.
3. Pull away the screw lock pins of the lifting lugs of the pump skid. Extend the
lifting lugs and insert the screw lock pins back, to secure the lifting lugs.

Unit 2
Caution
The lifting slings that are attached to the skid frame must be vertical to prevent the slings from
contacting and damaging the crash guards or any components of the skid. Spreader bars must be
installed to keep the slings vertical.
The eight lifting points, that are connected to the lifting slings, are the end rolls of the
two cross members of the primary skid, and the four lifting lugs of the pump skid (Figure
2-145). Sanjel requires using the G-209 S-209 screw lock pin anchor shackles (Figure
2-146) to fasten the slings to the lifting lugs. Refer to Table 2-45 for the specifications of
these types of shackles.
Figure 2-145: Eight Point Lifting using One Crane (with Secondary Skid Removed)

Unit 2
Figure 2-146: G-209 S-209 Screw Lock Pin Anchor Shackles
Table 2-45: Specifications of G-209 S-209 Screw Lock Pin Anchor Shackles
Nominal Working Stock No. Weight Dimensions (in.) Tolerance
Size Load Each +/-
(in.) Limit (t) G-209 S-209 (lbs.) A B C D E F C A
1-3/8 13-1/2 1018598 1018605 13.53 2.25 1.50 5.25 1.42 3.63 3.31 .025 .13
G H L M P
6.38 9.16 .75 6.84 1.50
2.18.4.2 Eight Point Lifting using One Crane (with the Secondary
Skid Removed)
Before lifting the primary skid using one crane, follow the procedure described in the
previous section, to remove the secondary skid from the primary skid and set up the
primary skid for lifting.
Caution
contacting and damaging the crash guards and any components of the skid. Spreader bars must
be installed to keep the slings vertical.

Unit 2
The eight lifting points, that are connected to the lifting slings, are the end rolls of the
two cross members of the primary skid, and the four lifting lugs of the pump skid (Figure
2-147). Sanjel requires using the G-209 S-209 screw lock pin anchor shackles (Figure
2-146) to fasten the slings to the lifting lugs. Refer to Table 2-45 for the specifications of
these types of shackles.
Figure 2-147: Eight Point Lifting using One Crane (with Secondary Skid Removed)

Unit 2
2.18.4.3 Four Point Lifting for each Single Skid

Before lifting each single skid, using one crane, follow the procedure below to remove
the secondary skid from the primary skid, disassemble the primary skid, and set up
each skid for lifting:
1. Unbolt all the Grade 8 bolts, and washers, fastening the secondary skid to the
primary skid.
2. Fold all the ladders and remove any tools and loose equipment.
3. Disconnect all the associated hydraulic lines, electrical lines, pipes, and drive
lines.
4. Pull away the screw lock pins of each skid. Extend the lifting lugs of the skid and
insert the screw lock pins back to secure the lifting lugs.
Caution
contacting and damaging the crash guards and any components of the skid. Spreader bars must
be installed to keep the slings vertical.

Unit 2
For the hydraulic skid, the four lifting points are the two end rolls of the cross member
and the two lifting eyes (Figure 2-148). For the pump skid, the four lifting points are the
four lifting lugs (Figure 2-149). For the engine skid, the four lifting points are the two end
rolls of the cross member and the two lifting lugs (Figure 2-150). Sanjel requires using
the G-209 S-209 screw lock pin anchor shackles (Figure 2-146) to fasten the slings to
the lifting lugs. Refer to Table 2-45 for the specifications of these types of shackles.
Figure 2-148: Four Point Lifting for Hydraulic Skid Figure 2-149: Four Point Lifting for Pump Skid

Unit 2
Figure 2-150: Four Point Lifting for Engine Skid

Unit 2
2.18.5 Four Point Lifting using Two Cranes (for the Iron
Skid)
Warning
The surge tank load cell safety pin must be locked prior to lifting and traveling.
The cement heads must be secured with chains, on the storage domes, prior to lifting and
traveling.
All iron must be locked on the racks prior to lifting and traveling.
The surge tank end is heavier than the swivel joint rack end of the iron skid, so in order
to keep a good balance when lifting the skid, two cranes should always be used. To lift
the skid using two cranes, the four points that are connected to the lifting slings are the
four end rolls of the two cross members (Figure 2-151).
Figure 2-151: Four Points Lifting using Two Cranes for Iron Skid

Unit 2
2.19 Equipment Pressure Testing

Pressure is constantly used, and is monitored diligently, in daily cementing and pumping
operations. All Sanjel equipment must adhere to a strict maintenance and testing
schedule to ensure a safe working environment for all personnel.
Warning
Always be familiar with the pressure limits of the equipment in use.
The maximum pressure is limited by the weakest equipment component.
Pressure test with a minimal number of personnel in the pressure test area.
Pressure test outside, whenever possible.
During pressure testing, secure and fasten all loose equipment using safety slings.
Place warning signs to alert all personnel to the planned pressure testing.
Cordon off the area surrounding the pressure test.
NOTE 1: Perform all the pressure tests with water.
NOTE 2: A safety meeting must be held prior to the pressure testing to ensure that all
personnel are aware of, and in compliance with, the pressure testing safety procedures.
2.19.1 Pressure Relief Valve Adjustment & Testing

The pressure relief valve adjustment and testing tasks are as follows:
• All pressure relief valves should be tested, on a weekly basis. The tests results
should be recorded in the unit maintenance manual. Recommended test dates
are during crew changes.
• Should the relief valve test at a different pressure than what is on the tag (± 5%
tolerance) remove the adjustment cap, adjust and retest the valve. Retag the
relief valve with the appropriate bypass pressure.

Unit 2
2.19.1.1 Pressure Relief Valve Maintenance

1. Attach the fitting to the wing half of the Haskell hydraulic pressure testing pump.
Attach the Haskell pump to the pressure relief valve and connect its water and air
lines.
NOTE 1: Using the Haskell pump to adjust and test the pressure relief valve is
simpler, and safer, than performing the operation using the pump on the SCM
unit.
NOTE 2: When the unit is equipped with Weco iron, adjust the discharge
pressure relief valve to 35 MPa (5,000 psi).
NOTE 3: When the unit is equipped with Guiberson iron, adjust the discharge
pressure relief valve to 28 MPa (4,000 psi).
2. Increase the pressure from the Haskell pump until the pressure relief valve
reaches bypass pressure. Record the bypass pressure value and release the
Haskell line pressure, so that the valve reseats. Increase the compression of the
spring stack by turning the adjusting nut on the valve by half turns. Repeat the
test until the valve reaches the desired bypass pressure (refer to Table 2-40).
Danger
Always stay clear of high pressure lines when adjusting and testing pressure relief valves to
protect against fitting failures or line breaks.

