JET Module6 - Bulk System

version 1.
0
JET Module 6
Bulk System
2
TABLE OF CONTENTS TOC
JET 6 Bulk System Training Manual
1 Introduction pg 5
2 Principles of operation pg 6
2.1 Purpose of a bulk system pg 6
2.2 Basic bulk system components pg 7
2.3 Principles of pneumatic conveying pg 8
2.42.4 Principles of vacuum conveying pg 13
3 Bulk systems pg 14
3.1 Bulk storage tanks pg 14
3.2 Pressure tank pg 16
3.2.1 Components of pressure tank pg 16
3.2.2 Weigh batch blender pg 21
3.2.3 Additive/cutting bottle pg 22
3.2.4 Bulk tank construction pg 22
3.3 Gravity discharge bulk tanks pg 24
3.3.1 Discharge valve pg 25
3.3.2 Air supply line pg 25
3.3.3 Aeration device pg 25
3.3.4 Sight glass pg 26
3.3.5 Weight indicator pg 26
3.4 Pressurized surge can pg 27
3.4.1 Vent line pg 27
3.4.2 Pressure sensor pg 27
3.4.3 Pneumatic controller pg 28
3.4.4 Side discharge pg 28
3.5 Air slide/commercial hauler pg 29
4 Air compressors pg 30
4.1 Reciprocating compressors pg 30
4.2 Rotary axial compressors pg 32
4.3 Vane-type compressors (blowers) pg 33
4.4 Compressor package pg 34
4.4.1 Compressor pg 34
4.4.2 Air filters pg 34
3
4.4.3 Power unit pg 34
4.4.4 Air receiver tank pg 34
4.4.5 Safety relief valve (PRV) pg 34
4.4.6 Pressure gauge pg 35
4.4.7 After cooler and dryers pg 35
4.4.8 Unloader lines pg 35
4.5 Air compressor moisture control pg 36
4.5.1 After-coolers pg 36
4.5.2 Water separator pg 36
4.5.3 Air dryers pg 37
4.5.4 Refrigeration pg 37
4.5.5 Absorption pg 37
5 Dust collectors pg 38
5.1 Dust collector operation pg 39
5.1.1 Cloth sock filters pg 39
5.1.2 Pleated paper cartridges pg 39
5.1.3 Overpressure protection pg 40
6 Bulk system piping pg 41
7 Pressure-vacuum systems pg 43
7.1 Principle of operation pg 43
7.2 Non-pressure bulk tanks pg 44
7.2.1 Vent line pg 44
7.2.2 Vacuum breaker pg 44
7.2.3 Pressure relief valve pg 44
7.2. 7.2.4 Pressure vacuum compressors pg 45
7.3 Weigh batch blender pg 46
7.4 Additive hopper pg 47
8.0 Bulk equipment operations pg 49
8.1 Operating bulk plant equipment on location pg 49
8.1.1 STEM 1 pg 49
8.1.2 Rigging up pg 49
8.1.3 Transferring bulk material on location pg 49
4
8.1.4 Operating bulk equipment during the job pg 51
8.1.5 Rigging down pg 57
8.1.6 At the District pg 57
9 Maintenance of bulk equipment pg 58
9.1 Butterfly valve pg 59
9.2 Check valves pg 60
9.3 Ball valves pg 61
9.4 Aeration devices pg 62
9.4.1 Pipe jets pg 62
9.4.2 Canvas pads pg 62
9.4.3 Stainless steel pads pg 62
9.5 Dust collector socks pg 63
9.6 Connections pg 63
9.6.1 Figure 206 unions pg 63
9.6.2 Victaulic connections (groove lock) pg 63
9.6.3 Dresser sleeve pg 63
9.7 Safety relief valve pg 65
9.8 Pressure gauges pg 66
9.9 Weight measuring devices pg 67
9.10 Annual pressure tank inspection pg 68
10 Glossary pg 69
11 References pg 70
12 Check your understanding pg 71
13 Answer key pg 74
pg 76
5
INTRODUCTION 1.0.0
describe bulk equipment maintenance and
troubleshooting procedures.
Safety Warnings
Proper supervision is required during
hands-on training. Request assistance
from your supervisor if you are unfamiliar or
uncomfortable with the operation.
All personnel who will be involved with bulk
equipment must understand the dangers
involved with dealing with pressurized tanks. All
WS and OFS safety standards must be met.
Follow proper procedures before and while
working with equipment (JSA, HARC, etc.).
It is recommended that all personnel operating
bulk plant systems and components should
watch the safety video Dont Tease the Tiger.
Use the following guidelines:
When any bulk tank is under pressure,
never permit anyone to be on or under the
tank for any reason whatsoever.
Under no circumstance may any piping,
connections, or unions be connected,
disconnected or worked on while the vessel
is under pressure.
Never hammer on pressure vessels.
Always monitor pressure gauges.
Never look into the end of a plugged line.
This module introduces bulk operations.
Advanced bulk operations and maintenance of
individual equipment pieces are included in the
Advanced Bulk Plant JET Module.
This module discusses how a bulk system
works, describes the systems major
components, reviews the systems proper
operation, and addresses important
maintenance issues. In addition, this module
also covers the operation of a pneumatic
system used in a bulk delivery system.
Schlumberger uses bulk systems to store and
blend bulk materials used in cementing and
fracturing. The system is also used to supply
bulk material such as cement and barite to
mixing equipment. The success of a job is
directly dependent on the proper blending and
delivery of materials, which is controlled by
proper operation of the bulk equipment.
Learning objectives
Upon completion of this module, you will be
able to:
explain the principle of pneumatic
conveyance in both full pressure and
vacuum plants
identify the differences among various types
of bulk storage tanks, air compressors,
vacuum pumps, dust collectors, piping, and
pressure-vacuum systems
describe the operational guidelines for
district bulk plants and bulk plant equipment
on location
PRINCIPLES OF OPERATION 2.0.0
Air bulk transport (ABT)
Adds
Cement and
pozzolans
Blend
Additive/
cutting
bottle
Weigh
batch
blender (WBB)
Holding
tanks
Pressure tanks
Compressor
Dust collector
Air
Air compressor
Bulk system
JET 6 Bulk System Training Manual v1.0
6
2.1 Purpose of a bulk system
There are many ways to move large quantities
of powdered or granular solid materials such
as sand, barite, or cement, including augers,
conveyor belts and hand-carried sacks.
The preferred method at Schlumberger is
pneumatic transport.
Pneumatic (operated by air) transport is a
system that uses compressed air to fuidize
the dry material and carry it from one place to
another within a bulk system. A bulk system as
defned here includes all associated equipment
used to store, blend, and transport bulk
material.
A pneumatic and vacuum bulk system is the
preferred way to move cement and other
materials like sand, bentonite, pozzolan, and
barite for the following reasons:
high transfer rates
low manpower requirements
less material lost or damaged
environmentally cleaner
In the vacuum plant the storage tanks are non-pressurized vessels. The only pressure tanks are
the WBB, holding tank, and mix tanks. All vacuum storage tanks require a full open vent and a
2-in vacuum breaker. These components should both be placed on top of the tank system.
7
BASIC BULK SYSTEM COMPONENTS 2.2.0
Air bulk transport (ABT)
Adds
Cement and
pozzolans
Blend
Additive/
cutting
bottle
Weigh
batch
blender (WBB)
Holding
tanks
Pressure tanks
Compressor
Dust collector
Air
Bulk system components
Schlumberger uses pneumatic bulk equipment
to store, blend, transport and deliver bulk
materials to mixing equipment. A basic
pressure bulk system is made up of the
following components:
air compressors (two: one high-pressure for
bulk plant controls, and one high-volume for
bulk)
vacuum pumps in pressure/vacuum
systems
bulk tank also called a pressure tank or
P-tank in pressurized bulk plants; storage
tanks are non-pressurized in the pressure/
vacuum system
piping for air supply, bulk loading, bulk
discharge, and venting
a dust control device (either sock or flter)
measuring and sampling devices (load
cells, gauges, cement samplers, etc.)
New plants involve the use of:
WBB (weigh batch blender)
double-stacked tank
truck mix tank
The WBB and the truck mix tank each have
measuring devices to ensure total product
delivery and service quality to the customer.
PRINCIPLES OF PNEUMATIC CONVEYING 2.3.0
Properties of particle materials
MATERIAL SIZE
SPECIFIC
GRAVITY
ILUMINITE
D18
4.45
SILICA SAND
D30
SILICA FLOUR
D66
FLY ASH
D35
2.65
2.65
2.48
3.16 CEMENT
Piping
Bulk tank
the amount of air and the size and weight of
the particles of material
8
As compressed air fows through bulk material,
it tends to fuff or aerate the particles. Once
aerated, the particles are carried by the air as it
moves to a lower pressure area.
The amount of material carried by the air
depends on many factors, including:
the size of the piping between the tanks,
and the cleanliness of the piping (dirty lines
reduce the pipe ID)
the length of piping between the tanks, as
well as elbows and restrictions
Dilute Phase 1
Few particles of the bulk material are being
carried; the air velocity is high.
the pressure of the holding tank
Surge can
9
the pressure of the receiving tank (e.g.,
surge can).
Ways in which air carries bulk material are
shown in the examples that follow.
Air velocity high
Air velocity high
Lower air velocity
Lower air velocity
High air velocity
Lower air velocity
Unsteady Conveying
10
Dilute Phase 2
Few particles of the bulk material are being carried; the air velocity is lower than in Dilute Phase 1.
Unsteady Conveying 1
Few particles of the bulk material are being carried; the air velocity is high above a dune and
lower in clear part of the line.
Unsteady Dense Plug Flow
Air velocity < Unsteady conveying 1 air velocity
Air velocity < Dense plug flow air velocity
Steady Dense Flow
11
A large amount of the bulk material is being carried; the air velocity is lower than Unsteady
Conveying 1. The air-bulk material ratio is not constant throughout the line.
Steady Dense Flow

