TCC202 CEMENT EQUIPMENT

CORRESPONDENCE COURSE

EDC – Tomball, Version 1.01 Revised: March 2005

Cementing Equipment

Copyright 2004, by BJ Services. All Rights reserved. No part of this manual may be reproduced in any form or
by any means (including electronic storage and retrieval or translation into a foreign language) without prior
agreement and written consent from BJ Services as governed by United States and international copyright laws

Training Department
BJ Services
11211 FM 2920
Tomball TX 77375

Printing History: First Edition – August 2004

Credits: Training Department: Luis Duque, Training Engineer; Tim Ramsey, Training Engineer:
Jim Wilke Manager Engineering Training Group; Ken Kenner Manager Corporate Training.

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BJ Services Tomball EDC- Training Department

INDEX
Subject Page
Introduction……………………………………….. 5

Cement Heads ………………………… 6

Cement Head Manifolds ……………………….. 9

Landing Joints / BJ Fas-Lok Cement Head……. 12

Conventional Cement Plugs…………………… 13

Subsea Equipment………………………………. 15

Cement Units……………………………………… 20
RAM Mixing System…………………………. 20
PSM Mixing System…………………………. 23
LAM Mixing System…………………………. 24
Jet Mixer System…………………………….. 25
Pacemaker Pump……………………………. 31
Hawk twin cement unit……………………… 32

Cement storage and handling…………………. 33

Cement Plant………………………………….. 33
Cement Transport……………………………. 33
Field Silo………………………………………. 34

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Cementing Equipment

INDEX (Cont.)

Cement Mixers………………….…………………. 36
TM-50 bbl Bulk Mix Unit …………………….. 37
Automated Foam Cement System…………. 38

Monitoring/Recording/Control Equipment…… 43
WTA 3600………………………………………. 43
Minimonitor II, 3305…………………………… 44
DB-II / Pneumatic Densimeter……………… 44
DB-IV Electronic Densimeter………………. 44
Nuclear Cement Densimeter………………... 45
Mass Flow Densimeter………………………. 45
Isoplex Monitoring System…………………. 45
Microplex Monitor……………………………. 46
Visiplex Monitor………………………………. 46
Automated Cement Control (ACC-II)……… 46
Isolink Wireless LAN………………………… 48
Wireless Wellhead Unit……………………… 48

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Cement Equipment Service Packers

Manifolds
Cement Heads
Introduction Cement Plugs
Pumps
This article was developed with the Cement Batch Mixers
intention to be guidance for the Bulk Trucks
correspondence course TCC202, Foam Cement Equipment
which forms part of the T-CAP Monitoring Equipment
training plan within BJ Services
Company. It presents an introduction The intention of this article is to
into the necessary equipment to highlight the following service
perform a BJ Cement Operation either equipment:
on land or offshore.
1. Cement Head
The equipment utilized in a cement 2. Cement Heads Manifolds
operation may comprise off the 3. Landing Joints
following: 4. Conventional Cement Plugs
5. Subsea Cementing Equipment
1. Casing Hardware: 6. Cement Pumps
7. Cement Mixers
Guide Shoes 8. Storage and handling equipment
Float Shoes and Float Collars 9. Foam Cement Equipment
Insert Float Valves 10. Monitoring Equipment.
Casing Fill –Up Equipment
Centralizers
Stage cementing Collars
Cement Retainers

2. Service Cement Equipment:

BJ Plug Catcher
Retrievable Bridge Plugs

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Cementing Equipment
1. CEMENT HEADS
Cement heads are a piece of
equipment used in primary Cement
operations, to hold a bottom or top
cement plug or both, and allow
circulation until they are released and
pumped down in the casing, during
cement operations. Ideally, Double
plug cement heads are preferred as
they allow for a non-stop operation.
Some types of cement head are
provided with a mechanical indicator
to confirm release of the plugs.
BJ Services utilizes several types of
cement heads, and the classification
of them is as follows:
a) Fas-Lok
a) Single
b) Double
b) Model M
a) Single
b) Double
c) Multiple String
d) Western Model A
e) Western Model B
The Fas-Lok Cementing Head fea-
tures a unique connector system for
fast, sure coupling of the wellhead to
the Fas-Lok Landing Joint installed in
the casing. Landing joints are avail-
able in 8-Round and Buttress casing
threads. Connection of the head to the
EDC – Tomball, Version 1.01 Revised: March 2005
Landing Joint installed in the casing
requires only a 30° turn with no
special tools or hammering necessary.
Landing Joints with premium grade
casing threads also are available upon
request. Fas-Lok Cementing Heads
are available in both single and
double plug configurations in sizes 4-
1/2” through 20”.
BJ Services’ Model M Cementing
Heads are economical and simple to
operate. They feature a quick
disconnect manifold that insures the
plug is pumped out of the head and
down the casing at the proper time.
No landing joints are necessary since
the casing thread is an integral part of
the head. Model M Heads are
available with both 8-Round and
Buttress casing threads and utilize the
reliable rotary type pin puller for plug
release. The Cementing Heads are
configured for both single and double
plugs in sizes 3-1/2” though 13-3/8”.
Western Model A and B Cement
Heads have the same configuration
and parts, but each model has a
different range of sizes. Model A is
from 2-7/8” to 20”, while Model B is
from 4-1/2” to 13-3/8”. These Cement
heads are considered dated and the
Fas-Lok models have replaced most
of them, due to the fact that they are
easier to rig up.
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In General, Cement Heads come in a

range of sizes from 2-7/8” to 20”, not
all model are in that range, nor all
sizes come in single and double
models either. To see details on sizes,
part numbers, pressure rating and
unions refer to:

The BJ Iron Manual on Lotus Notes

(LNCORP1/BJS/BJSERVICES/
Engineering/mechanical/BJIronMan)
or on Power Center Figure 12, FAS-LOK Double Cement Head
(https://powercenter.bjservices.com/__86256a8e006b
1cda.nsf/$defaultView?OpenView&Start=1&Count=
30&Expand=1#1)

In the following figures, some the

different available models are shown:

Figure 13, Model M Single Cement Head

Figure 11, FAS-LOK Single Cement Head

Figure 14, Model M Double Cement Head

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Cementing Equipment

Figure 16, Western Model B Cement Head

Figure 15, Multiple String Cement Head

Figure 15, Western Model A Cement Head

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2. CEMENT HEADS 1. BJ SINGLE: Into this category

MANIFOLDS BJ has, 4 different models:
The Cement Head Manifold is part of a) Fas-Lock
the surface equipment, used in b) Model M 1502
conjunction with the cement head, to c) Integral with Tee -
control the direction of the High d) Integral without Tee
Pressure flow in order to release
either the top or the bottom plug. In the following figure represents a
There are several models that BJ Model M 1502 BJ Single manifold:
Services use, original BJ design and
other models that came from the
Western merger as well as other
suppliers, like FMC.

They are classified as follows:

1. BJ Single
2. BJ Double
3. Western
4. FMC- Adjustable
Figure 1, Model M 1502 single manifold
Note: There may be still some 1002
union manifolds in the field, but these The drawing of the other single
are considered obsolete. In the past manifold as follows:
the 1002 has been used with 1502
Cement Heads, even though the
unions fitted, there was not a
hydraulic seal. In order to avoid this,
the 1002 Manifolds are obsolete and
all the cement heads have 1502
connections.

Integral type manifolds are the

preferred variation, as the design does
Figure 2, Fas-Lock single manifold
not utilize line pipe threaded
connections. This will eliminate
potential leak paths and simplify field
maintenance/inspection.