Unit 2
3. Once the correct relief valve bypass setting is reached, the pressure relief valve
should be labeled with an aluminium tag and wired between the adjusting screw
and lock nut. This tag lists the current valve bypass pressure setting, and serves
as an indicator to determine if the valve has been altered since the last
configuration and testing date.
4. Operators should follow the recommended pressure test procedure outlined in
accordance with the Engineering Memo (dated January 28, 2003), which
requests a chart documented function test of the pressure relief valve setting,
prior to any pumping operation test.
2.19.2 System Pressure Calibration

To ensure reliable operation of the pressure measurement system, weekly calibration
checks are performed. The Haskell pressure pump will calibrate the system and
establish gauge pressure, when a discrepancy between electronic sensor
measurements and panel gauge readings is detected. The pressure calibration steps
are as follows:
1. Install a pen chart in the chart recorder to capture the results of the pressure
system calibration.
2. Turn on the automation system.
3. Attach the Haskell pump to one of the discharge plug valves. Open the return line
valve to the unit tanks and open the discharge valve opposite the side of the
Haskell pump.

Unit 2
4. Circulate water from the Haskell pump through the discharge fluid end of the
pump and out the discharge valve. Close the discharge valve once water flows
out.
5. When circulation is established, close the return line valve and pressure the line
to 10 MPa (1,450 psi). Shut in the system and visually inspect the pen recorder,
deck gauges, and electronic pressure head on the HMI screen to verify that all
pressure readings are the same (± 5% tolerance). Hold the pressure for at least
three minutes. If the readings are not the same, isolate the inaccurate sensor,
perform the necessary maintenance, and repeat the pressure test.
6. When all the pressure sensor readings are in agreement, pressure the line to 32
MPa (4640 psi). Shut in the system and ensure the pressure sensors are still in
agreement. Hold the pressure for three minutes. If the readings are not the same,
isolate the inaccurate sensor, perform the necessary maintenance, and repeat.
NOTE: Do not go beyond 32 MPa (4,640 psi).
7. When all the pressure sensor readings are in agreement, bleed off the system
pressure to the unit tanks by opening the return valve. Remove the Haskell
pressure pump and add the pressure chart, with the date of calibration, to the
unit maintenance file.
8. Update the Component Pressure Maintenance Log. Keep it with the unit records.
9. Ensure all charts with the recorded pressure test measurements are dated and
kept with the unit maintenance record. NOTE: Occupational Health and Safety
(OH&S) inspectors onsite may request these records.

Unit 2
2.19.3 Onsite Pressure Testing

Before attempting the pressure testing procedure, it is imperative that Sanjel
Engineering has certified the treatment (or treating) iron for the current year. The
pressure relief valve, and pressure heads, must also be inspected and certified. The
onsite pressure testing steps are as follows:
1. Discuss the pressure line test, and pressure limits, with the company
representative before testing the lines.
2. Pressure test the lines to 10% over the maximum expected working pressure (job
specific) or the wellhead rating, without exceeding the maximum working
pressure of the treating iron.
3. Ensure the PLC automation system is operating.
4. With the discharge valve closed, prime the pumps by circulating fluid through the
return lines to the tanks, using only the pressurizer pump. Once circulation is
confirmed with the engine idle, engage the pump in pump gear to circulate back
to the unit tanks.
5. Perform the treating iron test. Ensure the fluid destination valve (well head, pit,
etc.) is open before opening the discharge valve. Close the unit return valve. If
possible, engage the pressurizer pump and confirm circulation by checking for
the tank volume decrease. If the discharge pressure is higher than the
pressurizer output, roll the pump at idle (and in high gear) while watching the
deck gauge pressure.

Unit 2
6. Once circulation is confirmed without pressure, shut the pump down and
pressure up for the pressure test. Shut in the fluid destination valve to “dead end”
the treatment line.
7. With the engine idling, and the unit in low gear, apply low pressure to the line
(approximately 25% of final pressure). Observe for any leaks (apparent by falling
pressure on the gauge). The treating iron pressure test is accepted when the
pressure remains at the required test pressure for ten minutes and is 10%
greater than the expected job treating pressure.
8. The Job Supervisor or a Sanjel employee must inspect the lines and pumps for
leaks.
Danger
Keep all other personnel away from the area.
NOTE: If there is a leak, ensure that all pumping stops. Release the treating iron
line pressure through the bleed off line (if a check valve is present) or by opening
the return valve on the unit (if no check valve is present). Once all pressure is
bled from the line, the supervisor may instruct Sanjel personnel to repair or
replace the leaking component.
9. Once an acceptable test has been performed, bleed off the treating iron line
pressure (refer to step 5).

Unit 2
2.19.4 Additional Regulations for Pumping

The additional regulations for pumping are as follows:
• Before connecting any treating iron, visually inspect each component for signs of
wear, damaged threads, and damaged or missing rubber inserts.
• Ensure each component has an intact serial number band or tag.
NOTE: Do not use the equipment unless the equipment is recertified and
re-serialized.
• Prior to (and during) pressure testing and pumping operations, move all
personnel to a safe area. All personnel involved in the pressure test must be in
constant communication either visually or by radio.
Warning
Install high pressure warning signs marked "DANGER-HIGH PRESSURE AREA-KEEP CLEAR"
near the iron and in locations that can be seen by individuals approaching the treating iron.
• Lay treating iron beside the catwalk or down the pipe rack to the V-door between
the catwalk and the rig floor. Stay away from the drilling pipe, casing, or tubing on
the rig.
• Ensure oil is used on all thread connections and that the thread connections are
properly tightened (do not over hammer).
• Secure the line at the top, and bottom of the V-door, to prevent the line from
sliding down or binding during pumping.

Unit 2
• Use water for pressure testing. Never pressure test with hydrocarbon based
fluids (i.e., diesel).
2.19.4.1 Maximum Working Pressures

The maximum working pressures and treating iron testing steps are as follows:
• Sanjel Weco Iron – 70 MPa (10,000 psi)
• Sanjel Guiberson Iron – 40 MPa (5,800 psi)
• Do not exceed the rated working pressure of the treating line connections, or the
fluid ends, during the pressure test. If, for any reason, the pressure ratings must
be exceeded, obtain written approval from the Engineering Department.
• Always test the wellhead and customer master valve, which is the final
connection between Sanjel equipment and the customer equipment. If the
customer valve does not hold the pressure, obtain approval from the customer
before continuing with the treatment. This approval must be recorded on the
Treatment Report.
NOTE: Never begin a treatment with a leak on the wellhead.
• Rented treating iron may be used only if it is rated to 103 MPa (15,000 psi)
working pressure. The vendor must provide proof that iron has been inspected,
and tested, in accordance with Sanjel Standards.
• Treating Iron Movement
o Ensure the treating lines are flexible and can move during the treatment.
Install swivel joints to allow the line to move safely.
• Treating Iron Above the Ground