A large amount of the bulk material is being carried; the air velocity is lower than Dense Plug
Flow. The air-bulk material ratio is constant throughout the line.
12
NOTE:
A more complete discussion of the
different types of fow regimes for bulk
materials in pneumatic transport can
be found in the Cementing Materials
Handling Manual, InTouch content
ID# 3845898.
Steady Dense Flow
The bulk-to-air ratio is constant throughout the transport line.
This type of fow appears as a steady stream of bulk material. The cement delivery rate can be
controlled at the discharge end of the transport line. There must be enough pressure at the bulk
tank to overcome all pressure drops in the transport line. To have this type of fow, the theoretical
pressure drop required is 1.6 psi for each foot of transport line.
An example of this type of fow is a MARK III mixer hooked up directly to a bulk trailer with a short
(<20-ft or <6.1-m) bulk hose.
The type of equipment used by Schlumberger generally causes the transport to be Steady Dense
Flow if the length of fow is 20 feet or less, and Unsteady Plug Flow if the length is over 20 feet.
The aeration system must be operating properly to use this rule.
Guidelines for operating Schlumberger bulk equipment for both types of fow can be found in
Section 8, Bulk equipment operations.
Schlumberger operates bulk systems using the last two types of fow - Unsteady Dense Plug
Flow and Steady Dense Flow.
The bulk-to-air ratio is constant in short sections of the transport line, and there are sections of
air between these bulk-air slugs.
This type of fow appears as slugs of dense bulk followed by a blast of air. The delivery rate is
controlled at the bulk tank located at the beginning of the transport line. Air may have to be added
to the system after the cement leaves the tank. The pressure drop required for this type of fow is
less than that required for Steady Dense Flow.
An example of this fow is a bulk plant on an offshore rig hooked up to a surge can through a long
(>20-ft or > 6.1-m) length of piping.
PRINCIPLES OF VACUUM CONVEYING 2.3.0
Vacuum conveying consists of the following
process:
All products stored in non-pressure storage
tanks are protected by both a full open
vent system and a vacuum breaker (these
containers cost less than pressure tanks).
Products to be blended on transfers are
moved to the WBB by means of vacuum
(differential pressure created between the
atmospheric and the vacuum pump).
The WBB is then pressurized for both
blending and transfer through the double
stack tank and then to the truck mix tank
and on to the bulk transport.
Additives are also moved to the WBB
through an additive cone by vacuum.
The pressure vacuum plant has the following
advantages:
All storage tanks are non-pressured and
considerably less costly.
When flters are properly maintained, the
plant is more environmentally friendly.
Additives are added by means of a cone
and vacuum and do not require an additive
tank or another pressure vessel.
Product transfer takes place at a higher
rate, reducing blend and load time.
The components involved are a high-volume
air compressor, a high-pressure air compressor
(for controls), a high-volume vacuum pump,
and a quality air dryer.
This process and the components involved are
discussed in depth in Section 7.0, Pressure-
Vacuum Systems.
13
BULK SYSTEMS 3.0.0
Bulk storage tank
14
This section describes the major components
used in Schlumberger pressure and vacuum
bulk systems and explains their principles of
operation.
3.1 Bulk storage tanks
A bulk tank is both a storage tank and bulk
feeder, supplying bulk materials to other parts
of the bulk system or discharging them to a
mixing system. This process occurs by way
of either pressure or vacuum, depending on
which type of plant is in place at the district.
Schlumberger uses two types of bulk storage
tanks:
ABT truck
Surge can
Names of pressurized tanks:
Bulk tanks Bulk trucks
Pressurized silos Pressurized tanks
P-tanks silo
P-cans ABT(Air bulk truck)
Banana bulk truck Field bin
Names of non-pressured tanks
Gravity bins Surge cans
Air slide Commercial hauler
Gravity cans Surge tanks
Storage tanks District storage
15
Non-pressurized tanks
These tanks do not meet the requirements
of pressure vessels, and have a maximum
allowable pressure of 1 bar or 15 psi. They
may also be zero pressure containers with a
5-psi pressure relief valve, a vacuum breaker
and a fuel open vent system on top of the
tanks. Pressure limits must be clearly marked
on each type of vessel, and necessary
pressure relief valves must be installed.
Some of the many names for tanks used as
bulk storage tanks are listed below.
Pressurized tanks are sometimes referred to by
their size, e.g.,1,050s for 1,050 ft
3
or 850s
for 850 ft
3
tanks. One of the more common is a
1,030 (1,030 ft
3
).
Non-pressurized tanks are also known by
several names, including the following:
Pressurized tanks

These tanks are pressure vessels that meet
strict requirements. Most countries consider
1 bar or 15 psi the critical pressure that
designates a tank as a pressure vessel.
PRESSURE TANK 3.2.0
Vent line Fill line
Pressure relief valve
Pressure gauge
Discharge line
Air supply line
Manway
Pressure tank Fill line and discharge line
16

3.2.1 Components of pressure tank
This section describes the functions of the
pressure tank components.
3.2.1.1 Fill line
The fll line is used to convey bulk material
from an outside supply to the inside of the tank.
The fll line is fabricated so the end of the line
extends into the interior of the tank at its top
such that the bulk material falls down into the
tank as it is flled, and bulk material does not
cover up the entrance into the tank. Care must
be taken not to overfll the tank when supply is
being delivered, as this may contaminate other
products or spill into the vent system.
3.2.1.2 Discharge line
Bulk material is discharged from the tank into
another tank or mixing system through the
discharge line. The discharge line originates
inside the bulk tank at the bottom, penetrates
the tank wall to a discharge point outside the
tank (see Pressure tank illustration, above left).
Some tanks are constructed with the discharge
line starting as a hole in the middle on the
bottom of the tank, while other tanks have the
discharge line starting as a dip pipe reaching
down to the middle of the bottom of the tank.
A valve is installed on the discharge line near
where the line exits the tank.
Pressure relief valve close-up
Vent line
17
3.2.1.3 Vent line
The vent line allows the venting of air and
pressure from inside the tank to the outside.
This is necessary when transferring bulk
materials into the tank (so that the air helping
to convey the material exits the system), or
when bleeding pressure from the tank.
The vent line is designed to start from the
inside of the top of the tank to a point towards
the bottom of the tank.The vent line can
indicate when the tank is full if bulk material
fows to the dust collector. Extreme care should
be taken to prevent material from entering the
dust collector. A valve is installed in the vent
line so that pressure can be put on the tank
when it is closed.
NOTE:
Vent line valves should be removed
from tanks used in vacuum systems to
prevent the tanks from collapsing.
3.2.1.4 Pressure relief valve
The fll line and vent lines are similar to each
other, but the vent line is identifable by its
pressure relief valve (commonly called a
pop-off valve) and pressure gauge.
The pressure relief valve can also be mounted
on the shell of the tank and is designed to
relieve tank pressure if it exceeds a preset
pressure. Most of the pressurized bulk
tanks used by Schlumberger are designed
to operate at 30 psi, and the pressure relief
valve is designed to open at 35 psi. Refer to
Maintenance Bulletin 625E, InTouch content
ID# 3998770.
Pressure vessel
location
Inland barges
Land bulk storage tanks
Offshore tanks
ASME coded
tank allowable
working pressure
valve setting
(psi)
Offshore tanks
Land bulk storage tanks
Truck bulk tanks
Portable field bins
Air slide transports
P-tanks P-tanks
Air slide transports
Pressurized surge cans
30
30
35
30
30
15
30
5
35
35
35
35
35
18+15 psi regulator
35
10
Pressure relief
18
Some tanks are also equipped with a rupture disc. This is an additional safety device designed to
shear if the pressure rises above the designed limit. When the disc ruptures, all pressure is lost
from the tank and the disc must be replaced before the tank can be used again.
Schlumberger uses many pressurized tanks. This list of tanks and their pressure relief valve
settings is taken from Maintenance Bulletin 625E, InTouch content ID# 3998770.
Pressure gauge
Vent line Fill line
Pressure gauge
Discharge line
Air supply line
Manway
Air supply line
19
3.2.1.5 Pressure gauge
For safety reasons and tank operation, every
bulk tank must have a working pressure gauge.
The gauge should be installed on the vent in a
position that will minimize the amount of dust
to which the gauge inlet is exposed during
operation. It is important that the gauge is
checked and inspected regularly during any
operation.
NOTE:
It is critical to Schlumberger that all
safety devices be kept in operating
condition at all times for both safety and
legal reasons.
3.2.1.6 Air supply line
This line supplies the compressed air used to
carry bulk material out of the tank. This line
could be mounted anywhere on the outside
of the tank, but it is connected to the aeration
device on the inside of the tank. A valve is
installed on the air supply line to control the
amount of air entering the tank. The air supply
line will normally have a check valve to prevent
bulk material from plugging the air system if the
aeration device fails.
Some tanks are equipped with a small valve
on the vent line to slowly bleed off the pressure
in the tank. This valve should not be used to
pressurize the tank; all air used to pressurize
the tank should go through the aeration
devices.
Pipe-jet
Offshore silo pads
Land based pads
Pads
20
NOTE:
Most tanks equipped with a pad-type
aeration device have an equalization
valve that keeps the pressure the same
on both the top and bottom of the pad.
If the pressure is not equalized, the pad
can rupture.
3.2.1.7 Aeration device
Schlumberger uses two types of aeration
devices that enable compressed air to fuff/
aerate through the cement. These devices
fuidize as much of the contents of the tank
as possible. The aeration device fuidizes bulk
material in the bottom of the tank so that it can
begin to fow out of the discharge.
3.2.1.8 Pipe jets
These are installed in the bottom of the tank
and direct air fow into the tank. The jets are
covered with a membrane to prevent them from
being flled with bulk material. A check valve
is also required on the inlet side (outside the
tank) to prevent backfow of dry material into
the air system.
3.2.1.9 Pads
Pads installed in the bottom of the tank are
made of a porous material that allows air fow
into the tank. The pads, which are commonly
made of canvas, are designed to a allow air
to fow into the tank but prevent cement from
fowing into the air system piping.
From
storage tanks
WBB
Double-stacked
tanks
Mix truck tank
Transport
Manway
Transfer of blend in vacuum system
21
This process is the same in both full-pressure
and pressure/vacuum plants, with the
exception that products and additives enter the
WBB under pressure and by way of a vacuum
in a pressure vacuum tank.
3.2.2 Weigh batch blender (WBB)
A weigh batch blender (WBB), shown below,
is a specialized pressure vessel used to weigh
and blend bulk material. A WBB has steep
sides in its cone area and jets as its aeration
device.
Our service quality standard specifes a
minimum of three movements of the bulk
blend to ensure a proper blend. This requires
the addition of the double stack and a truck
mix tank. These additions make a total of fve
movements:
1) WBB
2) top of the double stack
3) bottom of the double stack
4) to the mix tank
5) on to the transport.
3.2.1.10 Manway
Each tank is equipped with a manway that
allows inspection of the inside of the tank. The
manway can be located on the top, bottom or
side of the tank.
If the manway is located on the top of the tank,
a ladder should be permanently mounted on
the outside and inside of the tank. If the tank is
over 12 feet tall, the outside ladder must have
a cage.
NOTE:
Always comply with relevant safety
standards for working at heights,
manways, vessel entry, and when
lockout/tagout is applicable.
NOTE:
Never modify a tank that is
a ASME code vessel. Any
modifcations to an ASME tank
must be made by a company
certifed to do such work.
Additive/Cutting bottle Weigh batch blender
22
Vacuum/pressure tanks
In a pressure/vacuum plant, the additive bottle
is replaced by an additive cone operating under
vacuum. Additives are dumped into the hopper
and the rate of fow is controlled by a butterfy
valve.
3.2.4 Bulk tank construction
All of the pressure bulk tanks used by
Schlumberger are designed and built to
the standards of the American Society of
Mechanical Engineers (ASME) Boiler and
Pressure Vessel Code, Sections I, VIII and IX.
These standards govern the type of metal, the
welding procedures, and testing procedures
used during manufacture. In addition, the
code requires personnel involved in the
In the pressure vacuum plant the WBB is
both a pressure and a vacuum vessel, and is
protected with a PRV and a vacuum breaker.
Most WBBs are built with three legs. Two are
attached to the base with pins or ball-joints so
the third leg is free to move. The third leg is held
up by a load cell which transmits a hydraulic
or electronic pressure signal to a weight scale.
Strain gauges attached directly to the legs can
be used instead of the load cell, but they are
more costly to install.
3.2.3 Additive/Cutting bottle
Full pressure plant
An additive bottle is a small pressure tank that
adds sacked material to the WBB, and is used
in full pressure plants. Cutting bottles also
used to cut and load sacks and/or big bags of
material such as cement or sand when these
are not delivered in bulk.