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Cementing Equipment

The following drawings show the

different models

Figure 3, Integral with Tee single manifold

Figure 5, Fas-Lock Double manifold

Figure 4, Integral without Tee single manifold

2. BJ DOUBLE: This type of Figure 6, Model M 1502 Double manifold

manifolds have the same
classification as the single ones
have
a) Fas-Lock
b) Model M 1502
c) Model M 1002
d) Integral with Tee
e) Integral without Tee

Figure 7, Integral with Tee Double manifold

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Figure 8, Integral without Tee Double manifold

Figure 9, FMC-Adjustable single manifold

For reference to Western Cement
heads manifolds, as well as more
details on the fore mentioned, please
see:
The BJ Iron Manual on Lotus Notes
(LNCORP1/BJS/BJSERVICES/Engin
eering/mechanical/BJIronMan) or on
Power Center
(https://powercenter.bjservices.com/__86256a8e006b
1cda.nsf/$defaultView?OpenView&Start=1&Count=
30&Expand=1#1).
Besides, the FMC- Adjustable Double
manifold is also offered as an
alternative to the BJ standard
manifold.
This manifold is suitable for use with
any double plug cement head (Fas-
Lok, Model M, A, or B) whose
center-to-center inlet dimension falls
within the range of the “B” ( See
Figure 10 ) dimension and has 2"-
1502 connections.

FMC-Adjustable: This optional

manifold is offered as an alternative
to the BJ standard manifold. They can
be:

a) Single
b) Double

The Single manifold is suitable for

use with any single plug cement head
(Fas-Lok, Model M, A, or B) whose
center-to-center inlet dimension falls
within the range of the B dimension
(see Fig 9) and has 2"-1502 Figure 10, FMC-Adjustable double manifold
connections.
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Cementing Equipment
3. LANDING JOINTS / BJ FAS-
LOK CEMENT HEAD
The landing joint is the section at the
bottom of the Cement head that allow
it to connect to the top of the joint
casing, by a 30° clockwise rotation.
In the following drawings, the landing
joint of a Fas-Lok Cement Head is
shown
Figure 16, Cement Head Fas-Lok with landing joint
Figure 17, Landing joint, 8 round short thread
EDC – Tomball, Version 1.01 Revised: March 2005
In the BJ Iron Manual, Volume 2,
section 4 - Cement head pressure
rating; link in power center is:
(https://powercenter.bjservices.com/E
ngineering/Mechanical/BJIronMan.ns
f/072561aa006322660725618c006b0
9a0/94a0c428a5418919882569d2006
18a2a?OpenDocument). The table for
Fas-Lok single and double Cement
Head Landing Joints is there and
shows the pressure rating with one
and two O-Rings.
It is important to notice that the
pressure rating of this type of landing
Joint is affected by the number of O-
Rings used.
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4. CONVENTIONAL CEMENT
PLUGS
A cement plug is used to separate the
cement slurry from other fluids, thus
reducing possible contamination. Two
types of cementing plug are typically Figure 18, Top Cement, aluminum core
used on a cementing operation.
For more details of conventional
BJ Bottom Cementing Plugs cement plugs, see BJ Iron Manual.

Are red or yellow color, thus BJ Cement heads can also be used to
distinguishing the bottom plug launch other service companies’
apart from the top. The bottom plug cement plugs.
is launched ahead of the cement
slurry to minimize contamination
by fluids inside the casing prior to
cementing. A membrane/diaphragm
in the plug body ruptures to allow
the cement slurry to pass through
after the plug reaches or seats at the Figure 19, Top plastic core, Fas-Lok, Model A&M
heads, cement Plug
landing collar.

BJ Top Cementing Plugs

Readily identifiable by their black

color. The top plug has a solid body
that provides positive indication of
contact with the landing collar and
bottom plug through an increase in Figure 20, Top Aluminum core, Fas-Lok, Model M,
pump pressure. A&B heads, cement Plug

Both can be aluminum core or plastic

core, and drawings of both are shown
below:

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Cementing Equipment

Figure 20a, 3rd Party 9-5/8” conventional Top Plug

Figure 20c, 4-1/2” BJ conventional bottom Plug

Figure 20b, 3rd Party 9-5/8” conventional bottom

Plug

The following is a link to Power

center, where specific data about
cement plugs can be found.
(https://powercenter.bjservices.com/Engineering/Me Figure 20d, WFM 4-1/2 conventional Top Plug
chanical/BJIronMan.nsf/072561aa006322660725618
c006b09a0/fa7ab576d4b487c2882569d2006189fc?O
penDocument)

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5. SUBSEA CEMENT other accessories molded from

EQUIPMENT reinforced epoxy material –making
for compatible PDC bit drilling. They
The preferred method for handling drill out quickly and are inherently
and landing casing strings in marine non-rotating; some plugs incorporate
operations terminates the casing in a an anti-rotation/latch down feature.
casing hanger at the sea floor.
Conventional cementing plugs cannot
be used under these conditions;
however, by employing the BJ
Services Subsea Cementing Plug
Launching System – conventional
cementing procedures can be
followed.

The System differs from conventional

plug launching systems in three ways.

1. First, the location of the top and

bottom cementing plugs prior to
release is in the casing just below
the casing hanger at the mud line,
not at the surface.
2. The second difference is the plug
design. While externally the
plugs look like conventional
plugs, they have clear bores to
allow circulation through them
prior to release.
3. Finally, the cementing head is Figure 21, Subsea cementing equipment
small and adapts to the drill pipe.
It holds a ball and dart that, when
released, selectively launch the
cementing plugs for movement
down the well.

All BJ Subsea cementing plugs have

cores molded from high strength
phenolic material, with darts and
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Cementing Equipment

Generally speaking this system

consists of two major components:

I. A Subsea assembly located in

the casing below the casing
hanger.
II. A cementing head on the
drilling vessel which adapts to
the drill pipe and controls the
cementing plug release.

The plug distribution is as follows:

I. In the cementing head, a

launching ball and dart.
II. In the subsea assembly, top and
bottom cement plugs.

By chronological order of utilization,

(b) is the bottom plug launching ball
which, when released in front of the
cement slurry, seats in the bottom
plug (e). A pressure increase allows
the shearing of the plug connector (d)
and permits the bottom plug (RED)
(e) to travel down the casing until it
bumps on the float collar or casing
shoe,

Extra pump or hydrostatic pressure

extrudes the ball (b) through its
orifice seat and cement displacement
continues. A ball catcher (f) attached
to the lower end of the bottom hole
plug retains the ball. This ball catcher
can be also anti-rotation

Figure 22, Subsea cementing equipment

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Once the cement slurry has been

pumped, the top plug launching dart
(a) is released. It will seat into the
body of the top cement plug (c).
Increased circulation pressure will
then shear the retaining pins and
release the top plug (c) from the
launching mandrel. The cementing
operation thus continues. At the end
of slurry displacement, the top plug
(BLACK) (c) bumps on the float
collar or casing shoe.

In the subsea assembly the top plug is

pinned at the lower end of a running
mandrel, which has a swivel (g). This
avoids any rotation of the cementing
plugs inside the casing, which could
damage the shear pins.
The upper part of the mandrel is Figure 22a, Subsea launching dart
screwed onto the lower part of the
installation tool (h). This installation
tool is a crossover that adapts to the
casing hanger and serves to attach it
to the drill pipe.
Operational procedures, etc., can also
be found in the “ Operation and
Maintenance Manual” for BJ Subsea
Cementing Equipment, generated by
the engineering department in
Tomball.

Figure 22b, Subsea launching dart

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Cementing Equipment

However, as a reference, the

following pictures are shown; where a
top cement plug with aluminum core
and its dart can be seen.

Figure 22c, Subsea Connector

Figure 22g, Subsea top aluminum core plug with

aluminum dart

Some districts may still have these

type of cement plugs, for this reason,
is important to realize that even
though the darts look very similar
(plastic / aluminum), they do not have
the same profile, hence they are not
Figure 22 d & e, Subsea bottom plug with ball
catcher interchangeable; see details in figure
22 g.
Subsea cementing plugs with
aluminum core are now obsolete and
no longer in use. The reinforced
epoxy material core plugs are easier
to drill.