Unit 2
o All treating lines must be on a solid surface. If this is not possible, fasten
the line with chains or blocks. The air hoist, chains, and safety slings must
support the treating iron on the rig.
• Multiple Pumping Units
o For jobs with two or more pumps, the units must be connected to a
common treating line with laterals. The treating line from each pump unit
to the main treating line must have swivel joints that allow the line to
move. These swivel joints must be installed next to the lateral. Each of
the pump units must have an operating pressure transducer and the main
line must have an additional pressure transducer.
• Wellhead Pressure Rating
o Before installing a valve or treating iron, the supervisor must check the
pressure rating of the wellhead valves and fittings. If the rating is not
marked on the equipment, the supervisor must obtain the information
from the customer before connecting to the wellhead (see Table 2-46).
NOTE: Advise the customer immediately, if there is a problem with the equipment.
• Cement Plug Loading Heads, Swages, and Lead-Off Chicksans
o This equipment must be fastened to the elevator links with a safety cable.
If Chicksan loops are held in position, a second two-way Chicksan can be
connected to the cement head manifold. The safety cable can be
connected to the second Chicksan. The weight of the Chicksans can
controlled with the safety cable.

Unit 2
Table 2-46 gives an example of a Wellhead Pressure Rating/Inspection Service Log.
Table 2-46: Wellhead Pressure Rating/Inspection Service Log
WELLHEAD PRESSURE RATING / INSPECTION SERVICE LOG
(MPa/psi)
Pressure
Unit Number
MAX
INSPECTION INTERVAL: WEEKLY RECORD PRESSURE READING
ITEMS TO BE INSPECTED Jan/Feb Mar/Apr May/June July/Aug Sep/Oct Nov/Dec

Week 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5
28/
1 Manifold
4,000
70/
2 Deck Gauge
10,000
Discharge Electronic Pressure 103/

3
Transducers 15,000
Discharge Pressure Relief 70/
4 SCM W/MK IV AT units SPM Equipped 70
MPa 10,000
7/
5 Return Pressure Relief
1,000
Date
INSPECTORS
INITIALS
Cementing Services SCM W/MK IV AT Skid Operator Training Manual 2-197

Version 1.0
Unit 2
2.20 SCM Skid Process Troubleshooting

This section covers the basic troubleshooting of the skid unit operations and
performance malfunctions, their probable causes, and recommended solutions (see
Table 2-47).
Table 2-47: SCM Skid Process Troubleshooting
Problem Reason/Solution
Engine
Engine does not start • Check the night switches.

• Check the air kill valves.
• Check the battery and battery connections.
• If you just completed the service, check for fuel in the
fuel filter (air locked).
• Pump the fuel primer.
Engine overheats • Check the coolant level.

• Check for possible leaks in the coolant system.
• Turn the engine cooling fan on.
• Check the fan belt.
Transmission
Transmission is not shifting • Ensure the engine is at an idle.

• Check connections on shifting linkages.
Triplex Pump
Throttle lost • Check that engines are running.

• Check that the throttle is functioning properly.

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Unit 2
Triplex pump has insufficient oil • Check the fluid levels.

pressure
• Check the lines for leaks
• Check the pumping rate. In extreme conditions, the oil
pressure can be very low.
o Start the pump slowly and let the oil circulate

and warm up.
• Check the pressure relief valve return line. If the oil is
returning through the return line, the pressure relief
valve is set too low; contact the maintenance.
Triplex pump has no suction NOTE: It is important to circulate the truck first.
• Switch from the tub suction to the tank suction.
• Jack the short suction valve to remove any debris.
• Turn off the pump, remove the 2" caps, and pop valves
using the “valve popping stick”.
• If the valves will not pop (possibly debris is stuck in the
valve in the pump),
o Remove and inspect the pump components.

• If the valves pop and no fluid comes out of the valves,
then the seats, valves, and springs must be checked
for possible washing out.
Triplex pump has no discharge • Check to see if the return line is closed.
Lubrication
Lube line not functioning • Cement or debris is trapped in the lube line.
(plugged)
• Worn packing is trapped in the lube line.
• Check to determine if the valves are malfunctioning.
• Check the oil level (relieve pressure first).
• No pressure.
o Change the lube line, or manually dump oil on

the plunger during a job.
o Change the valves, if new valves are available.

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Unit 2
Centrifugal Pump
Low pressure on the mixing water • Check the water diffusion plate.
pump
• Check the mixing "Y" screen filter.
• Check the mix head pressure in the “Process
Variables” screen.
Low mix water rates • Check the rpm of the mix water pump.
• Check to determine if the supply valve to the mixing
water pump is fully open.
• Low water pressure in the centrifugal pump (mixing
water pump).
o Worn impeller inside the pump.
o Worn packing (sucking air).
o Low water level in the rig tank.

▪ Check the rig tank water level prior to
starting the job; it should be above the
centrifugal pump height.
▪ Decrease the hose distance between
the water tank and the pump.
▪ Call the water hauler to fill the tank or
ensure a second water supply is
available (Sanjel policy).
• The fish trap filter is plugged.
• The mixing tree "Y" screen filter is plugged.
Hydraulics
Hydraulics malfunctioning • Check the cooling fan.

• Clogged hydraulic filter; it will still operate but will go
through a bypass and the hydraulic fluid will not be
filtered.
• Check the hydraulic fluid level.
• Check for the source of the leak.

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Unit 2
Mixing System
Density fluctuating • Check the water rate – steady.

• Check the bulk unit operation.
• Use hard walled bulk hose.
• Check the bulk cement sleeve for build-up.
Loss of mixing density • There is obstruction in the line.

• Loose wire connection.
• There is too much aeration in the fluid. Add defoamer
to the cement slurry.
• Check the recirculation pump operation.
Density too high • Check if the PLC program is on the proper recipe.
• Check the problems with the mix water system.
• The bulk control valve is malfunctioning.
• The “MIX WATER VALVE” is set to “MANUAL”.
• The “CEMENT VALVE” is set to “MANUAL”.
Dry mixing • Open the displacement tank valve.

• Turn on the master water valve with the “Start Mixing”
function on.
• Turn the mix water valve to automatic mode with the
“Start Mixing” function on.
• Turn on the recirculation pump.
• Turn on the mix water pump.
• Make sure there is flow through the recirculation line.
Bulk control valve not opening • Visually inspect the bulk control valve for buildup.
• Disengage the hydraulics and operate manually.
• Turn the main and instrumentation power switches on.

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Unit 2
Mix water rate decreasing or low • The mix water automated valve is closed.
• The mixing water pump rpm is low.
• The fish trap filter is plugged.
• The mixing water pump is sucking air.
o Connections on the flush hoses are loose.
o Self loading too fast in tanks creates air

pockets in water.
• Turn the mix water valve to the automatic mode.
Wet mix head • Ensure the mix head is tight.