The additive bottle, which can be either of the
designs shown here, does not have a fll line;
material is added either through a hatch or a
valve built into the top of the tank.
Identication plate
Bulk tank
23
An ASME code inspector must approve the
work to be done and must inspect the work
after it is completed. The inspector prepares a
report (the partial data sheet), which indicates
his approval of the repairs. The report must
be kept on fle for the life of the tank. If repairs
are needed, approval must be obtained from
the local maintenance department before
beginning any repair.
NOTE:
Pressure bulk tanks that meet all
requirements of the ASME code are
called Coded Tanks, and bulk tanks
designed for pressures less than 15 psi
are referred to as Non-Coded Tanks.
welding and inspection to be ASME-approved.
The ASME code is the accepted standard in
most countries.
To construct a tank that qualifes as an ASME
tank, the manufacturer must have a current
certifcation called a U stamp. To make
repairs or modify an existing tank, the shop
doing the work must have a current certifcation
called an R stamp.
Each ASME-coded tank has an identifcation
plate similar to the one shown below, with the
working and test pressures of the tank stamped
on the plate. Information on this plate is
required for the tank to pass safety certifcation
inspections, and the plate must remain on the
tank throughout its life.
NOTE:
Any repairs to the tank itself that require
welding or cutting must be done by an
ASME-coded shop using a coded welder.
The records of these containers are registered
with the National Board with a serial number;
should a plate become unreadable, the
district records can be sent to the original
manufacturer to produce a new plate.
The plate must be protected throughout the life
of the tank; therefore, measures must be taken
to protect these plates during the process of
repainting, sand blasting, etc.
Only pre-approved suppliers are allowed to
manufacture bulk tanks for Schlumberger.
24
JET 6 Bulk System Training Manual October 2005 v1.0
24
24
Discharge valve
Aeration device jets
Weight indicator
Fill line
GRAVITY DISCHARGE BULK TANKS 3.3.0
Surge can
As the name indicates, gravity supplies the energy to empty gravity silos and surge cans. Air
is used to keep the bulk material fuffed up and to prevent it from bridging off inside the tank.
Because this tank uses gravity to empty, it is used only to deliver bulk material to a mixing unit.
The design of gravity silos and surge cans is similar, the biggest difference being their size. A
gravity silo is usually 550 ft
3
(15.7 m
3
), while a surge can is usually 70 ft
3
(1.98 m
3
).
A surge can performs three functions:
Separates the bulk material transport system from the bulk material supply system prior
to mixing. This is important for the Unsteady Plug State. This type of fow occurs if the
Schlumberger mixing unit is more than 20 feet away from the bulk tank.
Allows air used to transport the bulk material to escape. This is important for the Unsteady
Plug State due to the large amounts of air that are required for the distance the bulk material
is being conveyed.
Provides a buffer when switching from one P-tank to another.
Surge can components
Discharge valve
Aeration device jets
Weight indicator
Fill line
ojo
3.3.2 Air supply line
This line supplies air to fuff up the bulk
material. The air fow maintains a consistent
fow of bulk material and prevents the line from
bridging off inside the tank.
3.3.3 Aeration device
The aeration device enables the compressed
air vent to aerate through the bulk material.
This device is designed to fuidize as much of
the contents of tank as possible and, as with
pressure tanks, Schlumberger uses two types
of aeration devices (pads or jets).
Surge can components
Aeration device: jet
25
A gravity silo can perform all the functions of
a surge tank and is large enough to be used
as a storage tank for bulk material systems on
location.
Most of the components of gravity discharge
tanks perform the same function as a pressure
tank; however, a few of the tank components
have different functions, as described below:
The pressure relief valves (pop-offs)
on surge cans and gravity cans perform
the same function as those found on
pressurized tanks, limiting the maximum
pressure inside the tank

The pressure relief valves on surge
cans and gravity silos are set to much
lower pressures than the relief valves on
pressurized tanks. Gravity silos should be
equipped with safety relief valves set at
3 psi, and the pressure relief valves on
surge cans should be set at 10 psi. Some
tanks are equipped with rupture discs
instead of, or in addition to, pressure relief
valves.
3.3.1 Discharge valve
This valve controls the rate at which the bulk
material (usually cement) falls from a gravity
silo or surge can. The valve is relatively large,
usually 8 in (20 cm) or larger, so that high
discharge rates can be achieved.
The valve is normally a butterfy valve. It is
important that the valve is well maintained
and in good working condition, and that the
surrounding area inside the silo is clean and
free of cement after every job.
Sight glass
Sight glass
Sight glass
Load cell
Surge can and load cell
26
3.3.4 Sight glass
Surge cans are ftted with small windows to allow
visual monitoring of cement inside the tank.
3.3.5 Weight indicator
Surge cans can be ftted with weight indicators
so the level of bulk material inside the tank can
be measured. The load cell/indicator system
used on surge cans works in the same way as
systems found on most WBBs. The load cell
and weight indicator have to be calibrated to
take into account the weight of the tank so that
the read-out gives bulk material weight only.
A hydraulic load cell holds up one side of the
surge can, while the other side of the surge can
is connected to the frame with pins that allow
the surge can to pivot. The force from the tank
is exerted on the surface of a diaphragm in the
load cell.
The weight of the load cell forces the fuid to
the weight indicator gauge, which reads in
weight not pressure. The gauge is matched
to the load cell for calibration purposes. Field
replacement of either the gauge or the load
cell must be an exact match for proper weight
indication.
NOTE:
Gravity silos and surge cans (non-
code tanks) are not built to the rigid
standards required for tanks that will
have more than 15 psi of pressure.
Nonetheless, these tanks must be
treated with the same respect as
pressurized tanks. The amount of
force contained within these tanks is
tremendous, and the flm Dont Tease
the Tiger shows dramatically the power
of very low pressures exerted on large
surfaces.
Surge can
Vent line
27
JET 6 Bulk System Training Manual October 2005 v1.0
27
27
Schlumberger also uses a special-designed
surge can called a pressurized surge can.
This tank is a pressure vessel much like the
pressurized tanks described earlier, but it does
not meet the strict standards of ASME code for
a pressure vessel and its pressure is limited
to 15 psi just like a standard surge can. This
surge can is typically used in conjunction with
the Slurry Chief mixer on offshore skid units.
The special features of a pressurized surge
can are described below.
3.4.1 Vent line
The vent line is equipped with valves; a vent
control valve and a vent bypass valve. If
the bypass valve is left open, the surge can
performs as a standard surge can. The vent
control valve is automatically opened and
closed to maintain a set pressure inside the
surge can, usually 5 to 7 psi.
3.4.2 Pressure sensor
A pressure transducer is mounted on top of the
surge can. This transducer sends a pneumatic
pressure signal to the controller.
PRESSURIZED SURGE CAN 3.4.0
Fill line
Vent line
Vent control
valve
Air supply line
Weight indicator
Load cell
Jets
Discharge valve
Surge can
Pressure sensor
Pressure sensor
28
3.4.3 Pneumatic controller
A pneumatic controller controls the opening
and closing of the vent control valve. The
controller maintains pressure in the surge can
at a preset point.
3.4.4 Side discharge
In addition to the discharge valve in the bottom
of the surge can, the pressurized surge can
is equipped with a side discharge. The small
amount of pressure kept in the surge can
enables bulk material to be discharged a short
distance through this side discharge.
29
AIR SLIDE/COMMERCIAL HAULER 3.5.0
Trucks that transport bulk material are not
certifed pressure vessels, and are often
referred to as air slide and commercial haulers.
The differences between these trucks and
other pressure bulk tanks and trucks are the
working pressure limit and the type of aeration
system.
Unlike a pressurized tank, which operates
at pressures up to 30 psi, air slides and
commercial haulers have non-coded tanks
that operate under 15 psi. These tanks
have a pressure regulator set for 15 psi
and a pressure relief valve set for 18 psi.
Maintenance Bulletin 743A MUST-DO, InTouch
content ID #4128998, describes these safety
devices.
NOTE:
This type of bulk truck delivers cement
at rates of 1,000 to 2,000 lbm/min,
which is about half of what is expected
from a pressure-type coded bulk tank.
Commercial hauler
AIR COMPRESSORS 4.0.0
Compressor
Intake stroke
Compression stroke
30
Compression stroke
The air in the cylinder is compressed as the
piston travels up. The intake valve closes and
the exhaust valve opens as the air pressure
inside the cylinder exceeds the pressure in the
discharge piping.
The basic principles of operation of a
single-stage reciprocating compressor are
much like those of a two-cycle engine.
Intake stroke
The air passes through a flter to ensure that
only clean air reaches the cylinder. Air enters
the cylinder through the intake valve, which is
opened by the difference in pressure and is
drawn into the compressors cylinder as the
piston travels down.
Air compressors provide all of the energy
needed to run a bulk system. Schlumberger
uses several different types of air compressors,
most of which are designed to operate at 30 to
32 psi and deliver 300 to 400 ft
3
/min of air, or
29 in of mercury at 425 ft
3
/min.
4.1 Reciprocating compressor
Single-stage-reciprocating compressor are
commonly used in Schlumberger.
Unloader assembly
Cylinder
assembly
Unloader
pilot valve
Unloader
Intake stroke
31
How pressure is controlled
Regulator or unloader type system
The discharge pressure of the air compressor
is regulated to stay within preset limits. The
unloader valve senses system pressure versus
the desired preset pressure. When the desired
system pressure is achieved, the unloader
valve sends air pressure to the pilot unloader;
the plunger holds the intake valve open, thus
allowing the compressor to keep cool and
preventing the compression process.
The differential pressure of the unloader
should be set within 15 percent of the set
pressure. If the differential pressure is greater
than 15 percent it indicates an unloader
system malfunction that requires service and
calibration.
The diagram below illustrates a typical
unloader on reciprocating compressors.
Another type of system utilizes a pressure
switch to allow the electrical motor to turn on
and off as needed to maintain a set pressure.
This is the most common type of regulator
for small compressors that must furnish high
pressure (125 to 150 psi), for example in
maintenance shops. The pressure switch
senses tank or system pressure; when the
system reaches the set pressure, the pressure
switch turns off the electrical motor turning the
compressor. This system is primarily used
in the bulk plant for controls such as high-
pressure valve actuation.
A valve in the switch opens to bleed pressure
off the cylinder so that when the compressor
restarts it is not starting under load. The switch
has a differential spring setting, which should
be set at 20 percent of system pressure, to turn
the motor back on when necessary. It gives
no warning prior to starting, so it must display
a sign as described in the Well Services
Safety Standard 04: Facilities and Workshops,
InTouch content ID# 3313678.
ROTARY AXIAL COMPRESSOR 4.2.0
Rotary axial compressor
32
Rotary axial fow compressor, commonly
known as a screw compressor, is capable
of producing high volumes of air (100 to
1000 ft
3
/min at 100 to 175 psi).
Air is pulled into the compressor housing by
the rotation of the screw-type rotors, and is
trapped between the lobes of each rotor and
the housing wall.
As the screws rotate, the air is compressed
and moves toward the discharge end of the
rotors. The rotors are tapered to a smaller
diameter on the discharge end, which creates
a smaller chamber for the air, compressing it
before it is discharged.
Constant speed control regulation allows the
compressor to be unloaded at a set pressure
while the electric motor continues to operate
at a fxed RPM. The basic principle of constant
speed regulation is to throttle an intake
valve open or close, and regulate the ft
3
/min
discharge, thereby regulating the psi.
Some screw compressors are driven by diesel
engines. When the discharge pressure is at
or above a set pressure, a variable speed
regulator closes off a valve in the intake of the
compressor to restrict air to the compressor
to regulate discharge volume or ft
3
/min.
Simultaneously, it throttles the engine to idle
position. When it senses a 15 percent drop
in the pressure, it throttles the engine back to
fast idle RPM and then opens the valve to the
intake.
This type of system reduces the need for
large-volume storage tanks, but requires a
larger than average compressor for ft
3
/min
consumption.
VANE-TYPE COMPRESSORS (BLOWERS) 4.3.0
Blower
relies on a constant speed control regulator,
as described below. It is critical that air is
constantly passing through the blower.
1. Air from the receiver acts on the unloader
pilot valve. If the pressure is above the set
pressure (usually 32 psi), the pilot valve
opens, allowing air to fow to the 4-way
unloader valve.
2. The 4-way valve directs high-pressure air
to open the control valve, allowing excess
air to be discharged to the atmosphere.
This allows the compressor to keep running
unloaded.
3. The unloader valve piston will close as the
pressure falls below a set point (usually
28 psi). This causes the 4-way valve to
shift, closing the control valve.