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Figure 22 g, Subsea plastic and aluminum darts (Fins

not attached in this diagram)

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Cementing Equipment
6. CEMENTING UNITS
BJ has three types of Pump units
available, either mobile or skid
mounted, classifying them under the
mixing system, all of them with
Pacemaker Triplex Pumps:
1. Recirculating Averaging Mixer
(RAM)
2. Recirculating mixers (PSM)
3. Lightning Averaging Mixer
(LAM)
Either type may have, as a back up
mixing system, jet mixing.
Recirculating averaging mixer
(RAM). This is an automated cement
mixing and pumping unit utilizing the
patented integral Recirculating
Averaging Mixer (RAM) equipped
with a BJ Services Mini Monitor
(3305) that monitors and records
pertinent job parameters for on line
and post job analysis. To ensure
successful completion of a job in the
event of a component failure in the
drive train, hydraulic system, or
electronic system, back-up systems
are provided. It could come as a
Mobile Cement Pump (MCP) or as a
Skid Cement Pump (SCP).
The RAM is a mixing system that
provides density control and slurry
consistency over a wide range of
slurry weights and capable of mixing
EDC – Tomball, Version 1.01 Revised: March 2005
to within +/- 1 ppg. This system
allows the option of continuous or
batch mixing processes in automatic
or manual modes. The cement slurry
is initially mixed in the mixing
module, then passes into the 4 bbl
primary tub for additional mixing. At
this point, it flows over a weir into the
17 bbl secondary tub, where it is
mixed further by the agitator, and
continuously recirculated until the
desired density is achieved. The
system provides a dust free
environment, minimizes air
entrapment, and delivers a
homogeneous slurry. Micro Motion
mass meters are used to monitor both
the mixing and down-hole slurry
densities. The RAM offers a wide
range of mixing rates, which are
dependent on the slurry density.
Slurry rates have been achieved as
high as 12 bpm and densities up to 22
ppg.
The unit has the following main
components:
ACCII (Automatic Cement
Control)
This system utilizes a Micro Motion
mass meter, a bulk flow control valve
with position feedback, water control
valve with position feedback and a
microprocessor to attain target density
input by the operator. Job parameters
displayed include mix water rate,
target density, slurry rate and primary
density.
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Engine/Transmission Controls
& Indicators
Engine speed is controlled with
marine style lever control heads,
directly connected to the transmission
for fail-safe operation. Transmissions
can be equipped with the optional
quick shift to neutral. Features
include: Engine start/stop, engine
emergency stop, defoamer flow
control devices, Gages/indicators to
monitor engine oil pressure, water
temperature, tachometer, transmission
oil pressure, oil temperature, gear
indicator, and torque converter lock-
up indicator.
Electronic Control Module
This module contains main power
on/off, the 3305 data acquisition unit
and the ACC (auto cement control)
unit
Process Control System
A mimic panel with twenty-one
open/close process control valves and
indicators, one open/close mixing
tank drain valve & indicators, and the
agitator speed control. Joystick
controls for all mix water and slurry
pump speed operation. Joystick
control for manual backup operation
of the knife gate control valve.
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Mixing Water System
Includes mix water valve position
control, position indicator, and
OPEN/CLOSE control & indicator
mounted in control panel along with
mix water discharge pressure gage. In
the event of a failure in the
positioning device a total manual
back-up valve is provided. The two
mix water centrifugal pumps have
complete variable speed control (only
one pump is required for entire
mixwater flow needs).
Slurry Pumps
These pumps are specially equipped
with abrasion resistant material for
extended ^ service life and includes a
mechanical seal design, which
provides zero leakage and
maintenance.
Hydraulic Drives
Individual closed loop hydrostatic
transmissions drive the primary &
secondary recirculating pumps and
mix water pumps. All hydrostatic
drives incorporate a variable speed
drive system that allows the operator
to adjust centrifugal pump speed
while varying engine speed within the
limits of the system. A pressure
compensated auxiliary system
provides power for the bulk valve and
agitator.
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Cementing Equipment

Back Up Systems elapsed time. A Data cassette that

contains all of the recorded data is
Each engine package is identical also included. This cassette can be
providing 100% mechanical back-up. down loaded into a PC for post job
Each engine drives a mix water pump, analysis using BJ software program
a recirculating pump, and a F.A.C.T.S. (Field Applied
Pacemaker pump. A secondary Computerized Tracking System). An
recirculating pump is provided as a optional remote display can be
back-up for the mixing system. In the provided
event of a failure of the
microprocessor in the ACC module, a
potentiometer is mounted in the panel
that allows the operator to manually
control the bulk valve position. If all
electronics fail, the bulk valve is
controlled by a secondary manual
system.
Figure 23, Skid RAM
Densimeter
Slurry density is continuously
monitored with the Micro Motion
mass meter. Both mixing and down-
hole densities are monitored and
displayed with the down-hole density
being recorded. A nuclear densimeter
on the high-pressure discharge line is Figure 23a, SCP-348 RAM
optional.

Monitor
A BJ model 3305 Mini Monitor is
provided to monitor and record
critical job parameters. The
parameters displayed include
discharge pressure, slurry flow rate
with stage counters and totalizer,
down-hole density, and elapsed time.
A strip chart recorder is also included
that records discharge pressure, slurry
flow rate, down-hole density, and

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Figure 23b, RAM Mixing System
Recirculating mixers. The precision
slurry mixer (PSM), a recirculating
cement mixing system, provides
density control and slurry consistency
over a wide range of densities.
Compact and lightweight, the PSM
uses the energy of the recirculated
slurry to draw bulk cement into the
system and to mix the resultant slurry
thoroughly. The PSM, designed with
both the operator and the maintenance
man in mind, poses few maintenance
problems. The system has very few
moving parts and is controlled with a
single lever. Mobile versions of the
PSM include cementing units such as
the Model 118 (body load) shown in
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Figure 24, Model 148 trailer mounted
in figure 24c, and Model 138 (body
load) in figure 24d. The PSM is
designed to provide:
• Precise density control (capable of
mixing any pumpable slurry within
±0.2 ppg.)
• Consistent density (the system
maintains a smooth slurry
throughout the job)
• High-rate mixing (at rates
exceeding 10 bbl/min)
• Heavyweight mixing (slurries of
up to 22 ppg. at 4 bbl/min)
• Continuous mixing at any desired
rate to meet normal cementing
requirements, and batch mixing of
very small quantities of slurry.
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Cementing Equipment
Figure 24, Model 118 PSM Mobile Unit
Figure 24a, PSM Mixing Module
Figure 24b, PSM Mixing Module
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Figure 24c, Model 148 Trailer Mounted Pump
Figure 24d, MCP-138 / PSM 6X6
Figure 24e, Slurry Master Cementing Unit
Lightning Averaging Mixer (LAM).
The LAM slurry mixer, is an
improved design of the PSM mixing
system, with larger tubs, agitator in
tub and de-aerators. This cement
mixing system accurately maintains
slurry density and consistency over a
wide range of performance
requirements.
The main differences between a PSM
and LAM systems are:
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"Normal" density (14.8-16.5 ppg)

PSM System LAM System slurries can be mixed at rates of up to
4 bbl mixing tank 7 bbl mixing tank
8-9 bbl/min and lighter slurries at up
Agitation supplies Hydraulic powered to approximately 12 bbl/min. The
by a centrifugal agitator and heaviest slurry usually mixed today
pump centrifugal pump with jet mixers is about 17 ppg, with
the rate is reduced to 4—6 bbl/min or
less. The rate of mixing and slurry
depends on the make-up of the blend,
mixing water delivery method and
rate, the bulk equipment, and well
conditions such as pressures and
fluids in the hole. In most cases, with
any type of mixer, the bulk equipment
delivery system is the limiting factor
Figure 24f, Falcon Cementing unit with LAM system on the mixing rate.