• Check the O-rings on the bulk cement sleeve for wear.
• Check the operation of the vacuum breakers.
Low recirculation pressure • Pump rate is low.

• Check the cement buildup in the line.
• Check the incorrect positioning of valves.
• Fluid volume in tank is low.
Agitation paddles stop • The control is in “OFF” position.

• Check obstruction in the tanks.
Dry cement out of vacuum • Check the poppet. Replace, if it is not seating.
breaker
Aeration in slurry • Check the blend of the slurry. Add defoamer when
needed.
• There is excessive air in the cement. Check the bulk
operation starting from the bulk unit, the bulk cement
hose, to the bulk control valve.
Loss of information from mass • There is excessive air in the slurry.

flow meter
• Check for loose wire connection.
• Check for loss of power to the meter.

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Unit 2
Fluctuating rates of the 2" Coriolis • Set the valves in proper positions.
• Close 3" valve for two seconds to clean out 2"
recirculation line.
• Maintain proper rpm on the recirculation pump.
• Mixing tank volume is getting too low and sucking air.

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Unit 2
2.21 Top 10 Maintenance Items

Listed below are the top ten items that will help in the maintenance program of each
SCM unit. Performing these items will greatly reduce the frequency of breakdowns.
1. Inspect and clean up the mix head; check and clean the vacuum breakers after
every job.
2. Grease the unit twice per week.
3. Inspect the hydraulic, air, and coolant lines in areas where rubbing is suspected.
4. Complete a proper wash up and ensure that all components of the unit are clean.
5. Ensure the oiler oil is always full.
6. During prolonged engine idles, always keep the engine above 1000 rpm.
7. Wash the batteries whenever the truck is washed.
8. Inspect the plumbing system for potential wear and deterioration daily.
9. Diligently complete all pre-job and post-job inspections.
10. Maintain regular crews on all the equipment.

Version 1.0
Training Manual Feedback
3.0 APPENDIX A
3.1 MARK IV AT system description and
troubleshooting (for electricians)
The Sanjel Cyclonic Mixer (SCM) is a high energy mixing system that combines water
and dry bulk cement to produce uniform slurry. The control system for the SCM is called
the Mark IV with Automated Technology (AT). The operator enters the cement blend
data, which the system uses to calculate set-points for water and bulk cement delivery.
Numerous process variables are monitored and specific valves are adjusted,
continually, to maintain tight control over the process. The water and bulk cement
valves are controlled with hydraulic and pneumatic actuators.
3.2 System Overview

The core of the control system is the Programmable Logic Controller (PLC). The PLC is
essentially a computer that runs a custom program, which analyzes process variables,
performs calculations and generates outputs. These outputs are used to control the
process, as well as visually provide the operator with process status and variable
values. The interface to the PLC, and the process, is a Human Machine Interface (HMI).
The HMI is a 15" touch screen display that is also a computer running on Windows CE.
It provides the operator with a visual interface of the process, and the ability to input
data and execute functions used to control the process.
Cementing Service SCM W/MK IV AT Skid Operator Training Manual 3-1

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The system transmits data to the Field Data Acquisition Program (FDAS) program. This
job data is recorded and enables the operator to produce a graph, on location, for the
customer. Numerous process variables are also recorded to a data card located in the
HMI. This data can be used to analyze the job in the event there are concerns.
3.3 Detailed System Description

The main process takes place in two tanks. One tank is used for mixing and the other
for averaging. The water and cement are brought into a high energy mix head, which
sits above the mix tank. As the slurry volume increases, it eventually reaches the weir
that separates the two tanks. At this point, the slurry flows into the averaging tank. The
small fluctuations of density, in the mix tank, are averaged out by the volume of slurry in
the averaging tank. The high pressure pumps transport the cement slurry from the
averaging tank into the well.
The control system regulates three valves which control the process (master water
valve, mix water control valve, and bulk cement control valve). The descriptions of these
valves are as follows:
• Master Water Valve
o The master water valve is a pneumatic butterfly valve that sends an open,
or closed, feedback signal to the PLC. It can be controlled automatically
by the PLC or manually via the toggle switches on the upper control
console. When opened, it directs water to the high energy mix head and to
the mix water control valve.

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• Mix Water Control Valve
o Additional water for the process is regulated with the mix water control
valve. This valve is hydraulically actuated and provides position feedback
to the PLC and a BD101 servo valve driver board. It can also be controlled
automatically by the PLC or manually by the switches (and potentiometer)
on the upper control console. This valve directs water into the recirculating
loop of the mixing side of the process. In the event of hydraulic failure, the
valve can be actuated by hand.
• Bulk Cement Control Valve
o The bulk cement control valve adds dry bulk cement to the high energy
mix head via a pneumatic delivery system. This valve is hydraulically
actuated and provides position feedback to the PLC and the BD101 servo
valve driver board. It can also be controlled automatically by the PLC or
manually by the switches (and potentiometer) on the upper control
console. In the event of hydraulic failure, the valve can be actuated by
hand.

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The slurry on the mixing side is circulated, by a centrifugal pump, back to the bottom of
the high energy mix head. This helps to blend the slurry. Part of the circulated slurry is
directed through the 2" Coriolis mass flow meter. This meter continually measures the
slurry density and this value is used in calculations that control the bulk cement valve.
A surge can is used to aid in constant delivery of cement to the high energy mixing
head. There is still a small risk of fluctuations with the delivery of the bulk cement.
These fluctuations are mitigated by continually monitoring the process and updating the
position of the bulk cement valve.
The mix water control valve is controlled using a calculated set-point from the cement
program. Feedback is provided with a 3" magnetic flow meter. The water that is directed
to the high energy mix head goes through a series of jets. These jets form a water
pattern that wets, and blends, the incoming cement. The mix head combines the water,
and cement, with the recirculated cement to produce the cement slurry.
Cement that travels from the averaging tank to the down hole pump passes through the
4" Coriolis mass flow meter. This meter is used to measure down hole density and rate.
The system can also use the magnetic pickups on the down hole pumps to monitor
down hole rates.
The revolutions on all four centrifugal pumps are monitored. The rpm of the pumps are
directly related to the process pressures of the system. There are recommended
operating ranges for the centrifugal pumps, but the process pressures are what
determine the centrifugal pumps rpm settings.

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3.4 Process Variables

Figure 3-1 shows the Process Variables Screen.
Figure 3-1: Process Variables Screen
3.4.1 Rates
This subsection discusses the various flow rates.
3.4.1.1 Mix Water Flow Rate

The mix water flow rate is measure by a 3" magnetic flow meter. The output is
transmitted to the PLC via ProfiBus. The measuring range of the instrument is 0 – 3
m3/min (0 – 19 bbl/min). There is a display on the transmitter, which can be used to view
the mix water rate, in the event the control system fails. The flow rate to the mix head
jets is about 250 liters/min (66 US gal/min) with the unit operating at a recommended
rpm and pressure. The bypass flow rate to the recirculation line is about 1200 liters/min
(317 US gal/min) with the unit operating at a recommended rpm and pressure.