4. Compressed air is again supplied to the
system.
Pressure regulator
33
Vane type compressors, also called blowers,
are designed to deliver 150 to 400 ft
3
/min at
pressures up to 35 psi.
As the power source turns the rotor, centrifugal
force pushes the vanes outward, sealing the
vanes to the housing. Air is pulled into the area
between the vanes and housing, trapping the air.
As the vanes travel along the cam, the volume
between the rotor and the cam gets smaller,
which compresses the air. The cam is designed
so that the maximum volume between vanes
is at the air intake, and the minimum volume
between vanes is at the discharge.
A valve on the discharge fow stream is
the most commonly used control system
on a blower-type compressor. When the
preset system pressure is reached, an air
actuator opens the valve and the compressor
discharges to the atmosphere until the valve
closes again. A check valve contains the
pressure downstream of the tee.
Pressure regulation for blowers
The pressure of this type of compressor also
COMPRESSOR PACKAGE 4.4.0
A typical compressor package used by
Schlumberger includes many components, as
described below:
4.4.1 High-volume compressor and high-
pressure (controls) compressor
The compressor usually has two or three
cylinders, and is capable of delivering 300 to
400 ft
3
/min at 30 to 40 psi; or it can be a rotary
screw such as the Palatek unit, which can be
used on both a pressure or a vacuum pump.
4.4.2 Air lters
Each compressor usually has one air flter
per cylinder. It is common to see 3-cylinder
compressors with two, or even one, air flter
as long as the total ft
3
/min capabilities of the
air flters meet or exceed the needs of the
compressor. It is important to keep air
cleaners clean.
Vacuum pumps require their own flter or the
use of the dust collector flter on top of the
WBB in the vacuum mode.
Compressor components
Diesel engine
Air filter
Compressor
Air reciever tank
34
On a reciprocating compressor, if the
differential pressure of the flter is too high, it
will cause a vacuum between the air cleaner
and the cylinder. This usually results in a
vacuum that pulls oil up through the piston
rings and discharges it into the pressurized air.
This oil can be carried all the way to the pads
in the bulk cement tanks. Because dirt is very
abrasive, dirty air flters can cause serious
damage to the compressor.
Dirty air flters on a vane-type blower can
cause the vanes to disintegrate.
4.4.3 Power unit
A 70 HP diesel engine, an electric motor or the
engine of a tractor truck drives the compressor.

4.4.4 Air receiver tank
This tank stores a small volume of air that
can satisfy an increase of the ft
3
/min output
needed from the compressor, such as blowing
lines clean. The tank can also act as a water
trap if the air velocity in the tank is lowered
suffciently to allow water droplets to fall out of
the compressed air. The air receiver tank also
helps the length of the cycle time between the
time when the compressor unloads and when it
reloads. This is most often an ASME container.
4.4.5 Safety relief valve (PRV)
This valve is set to open if the pressure of
the compressor exceeds a set limit. All PRVs
should be tested periodically.
4.4.8 Unloader lines
The pressure regulation system of the
compressor uses these lines to transmit the
systems operating pressure to the compressor.
Water in the compressed air system can
damage the bulk material, make the bulk
material more diffcult to move and cause
blockage of the aeration devices (pads and
jets). The principle methods used to control
moisture in air systems are described below.
Water may also freeze in low temperatures and
prevent proper valve operation.
Unloader line
35
The three measures of pressure control in this
process are in this order:
1) cycle-through pressure regulation
2) PRV pressure relief valve
3) rupture disc.
4.4.6 Pressure gauge
This gauge allows the operator to check the
operation of the compressor. The location
of pressure gauges in the system helps
the operator identify potential problems or
restrictions in the system. This may also be a
lube oil pressure gauge.
4.4.7 After-cooler and dryers
After-coolers remove the heat that air acquires
during compression. The cooling of the air also
removes moisture, which is drained off.
Dryers, on the other hand, do nothing to cool
the air, but have passive desiccant cartridges
that remove the moisture from the air. The
moisture is channeled to the bottom of the
dryer where it is purged from the system by
a signal from the unloader. A typical air dryer
operating with a 235-CFM screw compressor
at 100 percent humidity can discharge 100 gal
of water in a 24-hour period. Desiccant dryers
require periodic servicing.
AIR COMPRESSOR MOISTURE CONTROL 4.5.0
Water separator
36
4.5.2 Water separator
A simple way to separate water from air is to
slow down the air and allow water droplets to
settle out and be drained off. A large receiving
tank works this way. The tank also tends to
radiate the heat of the air and this cooling
causes water in the air to condense.
To help separate moisture, air receivers or
volume tanks should always be plumbed
so that the discharge of the air compressor
comes into the tank lower than the air outlet.
In areas of high humidity, large volume tanks
are needed to capture the moisture to prevent
damage to air controls.
Smaller inline water separators, such as those
used on air controls, use a centrifuge method
in which air is swirled around the bowl to make
the water fall out. These separators work best
in low-volume applications.
4.5.1 After-coolers
After-coolers cool the hot compressed air
discharged by the compressor to remove
moisture.
Air heats up as it is compressed, and heated
air is able to hold more water as a vapor.
Cooling the air causes the water vapor to
condense, and the condensate can be drained
out of the system. A water-to-air or air-to-air
after-cooler is a device ftted directly to the
compressor discharge that is designed to cool
the air and cause water vapor to condense.
After cooler
Air dryer
37
4.5.4 Refrigeration
Compressed air is cooled to near freezing, and
most of the water content in the air condenses
then the air is reheated.
4.5.5 Absorption
A chemical absorbs water from the
compressed air, then turns into a liquid and is
drained away. The chemical is not reusable.
Refrigerant dryers are not usually found on
the compressors that Schlumberger uses
for bulk systems. Schlumberger uses after-
coolers and air receiver tanks to control the
water content of compressed air. Most of the
new or upgraded plants in North America use
refrigeration-type dryers.
4.5.3 Air dryers
Devices used to dry the air are more
complicated than the after-cooler and the water
separator discussed previously. Air dryers
use either the refrigeration or the absorption
method, described below, to lower the amount
of water in the air system.
NOTE:
Lubricators are necessary for the proper
operation of air control. Air frst travels
through the air dryer or water separator
to clean the air, then the lubricator adds
oil to the air for the components.
Lubrication must be adjusted to the
proper fow. Too much oil in the system
can be messy and cause problems
with some components, while too
little lubrication will result in some
components not getting any lubrication.
A good rule of thumb is 4-6 drops per
minute using SAE10 oil or engine oil cut
with diesel 50/50. Do not use Marvel
Mystery Oil because it creates a flm
that causes components to stick or
hang up. Make certain the air supply is
bled off when flling the lubricator.
DUST COLLECTORS 5.0.0
Vibrator
assembly
Air outlet
Air inlet
To the collection tank

