Operation and Maintenance Manual Double Pump Skid B01!00!073 - A英文说明书

Part Number: B01-00-073 Rev #: A
PCS-621A
Double Pump Cementer Skid
Operation & Maintenance Manual
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SJS LIMITED
Operation Manual For Model PCS-621A Double Pump Cementer Skid
P/N:B01-00-073 REV: A
CONTENTS
WARNINGS.................................................................................................................................3
CAUTIONS AND PRECAUTIONS .............................................................................................4
DEFINITION OF ABBREVIATION USED ................................................................................6
1.GENERAL DESCRIPTION.......................................................................................................7
1.1 COMPONENTS .........................................................................................................................7
1.2 AMBIENT PARAMETERS ..........................................................................................................8
1.3 WORKING PERFORMANCE .....................................................................................................8
1.4 DIMENSIONS AND WEIGHTS...................................................................................................9
15. CORE TECHNOLOGY DESCRIPTION ........................................................................................9
1.5.1 TPB600 pump.................................................................................................................9
1.5.2 High Energy Mixer ........................................................................................................9
1.5.3 Bulk Cement Metering Valve .........................................................................................9
1.5.4 ACM-III System .............................................................................................................9
1.5.5 Closed loop hydraulic system .........................................................................................9
2. EQUIPMENT STRUCTURE..................................................................................................10
2.1 POWER SYSTEM ....................................................................................................................10
2.1.1 Diesel Engine................................................................................................................10
2.1.2 Transmission ................................................................................................................10
2.1.3 Transmission Shaft....................................................................................................... 11
2.2 TRIPLEX PLUNGER PUMPS ................................................................................................... 11
2.2.1 Brief introduction ......................................................................................................... 11
2.2.2 Power End Lubrication System ...................................................................................12
2.2.3 Plunger Packing Lubrication System ..........................................................................13
2.3 METERING TANK..................................................................................................................15
2.4 MIXING SYSTEM ...................................................................................................................17
2.4.1 Introduction to the Mixing System ..............................................................................17
2.4.2 Low pressure piping ..................................................................................................17
2.4.3 Fresh water centrifugal pump...................................................................................23
2.4.4 Circulation centrifugal pump ......................................................................................24
2.4.5 Booster centrifugal pump.............................................................................................25
2.4.6 Mixing parts..................................................................................................................26
2.4.7 Cement metering valve .................................................................................................27
2.4.8 Spare parts list of mixing system..................................................................................29
2.5 HYDRAULIC SYSTEM............................................................................................................32
2.5.1 introduction ..................................................................................................................32
2.5.2 Hydraulic system operation .........................................................................................34
2.5.3 Troubleshooting for hydraulic system .........................................................................35
2.6 AIR SYSTEM ..........................................................................................................................35
2.6.1 introduction ..................................................................................................................35
2.6.2 Air system Operation ....................................................................................................36
2.6.3 Maintenance & Repair.................................................................................................38
2.7 HIGH-PRESSURE DISCHARGE SYSTEM................................................................................38
3.OPERATION .............................................................................................................................41
3.1 SETUP PROCEDURES .............................................................................................................41
3.2 CHECK THE SYSTEMS FOR READINESS ................................................................................41
3.3 TURN ON THE COMPUTER POWER SUPPLY AND THE INPUT JOB PARAMETERS ....................42
3.4 SIMULATOR CHECK OF SYSTEM AND SLURRY DESIGN PARAMETERS ..................................42
3.5 STARTING SYSTEM PROCEDURES (STEP BY STEP) ..............................................................42
3.5.1 Starting and operating the engine ...............................................................................42
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3.5.2 Check Instrumentation, Cement Metering Valve Calibration and Centrifugal pumps
........................................................................................................................................................43
4. CIRCUIT SYSTEM .................................................................................................................45
4.1 POWER SUPPLY CIRCUIT .....................................................................................................46
4.2 OVERPRESSURE PROTECTION CIRCUIT ..............................................................................46
4.3 METER AND ILLUMINATION .................................................................................................46
4.4 DENSITY AUTOMATIC CONTROL CIRCUIT ..........................................................................46
5.OIL SPECIFICATION AND DOSAGE ..................................................................................54
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Warnings
Proper service techniques and repair procedures are necessary for
reliable and safe operation of this equipment as well as safety of the
personnel performing the work. The following list contains some general
precautions the operator should follow when operating this equipment, to
avoid the possibility of personal injury or property damage:
1. Do not remove the cover or guard of any equipment while working
on this equipment.
2. The operator must wear proper personnel protective equipment
while working or maintaining this equipment. i.e. coverall, hard cap, steel
toe shoes and goggles.
3. Rotating machinery is dangerous, so keep away from rotating parts
of tank, drive shafts, blower, engine to avoid injury. Avoid hot surfaces on
engines.
4. Do not work under the vehicle when the engine is running.
5. If hydraulic system or other pipelines leak, do not try to block them
with hands or change the direction of the leaking fluid, high pressure fluid
will badly damage your body permanently, shutdown this equipment
immediately for troubleshooting.
6. Always wear rubber gloves and resistance-proof chemical clothes
while taking acid or other irritative liquid to skin.
7. Shutdown engine in case of fires, mechanical failure, and natural
gas entering into engine inlet resulting in engine out of control. The
emergency shutdown system can only be tested while stopping this
equipment or at idle run, do not test under full load to avoid damage to
engine, with resetting inlet valve of the emergency shutdown system after
tested and before starting engine.
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Cautions and Precautions
This manual covers main structure, specifications of components,