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3.4.1.2 Down Hole Pump Rates (PLC)

The down hole rate is measured by one of two methods. The preferred method of
measuring this rate is to use the 4" Coriolis mass flow meter, which is located in the
piping between the discharge of the down hole boost pump and the suction of the high
pressure down hole pumps. This flow rate is sent to the PLC via ProfiBus. Observe the
range of the 4" Coriolis meter in the density measurement area (Figure 3-1).
A magnetic pickup is located in the housing of each of the high pressure down hole
pumps (above the bull gear). When this gear makes one full revolution, it displaces
each of the pump plungers one time. The PLC uses the frequency signals from the bull
gears to calculate the flow rate of the pumps. The PLC adds these rates and displays a
combined down hole pumping rate.
3.4.1.3 Down Hole Pump Rates (Backup – Red Lion)

The down hole backup rate is measured by utilizing a second (redundant) magnetic
pickup, located on the high pressure down hole pumps. These rates are displayed,
individually, on panel-mounted LED meters.
3.4.1.4 Auxiliary Rates 1 and 2

When required, any additional rates can be monitored and recorded. There is an input
panel, located under the upper control console, that can be accessed from ground level.
Both these inputs are routed through magnetic pickup amplifiers. The operator can input
a meter factor for each channel and the value is displayed on the “Process Variables”
faceplate.
NOTE: Since the rate is calculated in the PLC, a meter factor of 1 is used in FDAS.

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3.4.2 Pressure
This subsection discusses the various pressures.
3.4.2.1 Treating Pressure (curb side)

This signal is produced by a 4 – 20 milliamp pressure sensor with a 0 – 103.4 MPa (0 –
15000 psi) range. There is a full range calibration mode on this sensor. The PLC
outputs a digital signal to an interposing relay, which activates the transducer’s full scale
output.
NOTE: The treating pressure sensor is located on the discharge piping of the high
pressure down hole pumps.
3.4.2.2 Treating Pressure (road side)

This signal is produced by a 4 – 20 milliamp pressure sensor with a 0 – 103.4 MPa (0 –
15000 psi) range. There is a full range calibration mode on this sensor. The PLC
outputs a digital signal to an interposing relay, which activates the transducer’s full scale
output.
NOTE: The treating pressure sensor is located on the discharge piping of the high
pressure down hole pumps.
3.4.2.3 Auxiliary Pressure

When required, a third pressure transducer can be used to monitor, and record, a
process pressure (annular pressure). There is a signal input panel, located under the
operator’s console, that can be accessed from ground level. This is where the operator
will find the connection point.

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This signal is typically produced by a 4 – 20 milliamp pressure sensor with a 0 – 15000
psi range. Use either a sensor that has the full range calibration mode or a standard two
wire 4 – 20 milliamp sensor. The value for this auxiliary transducer is displayed in the
“Process Variables” area.
3.4.2.4 Mix Water Pressure – Mix Head

This signal is produced by a 4 – 20 milliamp two wire pressure transducer with a 0 –
160 psi range. This measurement represents the water pressure at the mix head. The
value is displayed in the “Process Variables” area.
3.4.2.5 Slurry Recirculation Pressure – Mix Head

160 psi range. This measurement represents the recirculation pressure at the mix head.
The value is displayed in the “Process Variables” area.
3.4.2.6 Slurry Recirculation Pressure – 2" Coriolis Mass Flow

Meter
160 psi range. This measurement represents the back pressure in the 2" mass flow
meter, in the recirculating loop, of the mixing system. The value is displayed in the
“Process Variables” area.
3.4.2.7 Down Hole High Pressure Pump Charge Pressure

160 psi range. This measurement represents the boost pressure at the suction of the
high pressure down hole pumps. The value is displayed in the “Process Variables” area.

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3.4.3 Density
This subsection discusses the various densities.
3.4.3.1 Recirculation Density

This density is measured by a 2" Coriolis mass flow meter. This instrument also outputs
flow rate, total and temperature. These signals are transmitted to the PLC via ProfiBus.
The excitation current value is sent to the PLC via the 4 – 20 milliamp analog output.
The excitation current range is 0 – 100 milliamps. The instrument measures mass flow
and converts this to a liquid flow rate and density. The measuring limit varies with the
density of the slurry. The instrument has a range of 0 – 1150 kg/min (0 – 2500 lb/min).
Since water has a density of 1000 kg/m3 (8.34 lb/gal), then the measuring range would
be 0 – 1.150 m3/min (0 – 7.2 bbl/min). If the slurry being pumped had a density of 2000
kg/m3 (0 – 16.68 lb/gal), then the measuring range would be 0 – .575 m3/min (0 – 3.6
bbl/min).
3.4.3.2 Down Hole Density

This density is measured by a 4" Coriolis mass flow meter. This instrument also outputs
flow rate, total and temperature. These signals are transmitted to the PLC via ProfiBus.
The excitation current value is sent to the PLC via the 4 – 20 milliamp analog output.
The excitation current range is 0 – 100 milliamps. The instrument measures mass flow
and converts this to a liquid flow rate and density. The measuring limit varies with the
density of the slurry. The instrument has a range of 0 – 5800 kg/min (0 – 12, 787
lb/min). Since water has a density of 1000 kg/m3 (8.34 lb/gal) the measuring range
would be 0 – 5.800 m3/min (0 – 36.5 bbl/min).

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If the slurry being pumped had a density of 2000 kg/m3 (16.68 lb/gal) then the
measuring range would be 0 – 2.900 m3/min (0 – 18.5 bbl/min).
3.5 System Inputs and Outputs

3.5.1 Inputs (PLC)
This subsection discusses the PLC inputs.
3.5.1.1 Master Water Valve Feedback

Valve feedback is generated by a proximity sensor located on the pneumatic valve
actuator. There is a signal for open and a signal for closed. The feedback assembly is a
Namur sensor and is run through a Namur amplifier. The signals are amplified to a 24
volt level, which is sent to the PLC. The Namur amplifier also has an alarm output,
which is sent to the PLC. If one of the Namur sensors is faulty, an error message will be
displayed in the touch screen message window.
3.5.1.2 Master Water Valve Auto/Man Switch

This switch allows the PLC to control the electric/pneumatic valve when in “Auto” mode.
When in “Man” mode, the “Master Water Open/Close” switch controls the
electric/pneumatic valve. The master water valve “Auto/Man” switch also sends a 24
volt signal to the PLC, when in AUTO mode.
3.5.1.3 Mix Water Auto/Manual Switch

This switch is used to select either PLC “Auto” control or “Manual” control, using the
potentiometer. In “Auto” mode a 0 – 10 volt signal is sent from the PLC to the BD101
hydraulic driver board. In “Manual” mode the 0 – 10 volt control signal is generated by
the potentiometer on the operator control panel.