Dust collector
Interior of dust collector
Inlet line of dust collector
An inlet line is to be hooked to the vent line of
the bulk tank being loaded.
Outlet line of dust collector
The outlet line is a large opening that allows
clean air to exit the dust collection system.
Filter
The flter, such as a sock or cartridge prevents
dust from exiting the dust collector.
Dust collector bags are used on locations
where the bulk equipment is not equipped with
a permanent dust collection system.
38
Every bulk system must have some sort of dust
control system, which must be designed to
meet local air quality regulations.
Dust collectors are designed as illustrated.
DUST COLLECTOR OPERATION 5.1.0
Vibrator
assembly
Air outlet
Air inlet
To the collection tank
The dust collector system is divided into two
sections. The upper section contains the flters,
while the lower section is open to collect and
hold the dust particles in the collection tank.
Dirty air enters the system just below the flter
where dust is caught by the flter, allowing
clean air to exit the system. The flter has to
be cleaned for the system to continue to work
properly.
The methods used to clean the flters are
described below:
5.1.1 Cloth sock lters
Dust is fltered out onto the cloth material as
airfows through. Periodically the socks are
shaken off by a vibrator assembly built into
the top of the collector. Continuous shaking of
the socks causes dust to migrate through the
sock, and some dusty air will exit the collector.
The shaker should be run 15-20 seconds after
each load, or 30 to 60 seconds out of each
15 minutes of operation. Each district should
establish regular intervals for running the dust
collector.
Dust sock lter
5.1.2 Pleated paper cartridges
Another type of flter is the pleated paper type
shown in the illustration on the following page.
The dust flters out onto the pleated paper as
air fows through the cartridge. A jet of high-
pressure air clears the dust from the flter and
causes the accumulated product to fall into a
collection tank below the dust collector. The
frequency of the air blast can be varied, but
should be set for intervals of 4 to 6 seconds.
The air jet should be started before the dust
collector is used and continued until after the
dust collector is no longer needed.
NOTE:
It is normal to lose 0.5 to 3.0 percent of
the material being transferred as dust.
The vent system and dust collection
tank must be capable of holding this
amount of bulk material.
39
5.1.3 Overpressure protection
Dust collectors are designed with some type of overpressure protection to prevent them from
shutting down the whole bulk plant. If overpressured, sock-type flters simply blow apart or blow
off their mounting and allow dirty air to escape directly into the atmosphere. The pleated paper
cartridge type of dust collectors are constructed with a bypass mechanism that opens if the
pressure becomes too high.
These flters are also used to protect the vacuum pumps in pressure/vacuum plants by fltering
the air on the inlet side of the vacuum pumps.
Dust lter
Air outlet
Air inlet
Air jet assembly
High-pressure air supply
regulated to 60 psi
Air filter
housing
To the
collection
tank
Pleated paper cartridge
40
BULK SYSTEM PIPING 6.0.0
Delta wye
Discharge hose
Buttery valves
41
The pipe used for fll lines, discharge lines
and vent lines in a bulk system is usually 4-in
or 5-in diameter steel. Larger pipe requires
higher volumes of air to transport bulk material,
while smaller pipe requires higher pressures to
overcome friction losses.
To make fow through the lines as smooth as
possible, long radius elbows and Delta wyes
(shown below) are used instead of standard
elbows and tees. This is often referred to as
3R (triple the radius), the preferred alternative
being 2R (twice the radius).
Butterfy valves control the fow of materials
in a bulk system. The air supply line may be
equipped with either butterfy valves or ball
valves.
Bulk discharge hose (usually 4-in diameter)
is used to hook up to portable units and
must meet Schlumberger specifcations for a
discharge hose. The specifcations for blender
discharge hose and bulk discharge hose can
be found in the Treating Equipment Manual,
Version B, InTouch content ID# 3013931. The
hose must be double-clamped with clamps
90 degrees apart.
Blanking caps should be designed as shown,
so that the nut can be loosened and the plug
moved to check for pressure without the risk
of blowing the cap off. Never use one-piece
wet caps on a dry bulk line because it is not
possible to tell if there is pressure on it when
removing the cap.
A rock catcher flters chunks of hard cement or
rocks that may be present in dry bulk material
when it enters or leaves a bulk plant. The rock
catcher has a screen that allows bulk material
to fow through, but which will catch larger
particles.
Blanking caps
Rock catchers are intended, for the most part,
to ensure product quality from the supplier and
are installed on each individual product line
from the vendor.
The new version of the rock catcher has a
replaceable screen.
Rock catcher
42
WARNING:
Discharge hoses CANNOT be used on
the discharge side of triplex or other high-
pressure pumps, or on the suction side
of centrifugal pumps. Before using the
hose, check it carefully for any signs of
cracking or damage. The pressure rating
of the hose is between 100 and 125 psi;
therefore, if a damaged hose fails under
pressure, it causes damage to equipment
and injury or death to personnel.
PRESSURE-VACUUM SYSTEMS 7.0.0
Schlumberger uses pressure-vacuum bulk systems at some Districts. A pressure-vacuum system
uses basically the same components found in pressure bulk systems, except that the compressor
must be designed for a pressure-vacuum application and requires an additional flter process for
the compressor.
7.1 Principle of operation
The principle of moving material by vacuum is the same as that for a pressure system. Air carries
the bulk material from areas of high pressure to areas of low pressure. A vacuum system creates
low pressure in the tank to which the product will be transferred while fuffng and jetting the tank
from which the product will come. Bulk product is carried faster through this type of system.
The compressor is plumbed so that the inlet creates a vacuum while the discharge is
simultaneously expelled to the atmosphere, pressurizing the tank.
The bulk tanks are plumbed in such a way that the air used to carry the bulk material out of the
tank comes through the tanks vent system, pulled in by the compressor. In most new plants,
three separate units are used for pressure/vacuum systems.
A pressure-vacuum system has the following advantages over a straight pressure bulk system:
less dust is generated when adding additives to the WBB; the bulk tanks are easier to clean, the
cost of the tanks is lower, and the code is not needed.
The primary disadvantage is that the reciprocating compressor has a short life span if it is not
maintained correctly.
43
NON-PRESSURE BULK TANKS 7.2.0
Non-pressure tank
7.2 Non-pressure bulk tanks
(zero pressure)
Non-pressure bulk tanks used in pressure-
vacuum systems are constructed as shown
here. Most components of the tank perform
the same function as when used on a
pressure tank. The components with different
functions are described below. Pressure/
vacuum plants require zero pressure tanks for
storage containers. They require a full open
(preferred 5-in) vent on top of the tanks to a
vent collection tank. This tank has a single line
going to the dust collector, which sits on top of
a dust collection tank. The vent tank is also the
blow-down tank for products being returned to
the plant at the completion of the job.
7.2.3 Pressure relief valve
Since these silos are non-pressure tanks, they
must be equipped with a vacuum valve to
prevent collapse.
All storage tanks on the inlet side of the WBB
require a full open vent on top of the tank for
each individual product stored, and a 2-in
vacuum breaker on the tank.
All stored products and additives enter the
WBB by means of vacuum, and the blending/
transfer to the transport unit occurs through the
pressure process.
7.2.1 Vent line
The vent line allows air to enter the tank, and
does not have a valve. Being a full open vent, it
does not require a pressure relief valve.
7.2.2 Vacuum breaker
The tank has a vacuum relief system to prevent
the tank from collapsing if the vent becomes
plugged.
Fill line
Vacuum breaker
Discharge line
Air supply line
Manway
44
Air compressor components in pressure vacuum systems
7.2.4.1 Air compressor
An air compressor used in a pressure-vacuum
system works very much like an air compressor
in a pressure system. The key difference is that
the compressor in a pressure-vacuum system
includes fow selector valves.
Flow selector valves determine whether the
compressor pulls air in from the atmosphere
and discharges it to the WBB, or if it pulls air
in from the WBB. The compressor has an
additional flter on its suction to prevent pulling
in dust when acting as a vacuum pump. This
plant may incorporate the use of two separate
pumps, one for pressure and one for vacuum.
The new plants use a Sullivan Palatek
compressor for pressure and a DVT vacuum
pump for vacuum.
In an emergency, the Palatek unit can be used
as both a pressure and a vacuum pump when
the valve arrangement is properly set up to
PRESSURE VACUUM COMPRESSORS 7.2.4
accommodate both. This occurs when the DVT
unit fails.
Palatek compressor (above) and DVT vacuum pump(below)
45
WEIGH BATCH BLENDER 7.3.0
Weigh batch blender
A weigh batch blender (WBB) used in a
pressure-vacuum system is built to work both
as a vacuum tank and as a pressure tank.
In addition to the features explained earlier,
the WBB has a built-in dust collector located
at the top of the tank. This section flter
prevents the compressor from pulling dust
from the tank when it is being used as a
vacuum pump.
The WBB is evacuated through a flter by the
compressor to create the low pressure needed
for the system to blend and move material by
vacuum. The WBB is also used as a pressure
tank to blend and move material back out of
the tank.
New versions of the WBB have a separate dust
collector (metroplex) on top of the tank. This
is a dry flter type with a purge/ surge cleaning
device incorporated into the dust collector.
All products including additives enter the WBB
via separate lines. Therefore, if fve products
are stored in bulk, you will use fve openings on
top of the WBB, plus one for dry additives.
Most WBBs have eight openings on top of a
5-in groove lock type. This new type of tank
does not require the use of a vacuum breaker.
46
ADDITIVE HOPPER 7.4.0
In a pressure/vacuum plant the additive bottle is replaced by an additive cone operating under
vacuum. Additives are dumped into a hopper and the rate of fow is controlled by a butterfy valve
at the base of the cone (hopper).
The vacuum on the WBB is created by the vacuum pump and the vacuum on the weight batch
blender. Upon completion of the process, the additive valve is closed and the products are
blended and then transferred to the bulk transport.
One of the advantages of a pressure-vacuum system is its additive hopper. The hopper relies
on a vacuum to pull the additives into the WBB, thus eliminating much of the dust created when
adding sacked additives. This process may also be assisted by jets in the material line between
the additives cone and the WBB.
Upper clean out jet
Cone
Lower clean-out jet
Vacuum
vent valve
Cone base valve
control
Removable product
screen
Vent hood
Material
valve control
Lower and upper
clean-outs
5 in material valve
Material line
to the WBB
Additive hopper
47
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48
BULK EQUIPMENT OPERATIONS 8.0.0
Bulk truck
49
8.1.0 Operating bulk equipment on
location
8.1.1 STEM 1
All bulk equipment must be well maintained
and be inspected before and after every job.
Equipment used to transfer cement from
the District to location must pass a STEM 1
inspection before it is dispatched from the
District and as soon as the equipment reaches
location. This ensures that the equipment was
not damaged en route to the job site. Make
sure that the equipment is green-tagged and
STEM 1 paperwork is completed on the bulk
equipment in the same way you would perform
an inspection of the pumping equipment.
Equipment that is not operational should be
red-tagged and repaired as soon as possible.
8.1.2 Rigging up
Equipment should be spotted to keep the
bulk discharge lines as short as possible. The
longer the line, the more air is required to
transport the bulk material.
As the use of air increases, the amount of dust
created while moving the bulk material will
increase as well.
If portable air lines are rigged up on location,
blow air through them before hooking up to
ensure that the lines are clear of water and dirt;
also, be sure they are of proper construction to
prevent parting.
8.1.3 Transferring bulk material on location
Many jobs performed by Schlumberger require
cement material to be transferred on location.
It is sometimes better to store bulk material in
portable P-tanks or gravity silos rather than
trying to ft all of the material on location in bulk
trucks.
On larger jobs, there are several benefts
to using large bulk storage tanks instead of
relying on bulk trucks to supply the mixing
equipment:
Making multiple trips to the location with the
same truck(s) can reduce the number of
Hook-up
50
Follow these steps when transferring material
on location:
Each bulk truck must have a completed
load sheet. This sheet will list the amount
and type of material that is in each tank.
Each storage tank must pass a STEM 1
inspection before being carried to location.
The FSM or FS/FE assigned to the job has
determined the type of material that will be
loaded into each storage tank on location. A
sketch of the location showing where each load
is to go must be given to the FS. The storage
tank should be checked before it is loaded to
ensure that it has not been damaged on the
way to the location.
Each feld storage tank should be clearly
marked with its contents. A feld test blend
sample must be taken during the loading.
The proper equipment to rig up the truck to
the storage tank and the storage tank to a
dust control system must be available. The
exit of the dust control system must be routed
so that the chance of exposing personnel and
equipment to dust is minimized.
Most locations have rules that require
dust control when transferring cement. An
operational dust control system is required
on every job. The dust control device must be
hooked up before moving cement.
Two dust collectors devices are CUS-917
- Dust Collector (Cut Sheet), InTouch content
ID# 3994426; and CUS-900 - Dust Collector
(Cut Sheet), InTouch content ID #3994401.
If there are two or more compressors on
location, be sure to connect them together
to provide backup for each other. The use of
disposable dust bags may be required.
bulk trucks required to do the job.
The number of people required to do the
actual job can be reduced. A driver for each
bulk truck is required if all the material is
brought to location at the time of the job.
Large bulk tanks take up less space than
the number of bulk trucks needed to hold
the same volume of material. This is an
important consideration for small locations.
Fewer hoses, connections, etc. are required
to hook up the large bulk tanks than would
be required to hook up the number of bulk
trucks holding the same volume.
Fewer tanks require fewer tank changes.
Switching from an empty tank to a full tank
causes the fow of cement material to the
mixer to change, which can cause the slurry
density to vary.
RECEIVING MATERIAL AT THE BULK PLANT 7.2.0
Pre-job safety meeting Job execution
51
NOTE:
Contents of bulk tanks must be clearly
marked, documented and be up-to-date
with all parties informed. Costly
operational failures have resulted when
there has been confusion as to contents
of bulk tanks.
8.1.4 Operating bulk equipment during
the job
The operation of bulk equipment plays an
integral part in the success or failure of a job.
The following procedures are guidelines to
prevent job incidents caused by the improper
operation of bulk equipment.
8.1.4.1 Pre-job safety meeting
During the pre-job safety meeting, the FS/FE
reviews the location of each cement system
and ensures that the bulk operators know the
sequence to follow while unloading tanks.
The FS/FE ensuresthat the designed pump
rate does not exceed the capability of the bulk
system. A rule of thumb for the maximum bulk
delivery rate from a standard Schlumberger
pressurized bulk tank is 4,000 lbm/min. This
number can be used to calculate the maximum
mixing rate for each pump unit.
This is also the maximum rate for dry bulk
material passing through the knife-gate/mixing
bowl. This equals a maximum liquid 15.8 ppg
slurry rate of 8.2 bbl/min.
A bulk delivery log should be kept so that the
delivery rate from a specifc bulk system could
be better estimated.
The bulk operator must know how to operate
the bulk tanks to achieve the best delivery rate
possible. Review the discussion on Steady
Dense Flow and Unsteady Dense Plug Flow.
earlier in this module.
NOTE:
The bulk delivery rate for a bulk system
depends upon the type of bulk tank, the
capacity of the air compressor, the type
of aeration device, and the type of bulk
material.
52
The bulk operator, surge can operator and
pump operator must be able to communicate
with each other during the job. Review hand
signals during the pre-job safety meeting.
If possible, use radios with headsets to talk
during the job.
8.1.4.2 Surge can operation
The vent line from the surge tank should be
connected to a dust control device.
Before blowing cement into the surge can,
ensure that its valves are in the correct
position. Open the fll valve and open the air
supply lines and start blowing air through the
vent. This will ensure that the vent is clear
before attempting to load the tank with cement.
Set the weight indicator to zero with the tank
empty.
Mass balance
MASS BALANCE
Bulk cement
Lead 1500 sks
Tail 500 sks
Total
Tank
Stage Total Stage Total Stage Total Stage Total
Tank 1
Lead 500 sks 95 95 25 25 96 96 160 160
Tank 2
Lead 500 sks 95 190 25 50 96 192 160 320
Tank 3
Lead 500 sks 95 285 25 75 96 288 160 480
Tank 4 59 344 25 100 60 348 97 577
Tail 500 sks
Water
285 BBL
59 BBL
344 BBL
Additive
75 GAL
25 GAL
100 GAL
Mix Water
288 BBL
60 BBL
348 BBL
Slurry
480 BBL
97 BBL
477 BBL
Volume
BBL
Volume
BBL
Volume
BBL
Volume
GAL
NOTE:
The FS/FE should inform the bulk
operator and pump operator how much
slurry each bulk tank will make so that
both operators can estimate the volume
left in a bulk tank from the total slurry
pumped.
Weight indicator
53
Before the job starts, transfer cement into the
surge tank from a bulk tank. It is advantageous
to blow cement from as many tanks as possible
to ensure that the bulk lines between the tanks
and the surge can are open.
Check the level of the bulk material in the
surge can versus the amount indicated by the
weight indicator.
Leave the aeration devices in the surge
can going while discharging cement to a jet
mixer. This air keeps the material in the surge
can fuidized and prevents the cement from
bridging off inside the can.
Mark the scale of the weight indicator to show
the minimum and maximum weights with which
the surge can will be operated. The tank should
be kept as full as possible without overfowing.
Excessive dust will enter the dust control
system if the surge can is too full.
Helpful Hint: The maximum weight to put
into a surge tank can be estimated using the
following equation:
Maximum weight (lbm) = V x W x F x C
V = Volume of the surge can (ft
3
)
W = Weight of the bulk material (lbm/ft
3
)
F = Bulk load factor for the bulk material
C = 0.5 to 0.75 - this is a constant that
depends on the design of the surge can.
The minimum level should be set 500 to
700 lbm under the maximum level.
It is important to keep the level in the surge
can as constant as possible because the rate
of fow from the surge can is dependent on the
height of material in the can.
If the surge can is not equipped with a weight
indicator, it should be kept approximately
two-thirds full. This level can be maintained by
keeping the level of bulk material between the
frst and second sight glass.
54
8.1.4.3 Operation of gravity silos
NOTE:
A gravity silo is not a pressure vessel.
It is therefore not recommended
to connect the vent line from the
gravity silo to a dust control device.
If a dust control device is connected
to a gravity silo, there is a risk that it
could become pressurized if air fow
were restricted or if the dust control
device became plugged. This could
cause a catastrophic structural failure
of the gravity silo. Wherever possible,
therefore, the use of gravity silos should
be limited to specifc applications
where pressure vessels cannot be
made available; for example, in a
remote location where all equipment
and materials must be mobilized by
helicopter.
Before blowing cement into the gravity silo,
make sure that its valves are in the correct
position. Open the air supply lines and start
blowing air through the vent. This will ensure
that the vent and pads are clear before you
attempt to load the tank with cement.
Close off the air supply line and open the fll
line. Blow air from the bulk tank that will be
used to fll the gravity silo. The jet line from the
bulk tank can be used to supply the air. This
will ensure that the conveying line is open.
Only one type of cement system can be loaded
into the gravity silo. Make sure that you do not
exceed the capacity of the tank.
Before the job starts, fuff the cement in the
gravity silo. If a high-volume compressor is
used to supply air to the tank, fuff the material
for 10 minutes. You should fuff the material
for at least 20 minutes if you are using a low-
volume blower-type compressor sometimes
found on double pump cementing units.
Fluffng the bulk material helps it to fow out
of the tank during the job. The more air you
pass through the aeration devices and bulk
material, the more moisture you pass through
the system. Fluffng also tends to cause heavy
additives to settle in the tank. Therefore, avoid
fuffng for long periods of time.
It is important that the interior walls and
discharge valve of the gravity silo are clean
and free of hard cement.
Air compressor
Job execution
Monitor pressure gauge
55
8.1.4.4 Air compressor
If there are two or more compressors on
location, make sure that lines are run to
connect them together. This allows a smooth
transition from one compressor to the other if a
problem does arise.
The air compressor supplying air for the bulk
system must be dedicated to the bulk system
and not be used for other purposes during the
job. The rig may provide the bulk air supply.
The same air system may be used to supply
power to run air hoists, needle guns, the
drillers controls, and so on; therefore, it is
important to request the rig personnel to keep
their use of the air supply to a minimum during
the cement job.
Start the air compressors engine; allow
the engine to warm up for 5 minutes
before engaging the clutch to power the air
compressor. The air compressor must be run
at the manufacturers recommended maximum
speed.
8.1.4.5 Bulk tank
Transfer the bulk material from the bulk truck
to a storage tank or mixer using the same
methods described for moving material from a
bulk tank to a WBB in a pressure plant.
The bulk operator has to operate three valves
(bottle or silo valve, transport discharge valve
(if bulk truck), and gooseneck valve) to control
the discharge from a bulk tank.
8.1.4.6 Air supply valve
This valve is used to maintain the desired
pressure in the bulk tank. The operator must
monitor the pressure on the tank to keep the
correct pressure. The desired pressure is
1 to 1.5 psi for each foot the tank must
discharge through. A maximum of 30 psi
should be put on most of our tanks.
P
Taking a sample
56
8.1.4.7 Discharge valve
This valve, in conjunction with the jet air valve,
will determine the rate of bulk delivery.
8.1.4.8 Jet air valve
This valve supplies additional air needed
for the bulk tank to deliver material in the
Unsteady Dense Plug Flow.
8.1.4.9 Bulk tank level
The bulk operator must learn how to estimate
the level in a tank. Tracking the level of the
tank allows the bulk operator to anticipate
when the tank will empty. The bulk operator
should keep the pump operator informed of the
level of cement in the tank.
A weight indicator would be the preferred
method of estimating the amount of material
in a tank. Most bulk tanks are not equipped
with weight indicators, so some other method
must be used. A suggested method is to slap
the side of the tank with an open hand. The
vibration of the metal as well as the sound
of the slap can be used to estimate the level
of material in the tank. A new operator must
practice to develop the ability to determine the
level of material.
WARNING:
Never hit the tank with a hammer!
8.1.4.10 Wellsite execution requirements
A very important part of the operation is quality
control.
Samples must be collected in the feld for
quality control as required in the Cementing
Minimum Service Quality Standards, InTouch
content ID# 3200513, and in the worst case
scenario, incident investigation.
Rigging down
57
In Section 2 of the Cementing Minimum
Service Quality Standards, InTouch content
ID# 3200513, the amounts of cement, mix
water and additive samples are outlined.
Review and follow these requirements.
Be sure to also follow the policies of your
district regarding the labeling of sample bags
and containers.
8.1.5 Rigging down
After all the cement has been mixed, the bulk
equipment should be rigged down. Be sure that
the location is left as clean as it was on arrival.
Always check with the client and drilling
contractor to ensure that their environmental
protection procedures are followed together
with those of Schlumberger.
The pressure on the bulk tanks should be bled
off. Do not open the vent valve completely until
the pressure is below 5 psi. A small valve on
the vent system can be used to bleed off the
pressure in the tank to prevent erosion of the
4-in vent valve. Opening the 4-in vent valve
quickly will cause a very high air fow in the
vent lines. This high air fow can damage the
dust control equipment (high air fows can blow
the socks off sock-type dust collectors) and/or
cause any loose hoses in the vent system to be
whipped about wildly.
If any appreciable amount of material is left in
the bulk tank, its volume should be estimated
and the FS/FE notifed. The FS/FE will
determine how the excess material is to be
handled. If it is in a bulk truck, the material will
be returned to the District. If it is in a storage
tank, it will have to be blown back into a bulk
truck to be transported back to the District. If
the storage tank will be remaining on location
for future jobs and the same type of cement will
be used, the material can be left in the tank.
8.1.6 At the District
The bulk tanks used on a job should be blown
down into the junk or reclaim tank when they
are returned to the District.
It is very important that these tanks are
maintained and that waste product is removed
periodically to prevent overfow into the vent
system. No contaminants should be left in the
transport to be sure that the unit is ready for
the next job.
MAINTENANCE OF BULK EQUIPMENT 9.0.0
Maintaining bulk equipment
MAINTENANCE OF BULK EQUIPMENT
58
This section discusses the maintenance
of some basic bulk equipment parts.
Schlumberger depends on STEM inspections
being performed correctly. If a problem is found
during a STEM inspection it must be fxed. This
guide leads you through some of the basic
repairs needed on bulk equipment.
When dealing with maintenance issues, always
consult your maintenance personnel.
BUTTERFLY VALVE 9.1.0
Buttery valve
Butterfy valves should move easily and seal
against air pressure. The repair of butterfy
valves is covered in the JET 1: Low-Pressure
Equipment, InTouch content ID# 4127821.
Whenever a butterfy valve is removed from a
bulk tank or the bulk system, the piping should
be inspected for cement buildup. If buildup is
found, it must be removed at that time.
Buttery valve components
59
CHECK VALVES 9.2.0
Disc-type valves
Disc-type valves
60
Check valves are used in the air supply lines
(low-pressure) of bulk tanks as well as in the
discharge lines of air compressors. A check
valve allows fow in only one direction. These
valves help prevent the bulk material from
plugging up the air lines or damaging the air
compressor.
The standard check valve consists of a swing
gate. The valve should swing easily; it relies
on gravity to pull the gate down and close off
the line if air is not being blown through it. If the
check valve becomes plugged, or if it becomes
hung open, it should be removed and cleaned.
If the valve will not seal the swing gate, the
seal should be repaired or the whole valve
replaced. These valves should be disc type
and require no orientation to work properly.