JET MIXER The jet mixer, shown in

Figure 25, consists of a funnel-shaped
hopper, mixing bowl, discharge spout
("gooseneck"), tub, and water lines.
As the stream of water in the jet line
passes through the jet and into the
bowl of the mixer, it creates a
Figure 25, Jet Mixer scheme
vacuum, which pulls the cement down
out of the hopper at the same time that
gravity is causing the cement to fall in
the hopper (Figure 25).

When the dry cement contacts the

stream of water in the bowl of the
mixer, it becomes liquid cement
(slurry) and flows through the
gooseneck into the tub. If the slurry
needs to be lighter, additional water is
added through the by-pass line
downstream of the mixing bowl.
Figure 25a, Typical Jet cementing Operation

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Cementing Equipment

Current unit types are listed in BJ

Tool Box, in PowerCenter
(https://powercenter.bjservices.com/intranet/Technol
ogyToolbox/pif.nsf/SLbySingleRegion?OpenView&
Technical data
SL=Cementing%5EUS/Mexico)
can also be found in the equipment
articles, under the same source of
information.
In the following table the different
cementing units are classified, based
on the mixing configuration.

In some cases, a specific cement unit

Figure 25b, SCP-35-8-5 PSM
model, like the MCP-148/PSM,
includes variations with slight
modifications, made to meet
individual district’s requirements. For
instance, under Power Center you will
find:

• MCP-148A/PSM
• MCP-148F/PSM

Both units have the same main

component and capacities: HHP,
maximum working pressure, engine
transmission, mixing configuration,
densimeters, etc., but the hydraulic
systems are different, due to the fact
that MCP-148A/PSM is specially
equipped for high ambient
temperature locations, while the
MCP-148F/PSM is equipped for
Arctic service.

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Pump Classification by Mixing Configuration

PSM LAM RAM

MCP-118/PSM FALCON MCP-248/RAM

MCP-121B/PSM MCP-138/LAM SCP-40752/RAM

MCP-138/PSM MCP-148/LAM SCP-35-8-5/RAM

MCP-148/PSM SCP-348/RAM

SCP-35-8-5/PSM SCP-248/RAM
SLURRY MASTER

SCP = Skid Cement Pump

MCP = Mobile Cement Pump

(Truck)

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 Cementing Equipment

PUMPS WITH "PSM" MIXING CONFIGURATION - RELEVANT CARACTERISTICS

MCP-118/PSM MCP-121B/PSM MCP-138/PSM MCP-148/PSM SCP-35-8-5/PSM SLURRY

MASTER

HHP 482 390 800 800 482 800

MAX WORKING PRESSURE psi 15K 15K 15K 15K 15K 15K
MPa 103 103 103 103 103 103

ENGINE DETROIT DETROIT DETROIT 8V92T DETROIT 8V92T DETROIT 8V71N DETROIT
8V71N 8V92TA 6V92T/8V92T

TRANSMISSION ALLISON HT- FULLER RTO- ALLISON CLT 750 ALLISON CLT 750 ALLISON HT-750 ALLISON
750 12513 DR CLT754

MIXING SYSTEM PSM PSM PSM PSM PSM PSM

DENSIMETERS DB-IV CORIOLIS TYPE DB-IV DB-IV DB-IV NUCLEAR

MAX SLURRY RATES bbl/min 12 7 12 12 12 8

m3/min 1.9 1.1 1.9 1.9 1.9 1.3

MAX DENSITIES ppg 22 22 22 22 22 22

kg/m3 2,636 2,636 2,636 2,636 2,636 2,636

MAX DISPLACEMENT RATES bbl/min 20 20 20 20 20 20

m3/min 3.2 3.2 3.2 3.2 3.2 3.2

ACC Yes No Yes Yes Yes No

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PUMPS WITH "LAM" MIXING CONFIGURATION - RELEVANT CARACTERISTICS

FALCON MCP-138/LAM MCP-148/LAM

HHP 1000 800 800

MAX WORKING PRESSURE psi 15K 15K 15K

MPa
ENGINE DETROIT SERIES 60 DETROIT 8V92T DETROIT 8V92T

TRANSMISSION ALLISON CLT-6061 ALLISON CLT 750 ALLISON CLT 754

MIXING SYSTEM LAM LAM LAM

DENSIMETERS MICRO MOTION CORIOLIS TYPE DB-IV

MASS METER

MAX SLURRY RATES bbl/min 12 12 12

m3/min 1.9 1.9 1.9

MAX DENSITIES ppg 22 22 22

kg/m3 2,636 2,636 2,636

MAX DISPLACEMENT RATES bbl/min 20 20 20

m3/min 3.2 3.2 3.2

ACC Yes Yes Yes

Note: it is important to highlight that the densimeters, the Coriolis type and
Micromotion Mass Meter are the same (In technical articles, the two have been
named differently, but are the same device.)

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Cementing Equipment

PUMPS WITH "RAM" MIXING CONFIGURATION - RELEVANT CARACTERISTICS

MCP-248/RAM SCP-248/RAM SCP-348/RAM SCP-40752/RAM SCP-35-8-5/RAM

HHP 1000 800 800 800 800

MAX WORKING PRESSURE psi 15K 15K 15K 15K 15K

MPa
ENGINE DETROIT CATERPILLAR CATERPILLAR DETROIT DETROIT
SERIES 60 3406B 3406B 8V92T 8V92T

TRANSMISSION ALLISON ALLISON ALLISON ALLISON ALLISON

CLT-6061 HT-750 HT-750 CLT 750 CLT 754

MIXING SYSTEM RAM RAM RAM RAM RAM

DENSIMETERS CORIOLIS DB-IV DB-IV CORIOLIS DB-IV

TYPE TYPE

MAX SLURRY RATES bbl/min 12 12 12 12 12

m3/min 1.9 1.9 1.9 1.9 1.9

MAX DENSITIES ppg 22 22 22 22 22

kg/m3 2,636 2,636 2,636 2,636 2,636

MAX DISPLACEMENT RATES bbl/min 20 20 20 20 20

3
m /min 3.2 3.2 3.2 3.2 3.2

ACC Yes Yes Yes Yes Yes

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PACEMAKER PUMP
The BJ Pacemaker Triplex Pump is
compact, lightweight and efficient,
and is ideally suited for oilfield
cementing, stimulation, gravel pack
and other high-pressure pumping
services in both offshore and onshore
applications. The Pacemaker Pump is
rated at 575 hp (429 kW), and fea-
tures a short 4”. (10.2 cm) stroke and
pressurized power end lubrication
system.
The Pacemaker Pump is smaller and
lighter than conventional triplex
pumps of the same capacity. It is
available with a standard fluid end
that will accept 3.5”, 4”, 4.5” or 5”
(8.9,10.2,11.4 or 12.7 cm) plungers or
a large fluid end that will accept 5”,
5.5” or 6”. (12.7, 14.0 or 15.7 cm)
plungers. This extraordinary flexi-
bility makes the Pacemaker Pump
readily adaptable to most field
applications and conditions.

Pacemaker Pump Specifications:

Length ____ 5 ft. (1.5m)
Width_______4 ft. (1.2m)
Height______ 3 ft. (0.9m)
Weight 5000 Ibs (2275 kg)

Figure 26, Pacemaker Pump

Pacemaker Triplex Pump Specifications and Performance data (Intermittent Service)

Fluid Ends Maximum Working Maximum Flowrate @ 450 RPM Rec. Dischg.
Pressure Rating Connection Size
in cm psi MPa bbl/min gal/min l/min m3/min in cm

Standard Fluid Ends

3-1/2 8.89 15,000 103.42 5.1 213.7 809 0.81 2 5.08

4 10.16 12,500 86.18 6.6 279.0 1,056 1.06 2 5.08

4-1/2 11.43 10,000 68.94 8.4 353.2 1,337 1.34 2 or 3 5.08/7.62

5 12.7 8,500 58.6 10.4 435.6 1,649 1.65 3 7.62
Large Fluid Ends

5-1/2 13.97 7,000 48.26 12.5 526.5 1,992.8 1.99 3 7.62

6 15.24 6,000 41.36 14.9 625.5 2,367.5 2.37 3 7.62

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Cementing Equipment

Recently, BJS has developed a new

cementing unit The Hawk.