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NOTE: The potentiometers only utilize the middle 50% (5 turns of the 10 turns
available) of travel. This means there is a dead band at the bottom, and top, of the
potentiometers range. A 24 volt status signal is sent to the PLC when “Auto” is selected.
3.5.1.4 Cement Auto/Manual

This switch used to select either PLC “Auto” control or “Manual” control using the
potentiometer. In “Auto” mode a 0 – 10 volt signal is sent from the PLC to the BD101
hydraulic driver board. In “Manual” mode the 0 – 10 volt control signal is generated by
the potentiometer on the operator control panel.
NOTE: The potentiometers only utilize the middle 50% (5 turns of the 10 turns
available) of travel. This means there is a dead band at the bottom, and top, of the
potentiometers range. A 24 volt status signal is sent to the PLC when “Auto” mode is
selected.
3.5.1.5 Cement Valve Feedback

This 0 – 10 volt signal is generated by a potentiometer coupled to the hydraulic actuator
that operates the cement valve. The signal is sent to the BD101 servo driver board, as
well as the PLC. The signal represents 0 to 360 degrees of travel. The cement valve
only rotates about 160 degrees, so approximately 45% of the signal is utilized. The 10
volt reference voltage comes from the BD101 board.

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3.5.1.6 Mix Water Valve Feedback

This 0 – 10 volt signal is generated by a potentiometer coupled to the hydraulic actuator
that operates the cement valve. The signal is sent to the BD101 servo driver board, as
well as the PLC. The signal represents 0 to 360 degrees of travel. The mix water valve
only travels about 90 degrees, so only 25% of the signal is utilized. The 10 volt
reference voltage comes from the BD101 board.
3.5.1.7 2" Coriolis Excitation Current

This 4 – 20 milliamp signal is sent from the transmitter to the PLC. It represents 0 – 100
milliamps of excitation current.
NOTE: This signal causes the 2" Coriolis meter symbol on the “Process Variable”
screen.
3.5.1.8 4" Coriolis Excitation Current

This 4 – 20 milliamp signal is sent from the transmitter to the PLC. It represents 0 – 100
milliamps of excitation current.
NOTE: The excitation current level indicates the amount of entrained air present in the
slurry. The 2" and 4" Coriolis symbols change color depending on the level of the
excitation current. See the system’s Operation Manual for specifics.

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3.5.1.9 Surge Can (Tank) Signal

This 4 – 20 milliamp input signal is generated by a two wire pressure transducer (0 –
1000 psi). The pressure transducer signal first goes through a current loop splitter, so
that a signal can also be sent to a LED local display. See Section 3.7 Miscellaneous
Components for detailed info on the display.
The pressure transducer is connected to a hydraulic load cell, located under one of the
three mounting legs of the surge can. This measurement represents 50% of the weight
of the surge can. The hydraulic load cell has an effective measurement range of 8
inches. This means that whatever load is applied to the cell is distributed over the 8
inches.
When used with the 1000 psi pressure transducer, this provides a measuring range of 0
– 8000 lbs on the one leg of the surge can. Since the hydraulic cell only measures half
the weight of the surge can, a factor of two is applied to represent the entire weight of
the load cell. This means we have an effective measuring range of 0 – 16000 lbs.
NOTE: There is a tare function that allows the weight of the surge can to be “zeroed”.
This allows only product weight to be displayed.

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3.5.2 Outputs (PLC)

This subsection discusses the PLC outputs.
3.5.2.1 Master Water Valve Control

The control signal for the master water valve is a 24 volt signal, which controls an
interposing relay. The interposing relay sends a 12 volt signal to an electric/pneumatic
valve, which opens or closes the master water butterfly valve. The electric/pneumatic
valve can be manually actuated for testing, using mechanical overrides on the assembly
3.5.2.2 Water Valve Control Auto/Man

The water valve control signal is a 0 – 10 volt signal that is generated either by the PLC
(AUTO control) or the potentiometer on the control panel (MAN control). Both of these
signals are sent to the BD101 board via the water valve “AUTO/MAN” switch.
3.5.2.3 Cement Valve Control Auto/Man

The cement valve control signal is a 0 – 10 volt signal that is generated either by the
PLC (AUTO control) or the potentiometer on the control panel (MAN control). Both
these signals are sent to the BD101 board via the cement valve “AUTO/MAN” switch.
3.5.2.4 Over Pressure Trip

The skid unit has an over pressure trip function for each engine/pump combination. The
over pressure trip is activated when the treating pressure is greater than the over
pressure trip point. When the function is activated, it sends a signal to the engine ECM
“throttle inhibit” input, which sets the engine’s rpm to low idle. It also sends a signal to
the transmission TCM “Quick to Neutral” input, which puts the transmission to Neutral.
Both these signals are sent via interposing relays.

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To reset the over pressure trip, the treating pressure must be lower than the over
pressure trip value. Before resetting the over pressure trip function, return the
associated engine throttle to an idle.
NOTE: The transmissions will not shift into gear, when the rpm is 800 rpm or greater.
3.6 Miscellaneous Operator Panel Controls

3.6.1 High Pressure Return Valve
This valve is controlled with the switch on the Operator panel. It is an “ON-OFF-ON”
switch with a spring return to center. It sends a 12 volt signal to an electric/hydraulic
control valve that opens or closes the high pressure return valve. The speed, at which
the valve actuates, is controlled by an adjustable hydraulic flow limiting valve, in series
with the control valve.
3.6.2 Emergency Shutdown

This pushbutton control on the main panel shuts both engines down. The function
engages the “quick to neutral” and “throttle inhibit” functions, as well as cutting power to
the engine ignition power. These actions ensure the engines will be shut down in a
quick and safe manner.
NOTE: The Emergency Shutdown push-button must be pulled out, in order to reset the
rig savers.
3.6.3 Master Water Valve Open/Close

This switch sends a 12 volt signal to either the “open or close” solenoid of the
electric/pneumatic valve. This in turn actuates the master water valve.

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3.7 Miscellaneous Components

3.7.1 Weight Display on Surge Can (Tank)
The daylight readable LED display is mounted to the leg of the surge can (tank). The
purpose of the display is to provide a weight indication of the product in the surge can.
This indication will assist the operator with keeping the level constant during mixing
operations.
The display is powered by 24 volts. It receives a 4 – 20 milliamp signal (via a current
loop splitter) from a two wire 24 volt powered pressure transducer. The pressure
transducer is mounted to a hydraulic load cell located under one of the three legs of the
surge mount. This measurement represents 50% of the weight of the surge can.
The display is scaled to produce the actual weight of the surge can. A tare function can
be activated by a remote push button mounted near the display. This allows the
operator to tare the weight of the surge can with no product. After this is done, only the
weight of the product is displayed.