Schlumberger also uses inline-type check
valves on some air supply lines. An in-line
check valve relies on a spring to close the disc
and is now the preferred type of valve for this
process.
BALL VALVES 9.3.0
Nut
Handle
Packing nut
Packing
Body
Stem
Washer
Body end
Ball
Seats
Components of the ball valve
61
Ball valves
Low-pressure ball valves are used on the
air supply lines of bulk tanks. A ball valve is
designed as shown below. If the valve begins
to leak it should be repaired or replaced.
Pad holder
Pipe jets
62
If the pad has been in place for a long time,
the nuts may be diffcult to remove and the
studs may break. A local welder can replace
the studs in the pad holder. Remember to
follow the rules in Standard 25: Confned
Space Entry, InTouch content ID# 3313705
concerning tank entry and the performance
of hot work before making any kind of repairs
inside the tank.
9.4.3 Stainless steel pads
Some bulk tanks are constructed with stainless
steel or porous bronze pads. These pads
perform the same function as the canvas pads.
Be careful when cleaning this pad material with
a wire brush. If the pad is damaged it can be
replaced with canvas.
9.4.1 Pipe jets
The membrane covering the pipe jet should be
inspected and replaced if it becomes damaged.
Any cement must be removed from inside the
jet so that the inside is free of any buildup. The
preferred mounting is horizontal to prevent
product from entering upon closing.
9.4.2 Canvas pads
Any cement buildup on the top of the pad can
be removed with a wire brush. If the pad has
been damaged it must be removed and the
canvas replaced. The canvas material used is
4-ply cotton belting with interlock weave. The
canvas is cut to ft the pad it is replacing. The
area under the pad must be cleaned of any
cement when a pad is removed.
AERATION DEVICES 9.4.0
Dust collector socks
63
The dust collector socks (bags) can be
damaged or blown off by fowing air at an
excessive rate through the socks. This usually
happens when the pressure in a bulk tank is
released too quickly by opening a vent valve
too fast, or if the socks become plugged.
The socks will also be damaged or blown
off if a slug of cement is blown into the dust
collector. This will happen if a bulk tank is
overflled.
Maintenance Bulletin 532 , InTouch content
ID# 4128999, contains instructions for installing
and replacing dust collector socks.
DUST COLLECTOR SOCKS 9.5.0
Figure 206 unions
Victaulic connection
Dresser sleeve
Groove lock tting
64
9.6.1 Figure 206 unions
The main connections used with bulk
equipment are Figure 206 type hammer
unions. These unions are designed for low
pressure (rated working pressure of 2,000
psi) and come in various sizes. The Treating
Equipment Manual, Version B, InTouch content
ID# 3013931, lists the part numbers for various
size unions. The 207 one-piece cap must not
be used in cementing applications.
These unions should be cleaned and lubricated
each time they are to be hooked up. The O-ring
on the male half and the sealing surface on the
female half of each union should be cleaned
and inspected before they are made up.
9.6.2 Victaulic connections
Victaulic connections are used on bulk piping
to make connections that will not need to be
dismantled very often. These connections
are usually used to make the assembly of the
piping easier, and to allow the piping to be
dismantled and inspected.
9.6.3 Dresser sleeve
Dresser sleeve connections are also used
where a connection will not be dismantled very
often. These sleeves are used less frequently
because of the risk that vibrations will loosen
the sleeves.
CONNECTIONS 9.6.0
Safety relief valve
65
These valves are commonly called pop-offs.
It is essential that these pressure relief valves
function correctly when they are needed. The
valves keep the pressure in our bulk equipment
from exceeding set limits. This protects
people as well as equipment. All pressure
relief valves must comply with Well Services
Safety Standard 27: Inspection and Testing of
Pressure Relief Valves and Gauges, InTouch
content ID# 3313707.
The specifcations, as well as the proper way
to mount and inspect these valves, can be
found in Maintenance Bulletin 625E MUST DO
- Pressure Vessel, and Relief Valve Inspection
and Test Procedures, InTouch content ID#
3998770, which includes an inspection as
well as testing and calibration dates and
procedures.
Some countries have legal requirements
regarding the inspection and testing of
relief valves. If local requirements exceed
Maintenance Bulletin 625E they are to be
followed. In the absence of local regulations,
follow Maintenance Bulletin 625E.
SAFETY RELIEF VALVE 9.7.0
Vacuum/pressure gauge
All air compressors and bulk tanks should be
ftted with pressure gauges. Pressure gauges
allow an operator to control the operation of the
equipment safely and effciently.
As with all mechanical equipment, pressure
gauges must be checked to ensure that they
are working properly. The Maintenance Bulletin
625E MUST DO - Pressure Vessel and Relief
Valve Inspection and Test Procedures, InTouch
content ID# 3998770 lists part numbers for
the preferred gauges and also describes a
procedure for checking the accuracy of each
gauge.
The counterpart for the pressure gauge, which
is used in the pressure/vacuum system, is
a pressure/vacuum gauge that will have the
pressure and vacuum readings. It will read
30-in mercury to 60 psi pressure.
Pressure gauge
66