HAWK TWIN CEMENTER

This is a chassis mounted body load
cement unit, with the same features
and benefits of the Falcon Cement
unit. The twin deck engines are
Cummins QSM 446 hp, 2 BJ
pacemaker pumps, with micromotion
densimeter flowmeter, de-aerator
mixing tank and fully operated with
ACC II

Figure 27, Hawk Twin Cement Unit

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7. BULK STORAGE AND CEMENT TRANSPORT

HANDLING Cement and blends can be carried in
trucks or trailers mounted with tanks
CEMENT PLANTS of similar features to the storage silos.
Cement is stored in bulk cement silos They are provided with loading and
with varying capacities, tailored to fit discharge lines, a compressor, safety
available space in both offshore and devices and surge tanks to allow a
onshore locations. Cement silos are direct discharge into the jet mixing
designed not just for storage but for system (fig. 30).
pressurized discharge as well (Fig.
29).
Safety devices, such as pop off and
pressure limiting valves and
automatic compressor governors,
prevent overpressure during discharge
operations.
The blending of cement and dry Figure 30 600 ST-02 pneumatic Bulk unit
additives is done in 'weigh batch
blenders' which are small capacity
silos equipped with weighing systems
and dust collectors. Dry additives are
pre-mixed in additive bottles and
transferred to the weigh batch
blender, where there is already a
certain amount of cement loaded and
weighed. The final mixture is then
taken to bulk cement transports or Figure 30a, 700ST Bulk unit
storage silos, ready for use.

Figure 29, Bulk Plant

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Cementing Equipment

Figure 30d, Field Silo

Figure 30b, Bodyload 300 Cu Ft Bulk unit cabover

Figure 30c, Bodyload 300 Cu Ft Bulk unit

conventional

FIELD SILO
In remote locations where the bulk Figure 30e, Field Silo
cement has to be stored on location, a
cement field silo may be necessary -
also know as “P tank” or “field
Bin”. A field cement silo has the
same capabilities and features that the
plants’ cement silos have, like the
load cell, but also have a side skid
attached to it, for transportation and
lay down purposes, as is shown in the
figures 30d and 30e

The following chart shows the

specifications for vertical, horizontal
and field cement bulk silos.

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Vertical Bulk Cement Silos Specifications

Capacity Diameter Total Height Empty Weight
3 3
ft m ft m ft-in m lbs kg
820 23.22 10 3.04 14-3 4.34 8,029 3,642

2,200 62.30 10 3.04 35 10.66 15,100 6,849

1,475 41.77 12 3.65 17-5 5.31 10,500 4,762

1,915 54.23 12 3.65 22 6.70 17,090 7,752

1,925 54.51 13 3.96 19-10 6.04 15,000 6,804

Horizontal Bulk Cement Silos Specifications

500 14.16 8 2.43 14-7 4.44 7,665 3,472

1,150 32.56 10 3.04 23-6 7.16 13,800 6,260

Field Bulk Cement Silos Specifications

1,000 28.32 10 3.04 18-11 5.76 8,287 3,759

1,300 36.81 10 3.04 21 6.40 11,000 4,989

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Cementing Equipment

8. CEMENT MIXERS

The purpose of a mixing system in

any cementing operation is to ensure
correct proportions of dry cement and
carrier fluid. When this is
accomplished, the end result is a
cement slurry with predictable Figure 31, MCM-100A/VBM, 100 bbl batch mixer
characteristics, which may be pumped Truck

down hole at the desired rate (fig 31).

BJ has different models, classified as
MCM (Mobile Cement Mixer) or
SCM (Skid Cement Mixer), as can be
seen in the following list:

1. MCM-100A/VBM
2. MCM-200/RAM
3. SCM-100A/RAM
Figure 31a, MCM-100A/RAM –Mobile cement
4. SCM-100A/VBM Mixer
5. SCM-100E/VBM
6. SCM-200A/PSM
7. SCM-200/PSM

The mobile cement mixers (MCM)

are not designed to transport slurries
over the road. They are designed to be
transported empty.

Detailed information can be found in

PowerCenter under the tool box icon
Figure 31b, MCM-200/RAM
for cementing services
(https://powercenter.bjservices.com/intranet/Technol
ogyToolbox/pif.nsf/SLbySingleRegion?OpenView&
SL=Cementing%5EUS/Mexico)

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BJ Services Tomball EDC- Training Department

The TM 50 bbl Bulk Batch Unit is a

new piece of equipment, which serves
as both, bulk transport as well as
cement mixer. This unit has a 50 bbl
batch mix tank and a 320 ft3 tank,
among other features, like rear
chemical pallet area, compressor 160
m3 @ 28 psi, 5x6 mission slurry pump
and 9 bbl wash-up water tank.

Figure 31c, TM 50 bbl bulk batch unit.

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Cementing Equipment
9. FOAM CEMENT EQUIPMENT
For those cases where the low-density
slurries do not meet with the
requirements for certain cement job
conditions, foam cement can be an
option. To do so, the following foam
cement equipment is required.
BJ Services has introduced a new
Automated Foam Cement System
(AFCS). This system has been
successfully implemented both
onshore and. Incorporating the AFCS
with DeepSet™ (patent pending), a
slurry recently approved by Chevron
for use in deepwater shallow flow
applications, provides a complete
package for cementing across cold,
deepwater flow environments.
The AFCS automatically adds nitrogen
and liquid foaming agent to cement
slurries, precisely maintaining a
desired foam cement density. The
system combines mass and magnetic
flowmeters, along with mechanical
flowrate backups and state of the art
software, to accurately monitor and
control all aspect of a foam cement
job. All flowmeters are non-intrusive
type meters and provides more reliable
and accurate information than
mechanical pump stroke counters.
EDC – Tomball, Version 1.01 Revised: March 2005
Competitive Advantages of the
Automated Foam Cement System
(AFCS)
1. A magnetic flowmeter is used to
obtain an accurate base slurry rate.
2. The mass flowmeter used is
capable of accurately measuring
Nitrogen rates from 30-3000
scf/min (.84 – 84 scm/min).
3. Liquid additive addition is
monitored and controlled by mass
flowmeters, capable of Accurately
reading rates from 0.25-10 gal/min
(1–38 l/min).
4. All flowmeters have pump stroke
counters provided as backups.
System Features
1. Nitrogen and additives are
automatically ratioed to slurry.
2. Software package contains a foam
generator for building a ramp
schedule.
3. Controller can accurately ramp
Nitrogen rate to maintain accurate
bottomhole densities
4. The Treater can remotely control
the entire job from monitoring
location.
5. System control is easily switched to
pump stroke counters in event of a
meter failure.
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BJ Services Tomball EDC- Training Department
6. System can be configured to fit on
rig with minimal storage capacity.
7. All parameters are controlled by
slurry rate at cement unit. If the
slurry rate changes or stops the
nitrogen flow automatically
compensates for these changes.
Initial job results exhibited accuracy
of >99% for liquid additives and
>98% for nitrogen. In the past there
was concern as to the quality of the
slurry being pumped and no method
of accurately ramping the nitrogen.
Now with the use of the AFCS for job
control, and CEMFACTS software for
job design, the precision required to
assure accurate foam cement
operations, is obtained no matter if the
desired outcome is constant foam rate
or constant slurry density. Since the
additive rates, including nitrogen, are
based on slurry rate, obtaining an
accurate base slurry rate is critical.
A unique feature of BJ Services’
AFCS is the use of a magnetic
flowmeter to monitor slurry rate. This
eliminates the error inherent in
controlling from mechanical pump
stroke counters. Depending on air
entrapment, pump efficiency and
rates, volumes indicated by pump
stroke counters can be off by a wide
margin. Combining an accurate slurry
rate with mass flowmeters to control
nitrogen and additive rates greatly
increases the foam quality of nitrified
cement. The entire foam job is
EDC – Tomball, Version 1.01 Revised: March 2005
controlled from the cement unit, and
if there is a change in slurry volume
or density the nitrogen flow is
automatically changed to maintain the
programmed design. In the event of a
flowmeter failure, all meters have
pump stroke counters as backup, and
the system can be converted to
manual operation by the flip of a
switch.
The AFCS controller can be
programmed to inject nitrogen or
additives in a fixed ratio to the base
slurry rate, to control additive output
at a fixed rate, or to perform a
ramping operation.
Liquid additive injection rates of up to
10 gal/min (37 l/min) are achievable
with the AFCS. Nitrogen rates depend
on the particular nitrogen unit used. In
the Qatar tests, a 180K unit was tested
and showed acceptable control from
250-2400 scf/min (7-67 scm/min).
Initial testing results showed injection
accuracy of >99% for foaming agent
and >98% for nitrogen. The use of
CEMFACTS software for job design
and an AFCS for job control will
yield a precisely executed foam
cement operation.
39
Cementing Equipment