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3.8 Cement and Mix Water Hydraulic Valve

Control Components
The SCM system controls the mix water valve, and bulk cement valve, to regulate the
density of the mixed slurry. The hydraulic actuators were used because of their torque,
reliability and simplicity. The rotary hydraulic actuator rotates a valve by using a rack
and pinion assembly. See Figure 3-2 for the configuration of the hydraulic actuator.
Figure 3-2: Hydraulic Actuator

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The Parker BD101 board (Figure 3-3 and Figure 3-5) serves as a driver for the Parker
BD servo valves (Figure 3-4).
Figure 3-3: BD101 Board Figure 3-4: BD15 Servo Valve
Figure 3-5: BD101 Circuit Diagram
The BD101 uses the difference between the command signal and the feedback to
produce an output to the BD15 valve. The BD15 valve is controlled by a plus/minus 60
milliamp signal. The spool valve in the BD15 valve is normally centered. When the
BD101 board sends an output signal, it causes the spool valve to travel in one of two
directions.

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This causes pressurized hydraulic oil to be directed to one side of the hydraulic actuator
while the other side is returned to the reservoir. The result is that the valve being
controlled either opens or closes. A feedback potentiometer is mounted on the hydraulic
actuator and the signal is sent back to the BD101 board and the PLC. As the valve
moves, the error signal is reduced. When the command signal equals the feedback
signal, the output of the board is zero milliamps.
The command signal comes from two points. For automatic control, the 0 – 10 volt
signal comes from the PLC. When the manual control is desired, the signal comes from
the potentiometer located on the control panel. This signal is selected by using the
“AUTO/MAN” switch on the control panel. Because both the water and cement valves
do not turn 360 degrees, the command signal is not the full 0 – 10 volts. The control
range is approximately 3 – 7 volts. The feedback signal increases, as the valves open
and vice versa.
The command signal comes into the BD101 board as a positive signal. The feedback
signal comes into the board as a positive signal on the “FDBK” terminal. The amp
inverts the feedback signal and it is measured as a negative signal at TP2. If a reading,
with a meter, shows that the feedback signal is positive on TP2, reverse the wires on
terminals 1 and 2. The feedback signal that goes to the PLC is positive.
NOTE: For detailed instructions on how to setup, and troubleshoot, these components
see the BD101 equipment setup document.

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3.9 Process Ranges

3.9.1 Mix Water
The working range of the mix water flow rate is 0 – 1200 liter/min (0 – 320 gal/min US).
3.9.2 Bulk Cement Delivery

The typical range of the bulk cement delivery with a 5" hose is 0 – 1400 kg/min (0 –
3100 lb/min).
3.9.3 Mix Head Water Pressure

The normal pressure for mix water pressure is 120 psi, but can depend on the type of
centrifugal pump.
3.9.4 Mix Head Recirculation Pressure

The normal pressure for the recirculated slurry is 22 psi.
3.9.5 2" Coriolis Pressure

The normal back pressure for the Coriolis pressure is 24 psi. This instrument requires
back pressure to compress any entrained air in the slurry. Excessive entrained air can
cause erroneous readings from the instrument. In extreme cases it can cause the
instrument to stop reading, as the sensor’s operating limits may be exceeded.

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3.9.6 Down Hole Triplex Pump Boost Pressure

The normal pressure for this part of the process is 35 – 55 psi. This pressure represents
the boost pressure to the down hole pumps, as well as the back pressure on the 4"
Coriolis meter. Once again this back pressure is important for the correct operation of
the instrument.
Sufficient pressure is also important to ensure smooth pumping of the slurry. This
pressure can be regulated by the valve that restricts the circulating flow back to the
averaging tank.
NOTE: If the pressure drops too low (less then 10 psi), you will “starve” the down hole
Triplex pumps.
3.9.7 Mix Water Centrifugal Pumps

The normal revolutions for these pumps are 2100 rpm. This frequency signal comes
from a 24 volt powered pickup on the hydraulic motor.
3.9.8 Recirculation Centrifugal Pump

The normal revolutions for this pump is 1500 rpm. This frequency signal comes from a
24 volt powered pickup on the hydraulic motor.
3.9.9 Down Hole Boost Pump RPM

The normal revolutions for this pump are 1400 rpm. This frequency signal comes from a
24 volt powered pickup on the hydraulic motor.

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3.10 Start Mixing/Pause Conditions Summary

The conditions that must be met for the mixing function to start are as follows:
• Mix water valve “AUTO/MAN” switch set to “AUTO”
• Cement valve “AUTO/MAN” switch set to “AUTO”
• Master water valve switch in “AUTO” or “MAN” but the valve must be open
• Mix water centrifugal pump operating at 2200 rpm (min allowable is 1200)
• Recirculation centrifugal pump operating at 1600 rpm (min allowable is 1200)
• If any “simulation” is active (density or rate), the above conditions are overridden
and the system will go into mixing mode. The reason for this action is that
simulated values are typically used for testing.
3.10.1 Automatic Corrective Actions

• With the system in “AUTO” mode and mixing, if the mix water rate drops below
50 liter/min (12.5 US gal/min), the water valve area flashes.
o If the condition lasts more than 3 seconds, the cement valve will close.
o If the system is in “MAN”, the cement valve will not close as it is assumed
the operator requires this low flow rate.
• After “Start Mixing” is active, the cement valve will not open until the mix water
rate is 100 liter/min (25 gpm US)

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3.10.2 Alarms/Notifications
• If the recirculation density is 200 kg/m3 (2 lb/gal) higher than the set-point, the
cement valve area on the HMI will flash (Red/Yellow).
• During mixing, if the cement valve is 100% open and the density is 30 kg/m3
(0.25 lb/gal) lower than the set-point, the “bulker” symbol on the “Process
Variables” page flashes (orange/grey).
• If the recirculation pressure is less than 20 psi, the value flashes.
• If the down hole Triplex pump’s boost pressure is less than 30 psi, the value
flashes.
• The Coriolis meter symbols on the “Process Variables” page are colour coded
according to the amplitude of the excitation current signal.
o Green (0 – 18 ma)
o Orange (18 – 50 ma)
o Red (50 – 94 ma)
o Red Flash (94 – 100 ma)
• The centrifugal pump symbols are “color coded” dependent on the rpm. See
“Process Variables” details for more information.