PRESSURE GAUGES 9.8.0
Mechanical load cell
Digital readout (left) and electronic load cell (right)
67
There are two types of bulk pant weight
measuring devices used in Schlumberger. The
mechanical load cell type, and the electronic
load cell type with digital readouts, which are
used in most new or upgraded plants in North
America today. These systems also have
pointer confrmation with a data link to the front
offce.
WEIGHT MEASURING DEVICES 9.9.0
Mechanical load cell
The load cells used on the WBB and surge
cans are hydraulic and are similar to the gauge
saver diaphragms used on triplex pumps. The
same hand pump used to infate a gauge saver
diaphragm can be used to infate a load cell.
For proper maintenance and calibration, refer
to the product maintenance manual.
68
1. Inspect the exterior of the tank for:
A. Rust and pits in weld.
B. Cracks in and near welds.
C. Sharp dents, especially in welded
joints.
D. Pay particular attention to cone, shell,
and head penetrations (pipe entries)
for cracks and pitting near welds.
E. On the mobile tank pay particular
attention to welds at the tank supports,
which may be cracked due to fatigue
and loose tie-down bolts.
F. Any welding or cutting to be done on
the tank must be done by an ASME
code shop with an R stamp and re-
inspected by an ASME code inspector
who prepares a partial Data Report.
In countries outside North America
all work should be performed and
inspected to that countrys ASME
equivalent.