The items include in the AFCS are

listed bellow
• LIQUID ADDITIVE SKID (2
EA.) Stainless steel cabinet; lifting
eyes for portability; 2" suction and
1" discharge stainless steel quick Figure 33, MCM-1008
disconnect (cam and groove)
fittings; local display for mass MISCELLANEOUS SUPPLIED
flowmeter. Rates 0.25-10 gal/min ITEMS
(.96 – 38 l/min).
• MCM-1008 remote controller
• NITROGEN FLOWMETER • Magnetic flowmeter for RAM unit
SKID (1EA). 2” Fig 1502 (slurry rate)
connections; lifting eye for • Hydraulic power unit (powers
portability LAS skids)
• Nitrogen unit control box
• Nitrogen unit hydraulic
displacement control
• 3600 monitor
• All required cables
• Inlet valving for liquid additives
• Foam Tee
• Downhole Surface pressure
transducer

Figure 32, Foam Cement Skid

• MCM-1008 CONTROLLER
(1EA). Mounted on nitrogen
pumping unit; accepts base slurry
rate from cement unit; controls
nitrogen and two liquid additives;
operating modes - ratio, ramp, and
flow; up to 50 stages can be
programmed; mounts on nitrogen
skid; serial output to 3600; built-in
discharge rate simulator
The components provided in the
AFCS kit furnish the required
automation capability the standard
nitrogen and cement pumping units.
The attached schematic (fig 35) shows
the standard rig up from the cement
and nitrogen units up to the foam tee.
The location of the downhole pressure

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transducer and optional sampling iron mounting brackets to be welded

system will vary depending on each
installation. Items used in the AFCS
that the operating district must
provide are:
1. Cement unit w/ ADC-11
2. Hydraulically-driven nitrogen
pumping skid
3. Nitrogen storage tanks
4. Required relief and plug valves,
other high pressure iron
In order to supply the correct
Hydraulic Displacement Control
(HDC), the district requesting the
AFCS must provide identifying
information about the nitrogen pump
unit being used.
to the unit. In addition, four new 3/8"
hydraulic lines need to be fabricated
and installed.
As can be seen in the following
graph, the system has as one of the
main components, a foam tee, which
combines a 4’ (1.2 meters) long tee,
2.5” (6.3 cm) diameter, the unfoamed
cement slurry with nitrogen.
Internally it has a component, which
atomizes nitrogen uniformly into the
cement slurry.
Foam Generator “T”
Unf oam ed
Cement
Slurry
Holes (Atomizes Nitrogen
Uniformly into Cement Slurry)

Minor modifications that must be

made to the nitrogen and cement Foa med Nitroge n
Inlet
Cement
pumping units are detailed below. Slurry

z Generates Stable, Uniform Foam in 4’ of 2.5” Pipe

Cement Unit Modifications
A magnetic flowmeter and liquid
additive inlet manifold must be added Figure 34, Foam generator “T”
to the RAM cement unit. This
Automated Foam System Overview
modification involves minor piping
changes, for which documentation is MCM-1011 Unit
To Cement
Head
Relief Valve Bleed

supplied and an electronics technician Automated

(4000 psi) Valve

Foam Tee
D/H Pressure
Transducer

to install the flowmeter. Nitrogen Skid

Micromotion
Flowmeter
Nuclear
Dsnsiometer
Check
Valves

Contained in
Nitrogen Unit Modifications Job Monitor
w / 3600 &
MCM-1011
Remote
Automated Liquid
Additive System
Micromotion
Foam Cementing Manifold
1.
2.
N2 Micromotion
Cement Micromotion

The HDC, nitrogen control box, and Foamer Line

Flowmeter 3.
4.
5.
Foaming Tee
Two Check Valves
Two 2 x 2 Valves
6. Nuclear Densiometer

MCM-1008 Controller must be 35-8-5 RAM Unit

7.
8.
Three Pressure Transducers
Bleed off line w/ choke

installed on the nitrogen unit. The with ADC-II

HDC bolts on in place of the existing

Figure 35, Automated Foam Cement System
manual control. The nitrogen control
box and MCM-1008 require angle
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Cementing Equipment

Figure 35a, Foam Cement Trailer on duty

Figure 35b, Foam Cement Trailer

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10. MONITORING/RECORDING
& CONTROL EQUIPMENT
Monitoring, recording and cement
control equipment is crucial to job
performance. For this reason, BJ uses
the most advanced instruments in the
field to monitor job progress. Among
them being: the Well treatment
analyzer (WTA), model 3600; the
minimonitor II, Model 3305; the BD-
III Pneumatic Densimeter; the DB-IV
Electronic densimeter; the nuclear
densimeter; massflow densimeter;
Isoplex monitoring system, the
wireless LAN and the automated
cement control (ACC-II).
THE WTA MODEL 3600, is an
instrument (Figure 36) monitoring
and analyzing oil-well cementing and
stimulation services. The Model 3600,
which weighs 35 pounds, is easily
transportable. The unit measures 14”
x 18” x 23”; and although it is shock-
resistant and splash proof,
unnecessary exposure to rough
handling and water should be
avoided.
The three main components of the
Model 3600 are the touch screen
display, the combination
printer/plotter, and the solid-state
plug-in data cassette. The self-
prompting touch screen display is
bright and easy to read, and the touch
feature makes the WTA very simple
to operate. The printer/plotter
provides a real-time recording of the
EDC – Tomball, Version 1.01 Revised: March 2005
important job parameters, pressure,
flow rates and density. The back panel
allows for all input and output
connections. In special applications,
the outputs can be used to control
blending equipment, such as liquid
additive pumps and dry-additive
conveyors.
The Model 3600 operates in three
basic modes: cementing, acidizing,
and fracturing. It can monitor, store,
and record up to six frequency, six
analog, and two density inputs.
Normally, these parameters are
surface conditions, such as pressure,
flow rate, density, foam data, and
temperature.
The Model 3600 is virtually
maintenance-free, though; it must be
kept clean in order to function
properly. Cleanliness is especially
critical for the input/output
connectors. The unit is splash proof as
long as the back panel, the touch
screen, and the cover over the printer/
plotter are secured in place.
Figure 36, WTA 3600
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Cementing Equipment
MINIMONITOR II, MODEL 3305
The minimonitor II, Model 3305, is
portable data logging and monitoring
system used in cementing and
acidizing jobs. The unit, shown in
Figure 37, is rugged and suitable for
use in oil field and offshore
operations. It is compatible with
existing BJ equipment and accessories
such as the overhead and remote
displays, four-channel analog
recorder, external printer, nuclear
density gauge, pressure transducers,
and magnetic pick-up
Figure 37, Minimonitor II, Model
3305
DB-III PNEUMATIC
DENSIMETER
The DB-III pneumatic densimeter
consists of a pivoted U-tube supported
by a pneumatic load cell and actuator.
The U-tube is pivoted on two flexural
pivots and coupled to the fluid input
nipples through special flex
couplings. It continuously monitors
the slurry density during PSM
operations. The slurry inlet to the
EDC – Tomball, Version 1.01 Revised: March 2005
densimeter is connected to the pump
discharge manifold through a screen
and orifice. When the pump is
operating, slurry flows through the
densimeter's U-tube and back into the
mixing tank. A pneumatic signal is
sent from the densimeter to the
control panel where slurry density is
displayed on a gauge in pounds per
gallon. Located at one end of the
densimeter is an air-supply pressure
gauge, a U-tube lock, and an air filter
drain.
DB-IV ELECTRONIC
DENSIMETER
The DB-IV electronic densimeter
(Figure 38) consists of a pivoted U-
tube supported by an electronic load
cell. The U-tube is mounted on two
pivots and coupled to the fluid input
nipples. Both the U-tube and the fluid
input nipples are made from type 316
stainless steel; the couplings, from
Neoprene. The assembly is placed in
an all-aluminum case mounted on a
vibration isolation base. The standard
span of measurement of the
densimeter is 0 to 25 pounds per
gallon (0.00 to 3.00 grams per cubic
centimetre). The density read-out is
via a standard cable to the DB-IV
display module. The provided
auxiliary output on the display
module can feed the 3305 or 3600
monitor. Thus, the DB-IV can be used
when connected to a 3305 or a 3600
monitor locally or remotely via a
single standard cable.
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BJ Services Tomball EDC- Training Department