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3.11 System Troubleshooting

This section covers the basic troubleshooting of the instrumentation operation (see
Table 3-1).
Table 3-1: Instrumentation Troubleshooting
Problem Reason Solution
General
Does not power up • No power • Check battery disconnect

switches
• Dead batteries
• Measures battery level with volt
meter. Charge/replace if
necessary
Cannot start engines • Rig savers engaged • Reset rig savers
Cannot shift transmission into • Engine rpm too high • Reduce engine rpm to less than
gear 800
Cannot reset over pressure • Treating pressure is • Wait till treating pressure declines
greater than over
pressure trip value
HMI screen washed out • Excessive • Turn on Vortec AC air valve

temperature in located on right hand side of
control panel control panel. Interior panel
temperature will decrease which
will improve HMI visibility
Mixing Functions
Cannot achieve recommended • Hydraulic power • Set throttle switch to high

rpm on centrifugal pumps pack is in idle
System does not start after • See “Message” • Ensure conditions are met
“Start Mixing” is pressure area for warnings
• Wrong Mix Water • Select correct pump on “Process

pump selected Variables” screen. Press to select
No Mix water rate after “Start • Closed valve • Verify that all valves in flow path

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Mixing” pressed are open.
• Frozen valve • Check valve to verify it is

open/actuating
No recirculation rate (2" • Plugged inlet of 2" • Partially close the recirculation
Coriolis flow meter) Coriolis flow meter valve going to the mixing head.
This will direct more flow through
the 2" Coriolis. Once flow is
established, open the valve and
pinch it back if the 2" Coriolis
back pressure is low
Maximum mix water rate is • Mix water pump • Increase rpm of pump
less than 250 liter/min (66 rpm is low
gal/min) • Switch hydraulic engine to high
throttle
Cement valve does not move • Auto/Man switch is • Set to “Auto”

in “Man”
• Hydraulic bypass is • Set the hydraulic bypass for the

set to “Hand” mix water valve to “Auto”
Water valve does not move • Auto/Man switch is • Set to “Auto”

in “Man”
• Hydraulic bypass in • Set the hydraulic bypass for the

set to “Hand” cement valve to “Auto”
Process Errors
2" Coriolis Errors
Excitation current limit • Entrained air • Check back pressure reading.

Pinch in the recirculation flow to
the mix head to increase the
pressure to the 2" Coriolis flow
meter
• Add more defoamer
Sensor assembly exceeded • Plugged • Use the valve on the recirculation

tube/Bridging off to force more flow through the 2"
Coriolis flow meter. This will clean

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out the obstruction. If this does
not work, clean the assembly as
soon as the job is complete
4" Coriolis Errors
Excitation current limit • Entrained air • Check the back pressure reading.
Pinch in the recirculation flow to
the mix head to increase the
pressure to the 2" Coriolis flow
meter
Sensor assembly exceeded • Plugged • Close the valve on the averaging

tube/Bridging off tank recirculation to force more
flow through the 4" Coriolis flow
meter. This will clean out the
obstruction. If this does not work,
clean the assembly as soon as
the job is complete
Data
No data to FDAS • USB Network • Have IS troubleshoot

Interface Card
module in FDAS
system faulty
Cannot retrieve files from • Incorrect storage • Verify that the computer name is
memory card folder path in data correct
archiving screen in
HMI
• Incorrect network • See the setup documents for

addressing correct network settings
• SCM Data folder • Set the folder to have full access

setup incorrectly

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3.12 Process Error Codes from E&H Manual

Figure 3-6 shows the process error codes from the E&H manual.
Figure 3-6: Process Error Codes from E&H Manual

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3.13 System Error Messages from E&H

Manual
Figure 3-7 shows the system error messages from the E&H manual.
Figure 3-7: System Error Messages from E&H Manual

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3.14 Glossary
ProfiBus The PROFIBUS (Process Field Bus) is a standard for field bus
communication in automation technology.
PLC The PLC (Programmable Logic Controller) is a digitally operating

electronic apparatus which uses a programmable memory for the
internal storage of instructions for implementing specific functions,
such as logic, sequencing, timing, counting and arithmetic, to control
through digital or analog input/output, various types of machines or
process.
HMI The HMI (Human Computer Interface) is the aggregate of means by

which people—the users—interact with the system—a particular
machine, device, computer program or other complex tools.
The user interface provides means of:
Input - allowing the users to manipulate a system
Output - allowing the system to produce the effects of the users'
manipulation
ECM Engine Control Module
TCM Transmission Control Module

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4.0 TRAINING MANUAL FEEDBACK

Please evaluate the SCM W/MK IV AT Skid Unit Operator Training Manual by
answering the following questions. The training department uses this information to
improve the quality of training.
1. The objectives were clearly specified and achievable. Yes

If the answer is No, please explain. No
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Cementing Services — SCM Unit Operator Training Manual

Sanjel Cyclonic Mixer

Cementing Services SCM W/MK IV AT International Twin Cementing Skid ii

1.0 JOB OPERATIONS.........................................................................1-1

1.7 Post-job Procedures ........................................................................... 1-119

2.8 Drive Lines............................................................................................ 2-74

3.9.2 Bulk Cement Delivery ...................................................................... 3-20

Cementing Services SCM W/MK IV AT Skid vii

1.0 JOB OPERATIONS

• Identify the major components of the SCM W/MK IV AT skid unit.

• Understand all aspects of the unit.

• Perform job procedures accurately, properly and safely.

bbl/min) and densities up to 2400 kg/m3 (20 lb/gal).

Cementing Services SCM W/MK IV AT Skid 1-1

Figure 1-1: SCM W/MK IV AT International Twin Cementing Skid

The unit consists of the following major systems:

• High Pressure Triplex Pump Power System

• High Pressure Triplex Pump Power Distribution System

• Fluid Displacement System

• High Energy Mixing System

• Ground Mixing System

• High Pressure Pumping System

• Operation and Display System

Cementing Services SCM W/MK IV AT Skid 1-2

operation principles and function of each component are given as follows.

Cementing Services SCM W/MK IV AT Skid 1-3

1.2.1 Operation Principles

slurry density can be controlled either manually or automatically by the automation

the casing to fulfill the cementing job.

1.2.1.2 General Principles

back to the MK IV AT system.

Cementing Services SCM W/MK IV AT Skid 1-4

flow rate and feeds the signals back to the MK IV AT system.

• Mix Water Rate

• 2" Coriolis Rate

• 4" Coriolis Rate

• Triplex Rate (combined)

• Triplex Rate (road side)

• Triplex Rate (curb side)

• Mix Water Pump (road side) RPM

• Mix Water Pump (curb side) RPM

• Recirculation Pump RPM

• Pressurizer Pump RPM

Cementing Services SCM W/MK IV AT Skid 1-5

• Mix Head Pressure

• Mix Water Pressure

• 2" Coriolis Pressure

• Mix Water Rate Set-point

• Mix Water Valve Position (at set-point)

• Bulk Cement Rate Set-point

• Bulk Cement Rate Calculated Delivery

• 2" Coriolis Density

• 4" Coriolis Density

• Mix Water Valve Position (actual)

• Cement Valve Position (actual)

• 2" Coriolis Excitation Current

• 4" Coriolis Excitation Current