Items B and C should not be found on tanks in
permanent installations, but they may be fairly
common on mobile tanks.
2. All pressurized bulk tanks, regardless of the
products they contain, must be pneumatically
pressure tested to the manufacturers working
pressure annually. This test is best performed
with the tanks full, as follows:
A. Isolate and pressurize the tank to the
manufacturers working pressure.
B. Ensure that the pressure relief valve
is functioning by noting the pressure at
which it relieves.
C. Ensure that there are no leaks at any
connections or hatches. Any leaks
must be repaired before returning the
tank to service.
D. Document the results of the pressure
test and retain them at the district.
3. The gasket on the manway must be
removed, cleaned and greased. The mating
surface must be clean and fat.
4. If the visual or pressure inspection by a
Schlumberger inspector reveals any faws or
poor workmanship, an ASME code or equal
inspector must be consulted for advice on
how to proceed. The code inspector may run
a magnetic particle and sonic thickness test
to determine the extent of any faw, damage,
or wear. If the tank requires repair, an ASME
or equal repair facility must perform the work.
Each tank must have an identifying number
(unit/asset number) which will be used to make
a record of the test for the unit fle.
This test is best performed while the tanks are
flled to eliminate the tremendous air volumes
involved.
It is no longer a requirement to hydrostatically
test bulk tanks during the annual inspection.
The only time a hydrostatic test is required is
when a tank is repaired. This test is conducted
by the manufacturing or repair shop involved.
ANNUAL PRESSURE TANK INSPECTION 9.10.0
GLOSSARY 10.0.0
69
Blow-down
This term refers to the operation used to clean
out a bulk tank transport of any remaining
bulk material. The process used to clean out
residual bulk material is the same as that
used to empty a full bulk tank. The bulk tank
truck must be pressured up, and then the
discharge valve opened; the pressure in the
tank will fall quickly as the tank empties. This
process should be repeated until little or no
bulk material is discharged when the discharge
valve is opened.
Junk tank or reclaim tank
A bulk waste tank at the District must be set
up to receive unused bulk material left in bulk
tanks. The collection tank of the dust collector
is used as a junk tank at many Districts. This
bulk tank must be separated from the rest of
the bulk system to reduce the possibility of
contaminating other bulk materials with the
returned cement systems.
In a pressure/vacuum plant the use of the
weigh batch blender is required to remove
waste product from the waste collection tank.
Product is drawn into the WBB by means of
vacuum and then transferred directly to the
bulk transport for waste removal through
an isolated valve primarily intended for this
purpose. This valve remains locked at all
other times.
REFERENCES 11.0.0
All Schlumberger employees must be familiar with the relevant safety regulations and
precautions because of the many hazards involved in the oilfeld industry. Be sure that you
know the relevant contents of the material safety data sheet (MSDS) regarding required
personal protective equipment (PPE) and handling procedures when handling chemicals.
CMSQS Cementing Minimum Service Quality Standards
JET modules
JET 1: Low-Pressure Equipment, InTouch content ID# 4127821
JET 4: Basic Oilfeld Equipment, InTouch content ID# 4127828
JET 5: LP Fluid Equipment, InTouch content ID# 4127829
JET 6: Bulk Plant, InTouch content ID# 4127830
Well Services Safety Standards
Safety Standard 4: Facilities and Workshops, InTouch content ID# 3313678
Safety Standard 5: Pressure Pumping and Location Safety, InTouch content ID# 3313681
Safety Standard 11: Pumping Nitrogen, InTouch content ID# 3313684
Safety Standard 15: Lockout/Tagout, InTouch content ID# 3313691
Safety Standard 17: Storage and Handling of Oxidizers, InTouch content ID# 3313693
Safety Standard 18: HAZCOM, InTouch content ID# 3313694
Safety Standard 22: Coiled Tubing Operations, InTouch content ID# 3313710
Standard 25: Confned Space Entry, InTouch content ID #3313705
Safety Standard 26: Air Tanks and Receivers, InTouch content ID# 3313706
Safety Standard 27: Inspection and Testing of Pressure Relief Valves and Gauges, InTouch
content ID# 3313707
Safety Standard 28: Pressure Management Operations, November, 2003, InTouch content
ID# 3313708
Safety Standard 30: Pumping Combustible and Flammable Fluids, InTouch content
ID# 3313709
Standard S001: Journey Management and Driving, InTouch content ID# 3051691
Standard S002: QHSE Reporting, InTouch content ID# 3260257
Standard S003: Personal Protective Equipment, InTouch content ID# 3260259
Standard S004: Emergency Response, InTouch content ID# 3253244
Standard S013: Mechanical Lifting, InTouch content ID# 3260276
70
71
Q 01
Q 02
Q 03
Q 04
Q 05
Q 06
Q 07
Q 08
As compressed air fows though bulk
material, it tends to compact the
particles.
True
False
The amount of material carried by air
depends on which of the following
factors? Select all the correct answers.
atmospheric pressure
amount of compressed air
geographical location
pressure inside the holding tank
size of piping between tanks
pressure inside the receiving tank
When conveying bulk material
using Unsteady Dense Plug Flow,
the delivery rate is controlled at the
discharge end of the transport line.
True
False
Which of the following is true about the
fll line on a pressure tank?
The opening of the line will be at the
bottom of the tank.
top of the tank.
The line is often constructed as a dip
tube.
The line must be positioned in a
specifc place on the outside of the
tank.
On most Schlumberger pressure tanks,
the pressure relief valves are designed
to relieve at what pressure?
35 psi
30 psi
20 psi
15 psi
The porous media used as aeration
devices in pressure tanks are
commonly made of high-density plastic.
True
False
Which aspects of coded pressure vessel
construction does the ASME govern?
Select all the correct answers.
who owns the tank
type of metal used for construction
welding procedures
testing procedures
utilization of approved welders and
inspectors
Match each pressure vessel
component with its description.
Vacuum systems:
an additional safety device
b. discharge
line
Primary pressure relief
safety device
b. pop-off
Starts as a hole in the
middle-bottom of the tank
c. rupture
disk
Enables compressed air
to aerate through cement
d. pipe jets
Pressure system and
additional safety device
e. vacuum
breaker
CHECK YOUR UNDERSTANDING 12.0.0
72
Q 13 Q 09
Q 10
Q 11
Q 12
Q 14
Q 15
Q 16
Q 17
Which of the following statements are
true for both surge cans and gravity
silos? Select all the correct answers.
They separate bulk material transport
from bulk material supply metering.
They allow air used to transport bulk
material to escape.
They provide a buffer when switching
from one P-tank to another.
They can be used as storage tanks for
bulk material on location.
They are considered code tanks.

The pressurized surge cans used by
Schlumberger are equipped with a side
discharge.
True
False
Which of the following components
on a reciprocating compressor is
responsible for maintaining the desired
pressure?
pop-off
after-cooler
bleeder valve
unloader
How is the ft
3
/min discharge of a rotary
axial compressor regulated?
by varying the rpm at which the
compressor turns
by throttling the intake valve
by throttling the exhaust valve
by an adjustable relief valve
Match each type of compressor with its
principle of operation.
Air is forced into a
smaller diameter
on the discharge
end.
a. reciprocating
Acts like a blower. b. rotary axial
Works like a two-
cycle engine.
c. vane type

Which of the following is a risk of having
a dirty air flter on a reciprocating
compressor?
Dirt could cause vanes to disintegrate.
The four-way valve could be clogged.
Oil could be carried to the pads in the
bulk cement tank.
The after-coolers could overheat.
Match each moisture removal device
with its principle of operation.
Desiccant cartridge a. after-cooler
Centrifugal force b. dryer
Condensation through
thermal change
c. water
separator
Slows air down d. inline water
separator

What is the rule-of-thumb amount of
lubricant that a lubricator should add to
compressed air?
1416 drops per minute
1012 drops per minute
46 drops per minute
12 drops per minute
National regulations are the most
important regulations in the design of
Schlumberger dust control devices.
True
False
Pleated paper cartridge dust collectors
are built with a bypass mechanism that
provides overpressure protection.
True.
False.
The use of the additive hopper
eliminates the use of:
additive hopper
compressor
WBB

A pressure vacuum system has the
following advantages:
Less dust is generated.
Cleaning is easier than for the bulk
tanks.
Costs are higher.
Code is needed.
All storage tanks on the inlet side of
the WBB require a full _____ vent
on top of the tank for each individual
product being stored, and a 2-in
_____ _____ on the tank.
The vacuum pressure plants use ____
pumps:
1
2
3
The WBB is also used as a _________
___ to blend and move material.
Q 18
Q 19
Q 20
Q 21
Q 22
Q 23
73
ANSWER KEY 13.0.0
A 20
A 19
A 21
74
False
Amount of compressed air
Pressure inside the holding tank
Size of piping between tanks
Pressure inside the receiving tank
False
top of the tank.
35 psi
False
Type of metal used for construction
Welding procedures
Testing procedures
Utilization of approved welders and
inspectors
e
c
b
a
d

They separate bulk material transport
from bulk material supply metering.
They allow air used to transport bulk
material to escape.
They provide a buffer when switching
from one P-tank to another.
True
A 01
A 02
A 03
A 04
A 05
A 06
A 07
A 08
A 08
A 10
A 11
A 12
A 13
A 14
A 15
A 16
A 17
A 18
Unloader
By throttling the intake valve
b
c
a

Oil could be carried to the pads in the
bulk cement tank.
b
d
a
c
46 drops per minute
False
True
A
Less dust is generated.
Cleaning is easier than for the bulk
tanks.

open
vacuum breaker
2
P-tank
ANSWERS
A 22
A 23

JET Module6 - Bulk System

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