Figure 38, DB-IV Electronic

Densimeter Figure 39, Nuclear Cement
NUCLEAR CEMENT Densimeter
DENSIMETER
MASS FLOW DENSIMETER
The nuclear cement densimeter
(Figure 39) is a density-monitoring The massflow densimeter measures
system designed specifically for true downhole slurry, displacement
cementing operations. It consists of a rate and volume; non-nuclear source.
display/recorder unit, a ISOPLEX MONITORING
source/detector assembly and an SYSTEM
optional remote indicator. A beam of
radiation, from a small nuclear source The Isoplex monitoring system can be
passes through the pipe and the used for specialized operations, like
cement slurry and received by a foam or ultra lightweight cement
detector. The amount of radiation monitoring. Is used to run JobMaster
absorbed by the fluid is amplified by software.
the detector, displayed on a large,
easy-to-read liquid crystal display
(LCD), and produces a calibrated
trace on the integral strip chart
recorder.

Figure 40. Isoplex Monitoring System

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Cementing Equipment
MICROPLEX MONITOR
The Microplex monitor is a versatile
cost-effective solution for oilfield
monitoring and remote data
acquisition. The unit may be operated
with or without it's companion battery
unit and/or wireless LAN unit. The
Microplex is designed to operate with
BJ's JobMaster system
. system, which provides automated
Figure 41. Microplex Monitor
VISIPLEX MONITOR
The Visiplex with it's companion unit,
the MicroPlex, provides a monitoring
system for pressure pumping
applications. The system replaces
the 3305 Mini-Monitor. The unit has
a color, sunlight viewable graphics
screen that presents the job data along
with a real-time chart and bar graph.
The chart may be reviewed at any
time. The data is captured in internal
memory and may be transferred to a
"Thumb Drive" for storage or transfer
to a PC. A knob and 2 buttons provide
EDC – Tomball, Version 1.01 Revised: March 2005
the intuitive user interface. The unit is
extremely rugged and suitable for
exterior mounting on BJ equipment.
Figure 42. VisiPlex Monitor
ATOMATED CEMENT
CONTROL (ACC-II)
The ACC-II provides an efficient
density control for cement mixing and
pumping operation
Automated means adjustments to the
water and cement rates changed by
the ACC-II base in actual downhole
rate.
Control means density is actually
controlled by the ACC-II by changing
the ratio of cement to water.
The operation of the ACC-II is
governed by information entered by
the operator before the job. This
information directs the ACC-II to mix
and pump the proper density cement.
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BJ Services Tomball EDC- Training Department

The ACC-II module works with all of In the following drawing the ACC-II
the major components in the system. system is shown
Based on the operator-entered
ACC-II

program and various sensors located Module

Bulk

on the unit, the module controls the Valve

Bulk

cement mixing processes. Surge

Can
Supply

Load
Cell

The ACC II monitors: Knife

Gate
Downhole
Rate

Valve
Flow
Mix Meter Downhole
Pri

• Downhole Rate
Water Densimeter
Pump Tub Sec
Mixing Tub
Densimeter
CONTINUOUS
MIX MODE

• Water Rate (And Water Valve

Recirculating Pump Downhol
e Pump

Position)
Figure 41. ACC-II System
• Slurry Density (And Knife Gate
Position) Components of the ACC-II System

• Surge Can Weight The automated components of the

ACC-II system in the “continuous”
The ACC-II Controls mixing mode include the Water
Valve, Knifegate and Bulk Valve.
• Water Rate (And Water Valve
Position) The Operator establishes the
downhole rate.
• Cement Rate (And Knife Gate
Based on the actual downhole rate
Position), Which Ultimately
(and the desired density) the Water
Controls Slurry Density
Valve is adjusted to achieve the
proper water flow rate.
• Bulk Valve Position, Which
Ultimately Controls Surge Can Based on the actual water flow rate
Level the Knifegate is adjusted to achieve
the proper slurry density. The slurry
density is constantly monitored and
adjustments are made to the Knifegate
as necessary.
Based on the weight of the Surge
Tank, the Bulk Valve is adjusted to
maintain the ACTUAL surge tank
weight based on the TARGET weight.
This, in turn, controls the level of
cement in the Surge Can.
EDC – Tomball, Version 1.01 Revised: March 2005 47
Cementing Equipment

ISOLINK WIRELESS LAN

The BJ Services Wireless LAN
System replaces well site LAN
cabling with radio links allowing for
zero time deployment at the wellsite
of treatment data communication. The
units directly replace BJ LAN cables
or may be used interchangeable with
LAN cables. Since cabling is not
used, the problems with maintaining
conventional cables are eliminated
and the reliability of the signals are
improved.
Features and Benefits
• Operates in extremely harsh Figure 43. Wireless LAN
environments with immunity from
interference. WIRELESS WELLHEAD UNIT

• Eliminates the need to run LAN
cables between units and the time it
takes to lay, retrieve, clean and store
these cables.
• Supports wireless data transmission
between 3305 and remote computers
via the computer serial port.
The Wireless Wellhead Unit provides
complete monitoring capabilities at
the wellhead without the need for
cables running back to the monitoring
van. The unit incorporates the
Microplex Monitor, companion
battery pack and an IsoLink Wireless
LAN module to form a complete
integrated package. (See individual
spec sheets for complete
specifications) The Wireless
Wellhead Unit is designed to operate
with BJ's JobMaster system. The unit
is approximately 5 1/2 feet high.

Figure 42. Wireless LAN

EDC – Tomball, Version 1.01 Revised: March 2005 48
BJ Services Tomball EDC- Training Department

Common Units of Measurement

and Terms

Volume:
bbl barrel
m3 cubic meter
l liter
gal gallon(US)

Pressure:
psi
MPa

Flow Rate:
Bbl/min
m3/min

Gas Flow Rate

scf/min standard cubic feet/minute
scm/min standard cubic meter/minute

Density
ppg pounds per gallon
kg/m3 kilograms per cubic meter
Figure 44. Wireless Wellhead Unit

Recommended Accessories:
• 20.000 psi pressure transducer
• Pressure Cable 15 ft
• Density Cable 15 ft

EDC – Tomball, Version 1.01 Revised: March 2005 49

Flow Meters

BJ uses a variety of devices to measure flow. They include:

• Turbine Flow Meters - to measure fluids or slurries
• Magnetic Flow Meters - to measure fluid, slurries, and N2 gas
• Target Meters - to measure N2 gas
• Mass Flow Meters - to measure fluid and slurries

The first three measure volumetric flow and the latter, mass flow. Turbine
Flow meters work best in low viscosity laminar flow. Target and Magnetic
Meters perform well in laminar and turbulent flow patterns. The target meter
is recommended for both gas and liquid service but not for slurries.
Although Magnetic Meters are not designed for gas measurement, they
generally work well in all fluid services. The Turbine Meter performance is
most affected by changes in Fluid Properties.

