sniaeo%7 ‘Cemeriing Pump Urit Essentials | Upetraam Pumping
Cementing Pump Unit Essentials
Rugged and carefully selected equipment
ensures reliability during this harsh and
abrasive well service.
by Nick Ferguson, Southwest Cilfield Products
Above: The cement unit's 600-horsepower triplex pumps When
drilling a well, numerous, critical steps must be followed to
ensure its successful completion and to protect the drilling
crew and other valuable assets. In addition to people and
processes, the equipment needed for successful well
completion is equally important, One critical step in the
drilling and completion process is wellbore cementing. This
mandatory process involves pumping specially-formulated
cement slurry into the wellbore. The cement provides
structural support to the well casing and zonal isolation.
‘Whether preparing a well for additional drilling, production
or abandonment, well cementing is required. Cement
pumping units are the heart of the well cementing operation
and must feature rugged and reliable construction to handle
the challenges associated with this task. Cement pumpers are
manufactured in many configurations including skid, chassis
and trailer-mounted units. Skid-mounted units are primarily
used offshore. Chassis and trailer-mounted units are built
with mobility in mind and are used for land drilling
operations, Regardless of location, cement pumping units
must mix and pump a precise density of cement slurry into
the wellbore. To accomplish this task, cement pumping units
are comprised of six key components that work together to
ensure the successful completion of well cementing projects.
‘These critical components and subsystems include:
= Engines
= Transmissions
= Pumps
= Mixing head
= Circulation system
= Control panel
For redundancy purposes, most common skid configurations
will consist of twin engines, transmissions and triplex pumps.
Engines & Transmissions
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Essential for providing power to drive the pumps, cement
pumping skids use twin diesel engines that are rated at 450 to
600 horsepower each, Depending on the manufacturer, the
engine configuration could be an inline or v-style design
featuring six to eight cylinders. In an effort to reduce harm to
the environment, new cement skids use low-emission
engines that are designed to minimize nitrogen oxides to
meet current Environmental Protection Agency regulations.
With a fan-cooled radiator, these liquid-cooled engines must
be capable of operating continuously for extended periods of
time, in extreme temperatures—such as arctic or desert
climates. To convert the power provided by the twin engines
into a useful energy source, each engine is coupled to a
transmission, The transmission, commonly referred to as a
gearbox, uses a series of gears and gear trains to provide
controlled application of the power provided by the engine.
A typical transmission package for a cement unit will feature
five gears and neutral. When operating a cement pumping
unit, gear selection determines the pump’s speed, torque and
flow rate, The transmission and engine make up the drive
end of the cement pumping unit. For reliable, peak
performance, the engine and transmission must be
compatible to mitigate mechanical issues caused by excess
wear and tear. For example, a transmission that is not
manufactured to handle the engine's torque parameters will
likely fail prematurely because of the additional stress placed
on the transmission’ components during pumping
operations, Conversely, an underpowered engine must
operate at peak power if the transmission is oversized, which,
would result in poor fuel economy and additional wear and
tear on the engine.
The Pumps
Operators must consider flow, pressure and volume when
selecting pumps for a cement pumping unit. Similar to
engine and transmission manufacturers, many pump
suppliers are available in the market. The most common.
pump configurations for downhole cementing are triplex or
quintuplex design. Both pump types are capable of reaching
pressures of approximately 15,000 psi and can be used on
cement pumping units. The main determining factor is user
preference. The key difference between triplex and
quintuplex designs is the number of cylinders. A triplex
pump features three cylinders, and a quintuplex pump has
five. The additional cylinders on a quintuplex pump allow for
larger pumping volume. In addition to increased volume, the
extra cylinders also increase the horsepower rating of the
pump. On the smaller triplex designs, each cylinder is rated
to handle 200 horsepower or 600 horsepower per unit. On.
the quintuplex designs, the horsepower rating is 1,000.
‘Whether operators choose a 600-horsepower triplex or
1,000-horsepower quintuplex pump, both have a compact
design that allows them to be mounted on the cement
pumping unit in a back-to-back configuration.
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“The cement skids contol panel
Moreover, many of the manufacturers in the industry have
standardized the pump components to allow for the
interchangeability of critical pump equipment from one
manufacturer to the next. Critical wear items—such as fluid-
ends, valves, seats, springs, plungers and plunger packing—
are interchangeable among different manufacturers’ models,
which eases maintenance and increases aftermarket parts
availability for end users.
" See how the momentum
of forward thinking
accelerates wellhead
installation.
The Mixing Head & Circulation System
‘With the engines to provide power, transmissions to convert
that power to usable drive force and pumps for pumping, a
unit essentially has all the necessary equipment to pump a
slurry of cement downhole. However, a cement unit is not
complete without the mixing head and associated circulation
system. The mixing head and mixing tub, which make up the
mixing system, are the most critical components of a quality
cement pumping unit, The mixing head controls the amount
of bulk cement and water that enters the mixing tub. The
mixing system can be fully automated or manually controlled,
requiring the operator to throttle the cement valve and water
valve to achieve the desired density. The circulation system
typically consists of three centrifugal pumps—one for water
supply, one for recirculation and one for boosting the cement
slurry into the twin pumps. Once the cement is in the tub,
the recirculation pump sends slurry back into the
recirculation nozzle of the mixing head. This allows the
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MENU
sample to be taken and manually weighed prior to downhole
pumping.
System Control
Some operators may choose manual operation of the
cementing system. However, to ensure that the proper
cement density is mixed and that itis pumped at the desired
pressure and flow rate, many operators rely on a control
system that can be monitored using a control panel. The
control system features instrumentation and gauges. These
components allow the operator to monitor and adjust many
aspects of the equipment, such as:
= Flow rate
= Density
= Pressure
= Engagement and disengagement with other equipment
(pumps and agitators)
Data recording is a critical function of the control system,
This data is incorporated into the well report developed for
every well that is drilled and completed.
Reliability & Maintenance
As with all mechanical equipment, reliability is critical to the
unit's operation. Depending on the configuration, a new
cement pump unit can range from $600,000 to more than $1
million. The unit should be thoroughly inspected after each
project to identify potential issues. It should be maintained
and cleaned as well. Operators should ensure that all the
cement is removed from the unit and perform preventive
maintenance in preparation for the next job. Maintaining
this equipment with good startup and shutdown procedures
is essential to protecting this investment and keeping it
operational for years.
ABOUT THE AUTHOR
[ick Ferguson is the goneral manager at Southwest Oilfield Products (SWOP) ~
‘Well Service Equipment division, He has more than 17 years of well service
‘equipment manufacturing experience snd i responsible for overseing all
operations at SWOP's Fort Worth, Texas, fii
ferguson@swoil.com,
Ferguson may be reached at
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