The largest measurement errors with volumetric flow meters occur at low
rates. This demonstrates the importance of sizing the flow meter for the
application. Meters with large diameters will have more measurement error
at nominal flow rates than smaller diameter meters will. If the meter is too
small for the desired rate, there will be a significant pressure drop across the
meter.

Types of meters to measure volumetric flow.

• Turbine Flow Meter
• Magnetic Flow Meter
• Target Meter

Turbines Flow Meters

Turbine flow meters indicate flow rate and measure total throughput of a
liquid line. The unit consists of a multiple-bladed rotor, or impeller, mounted
within a pipe, perpendicular to the liquid flow. Most turbines use flow
straighteners on both the inlet and discharge end of the meter to make the
flow pattern more laminar. As liquid flows through the meter and over the
rotor, the rotor turns at a speed that is directly proportional to the flow rate.
A magnetic pickup senses the rotor blades as they pass and generates an
electrical (sine wave) signal. The magnetic pickup is mounted outside the
flow tube, and the electrical pulses from this pickup can be converted to
proportional flow rate or counted and totaled in a remote monitor.
The Turbine Flow Meter is designed to measure the flow of liquids and
gases in pipes to 2% inaccuracy. They are volumetric flow measuring
devices and have been available since the late 1940s. The Turbine Flow
Meter is a flow measurement “workhorse”, having proven itself over the
years. In spite of the many new types of flow meters now in use, the
Turbine is still a popular choice. Turbine Flow meters are very accurate for
measuring clean fluids of low to medium viscosity. The turbine has a linear
output. Turbines are available for virtually any pressure and for high and low
temperature applications. Limitations are incompatibility with high viscosity
or slurries. Gas turbines are designed for gas service only; not fluid.

Turbines are used primarily for the following BJ applications:

• On the suction side of blenders to measure clean rate
• On the discharge side of blenders to measure slurry rate
• Measure hydraulic fluid flow for the impeller, suction and discharge
centrifugal pumps on blenders.
• With CO2 manifolds to measure liquid CO2 rate
• On Canadian nitrogen pumpers to measure gas rate
• Measuring mix water rate on cement pumpers

Mechanical Installation - Turbine Flow Meters

Magnetic Flow Meters

The Magnetic Flow Meter (often called “Magmeter”) provides a free flow
measurement which is unaffected by density, temperature, pressure or
viscosity changes in the fluid.

Advantages
• No moving parts.
• Unobstructed bore.
• Can measure bi-directional flow.
• Minimal pressure drop across meter.
• Unaffected by turbulent flow patterns.
• Linear output.
• Good accuracy and range.

Limitations
• Maximum pressure is 4,500 psi.
• Process fluid must be more conductive than 5 µSiemens/cm.
(µ micro)
• Unsuitable for oil based fluids or distilled water.

Magnetic flow meters measure volumetric flow by monitoring the distortion

of an induced magnetic field. The distortion is caused by the flow of a
conductive fluid in the pipe. The advantages of this type of flow device are
that there are no moving parts and nothing protruding into the flow.
Viscosity and consistency also have no adverse effect on their performance,
however particulate in the fluid such as sand can be a problem if the
concentration of particulate becomes too high (>25% of volume). Mag
meters can be used for bi-directional flow measurement.

There is, however, one major disadvantage for our application in that the
fluid to be measured must be electrically conductive (usually greater than 5
µSiemens per cubic centimeter). Pure substances, including many
hydrocarbons and gases, tend to fall below the 5µS/cm threshold. Some
typical fluids are listed in the table below:
 Conductive Non-Conductive

Hydrochloric Acid 400,000 µS/cm Glycol 0.3 µS/cm

Sodium Hydroxide 40,000 µS/cm Kerosene 0.017 µS/cm
Acetic Acid 250 µS/cm Ethyl Alcohol 0.0013 µS/cm
Potable Water 70 µS/cm Xylene 0.000000001 µS/cm

Theory of Operation - Magnetic Flow Meters

Mass Flow Meters

Flow Meters that measure mass directly using the properties of mass, as
opposed to those that measure volume or velocity, were developed and
commercialized in the 1980s. Other flow meter technologies are affected by
changes in fluid density, viscosity, pressure and/or temperature.

Mass is the amount of matter in an object. Mass Flow measurement is based

on the laws of nature that prohibit a stream from accumulating or loosing
mass. Therefore, Mass Flow measurements are independent of changes in
temperature, or pressure.

Meters that measure mass directly, in effect, weigh the fluid as it passes
through the meter, yielding a highly accurate measurement that is virtually
independent of varying process conditions that often occur. Because of this
unique ability, it is possible to use a Coriolis Flow Meter on a wide variety
of chemicals without need for re-calibration or compensation to specific
fluid parameters.

Several types of mass meters are available including radiation, angular

momentum, Coriolis, heat transfer, and hot-wire probes type. BJ has
standardized on the Coriolis style of mass meter.

Coriolis Mass Flow Meters offer many advantages:

• Multi-measurement including:
– Mass Flow rate
– Volumetric Flow rate
– Density
– Temperature
• High accuracy (+/-0.1%) and repeatability, especially at low flow
rates, which means improved product quality and reduced waste.
• Installation is simplified because there are no flow conditioning nor
straight pipe run requirements.
• Low maintenance because there are no moving parts, and the system
is non-intrusive.
• Wide working range (turndown) of 10:1.
• The mass meter provides an alternative to nuclear densimeters.

Mass Flow - Density Determination

Density is defined as mass per unit volume, or mass divided by volume. The
volume of the fluid contained in the Flow Tubes remains constant. Then the
only way mass can change is if density changes. Because of this
relationship, the natural frequency of the Flow Tubes indicates not only the
mass of the fluid contained, but also the density.
The density of the process fluid can be derived from the frequency of
oscillation of the sensor. As the density increases, the natural frequency of
the system decreases.

Micro Motion Coriolis Meters

The Coriolis meter is more expensive than conventional turbine Flow Meters
or encoder systems. However, when maintenance costs are examined, the
Mass Flow Meter compares favorably with other methods of flow
measurement.
BJ uses Micro Motion meters in a variety of applications:
• R-Series Coriolis meters to measure chemical additive rates
• D Series Coriolis meters to measure cement mass flow, volumetric flow
and density
• DH Series meters to measure N2 for foam cement jobs
• DL Series meters to measure cement mass flow
• Basis meters to measure chemical additive rates
• Elite meters to measure chemical additive rates

Conclusion
Some points of consideration when selecting a mass flow meter include:
• Meter accuracy
• Required signal outputs
• Available mounting space
• Sizing for fluid velocity
• Process fluid properties
• Instrument delivery and support
• Cost
Cementing Equipment

Acknowledgements:

The authors would like to thank.

Tomball’s Engineering Department:
Mr. Jack Barrington, Rick Jones and
Mike Cosgrove

References:

BJ Services Applied Cementing- by

Ken Kenner-1991

BJ Services Iron Manual- by BJ

Tomball Engineering Department

BJ Operations and Maintenance

Manuals for Cementing Equipment -
by BJ Tomball Engineering
Department

BJ Services Equipment and

Technology Magazine –1994

BJ Services PowerCenter – Links.

EDC – Tomball, Version 1.01 Revised: March 2005 50