operation and maintenance of PCS-621A twin pump cementing skid with
automatic density control. Read these instructions thoroughly and review until
you fully understand before proceeding with the work described in this
manual. Failure to follow these instructions will result in personal injury or
damage to the equipment.
1. Only qualified personnel trained or familiarized with engine, transmission
and plunger pumps should be permitted to install or operate these units.
2. After the completion of cementing operation, immediately wash and clean
mixing pipelines and densimeter to ensure there is no any sediment.
3. The bulk cement metering valve shall be turned upwardly while washing
or claeaning the mixer; Caution: the bulk cement metering valve is not
allowed to clean with water.
4. Make sure to pin the leg of the surge to the frame after the job to protect
to load cell from being damaged when the vehicle is moving.
5. The electrical parts can be damaged from welding on the unit. It is
necessary to protect these systems from potential damage from welding by
disconnecting the battery before welding and not to allow welding leads to be
close to the sensor system electrical leads. The welding leads can induce high
voltage current in wires that are close to the welding leads.
6. The specific preventative maintenance plan shall be established and
strictly follow specific instructions to ensure long-term normal working
condition of these equipment.
7. This manual doesnt contain operation and maintenance of diesel engine,
transmission, plunger pump, and other standard components, but you can
attain them from documentation with these equipment packages.
8. The documentation with the equipment should cover operation and
maintenance manual of the cementing PCS-621A, operation and parts
manuals of engine, manual of the transmission, manual of ACM-III system,
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4x3 centrifugal pump manual, 5x6 centrifugal pump manual, TPB600 plunger
pump manual, etc.
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Definition of Abbreviation used
Abbreviation Unit
lb Pound
kg Kilogram
ft Foot
oC Degree Celsius
oF Degree Fahrenheit
m Meter
in. Inch
min Minute
bbl Barrel
kw Kilowatt
gal Gallon
hp Horsepower
Mpa Mega-pascal
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1.General description
PCS-621A twin pump cementing skid developed by SJS is the most

advanced, accurate computer controlled cement mixing system available in
the world. It is designed to reliably mix and pump cement fluid with minimal
maintenance in rugged oilfeild conditions and extremenly harsh environments
in temperatures of -20 OC to 50 oC. Its successful cementing applications in
inland oilfields have proved it an ideal choice. Patents covering the system
have been issued &/or pending in various countries.
1.1 Components
Figure1.1---assembly, twin pump cementing skid
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The plunger-pumping skid comprises of the following components:

(2) CAT C13 Diesel Engine, 475 HP each
(2) ALLISON 4700OFS transmission
(1) TPB600 X 4.5" Dia Plunger Triplex Pump (left pump)
(2) TPB600 X 3" Dia Plunger Triplex Pump (right pump)
(1) 7 bbl mixing tank
(1) 20 bbl equalizing tank
(1) 20 bbl displacement tank, (i.e. 2 10 bbl tanks)
(2) 6 x 5 centrifugal pumps (re-circulation and booster pump)
(1) 4x3 centrifugal pump (water and displacement fluid)
(1) Mixing Automatic Control (ACM-III) for density
(1) Hydraulic oil tank
(1) Fuel supply,1600L tank capacity for three engine
(1) Air reservoir, 40 gal
1.2 Ambient parameters
1.3.1 Temperature
Minimum working temperature: -20(-4)
Maximum working temperature: 50(122)
1.3.2 Humidity
Relative humidity: 90%
1.3 Working performance
1.4.1 Pressure range

Maximum working pressure: 97Mpa
1.4.2 Flow rate
Maximum flow rate: 3.0 m3/min
1.4.3 Slurry density range
Maximum slurry density variation: 1.0~2.5g/ cm3 (8.33~20.8 lb./gal)
1.4.4 Mixing capacity
Mixing capacity: 0~2.3 m3/min (0~14.4bpm)
1.4.5 Slurry density precision
When system is close to stable status, i.e. stable delivery of dry bulk
cement, density gauge reading will display 0.01~0.02 g/cm3
(.083~.167lb./gal) under auto control mode.
1.4.6 Working time
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2 hours continuous operation @ rated working pressure of 70MPa.

Over 3 hours continuous operation @ maximum flow rate.
1.4 Dimensions and Weights
Gross weight, w/o Iron (dry): 18.9 t(39,400lb)

Weight (wet): 19.1 t (with lubricant and hydraulic fluids only)
Material for skid frame: 40c dual channel bar
Length, overall: 23.5 ft. (7178mm)
Width: 102 in. (2590 mm)
Height: 121 in. (3067mm) (to top of cement metering valve)
115 in. (2930mm) (to top of control console
1.5. Core technology description

1.5.1 TPB600 pump
TPB600 triplex plunger pump is an ideal choice for cementing job because of
its lower weight, smaller size and bigger volumetric displacement.
1.5.2 High Energy Mixer
High Energy Mixer mixes the dry bulk cement with mix water and recirculated
slurry. The rate of mix water addition is controlled by a valve built within the
mixer (handwheel operated externally).
1.5.3 Bulk Cement Metering Valve
The rotary-actuated cement-metering valve adjusts the rate of the flow of bulk
cement. It may be operated manually or hydraulically. The valve is
approximately linear and will provide almost equal increases in bulk cement
slurry delivery per increment of rotation. A particularly important feature is the
ability to meter cement at low flow rates without bridging off.
1.5.4 ACM-III System
The density Automatic Control Mixing system, the crucial parts, is a state-of-
the-art technology in accurately mixing and density control.
1.5.5 Closed loop hydraulic system
The hydraulic system which powers three centrifugal pumps is designed to be
closed loop circuit and it contains variable displacement piston pump, fixed
displacemnet motor and control valves. The operator can control rpm of the
centrifugal pumps through handle on the control panel. Comparing to open
system, the closed loop features high efficiency, low heat generation, high
precision adjustment, integrity and dramatically enhancement of service life of
oil pump.
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2. Equipment Structure
PCS-621 twin cementing skid, the high pressure pumping unit, consists of
power system, lubrication system, air system, circulation mixing system, high
pressure pumping system, control system and hydraulic system, etc.
2.1 Power system

2 ea diesel engines drive 2 ea high-pressure triplex plunger pumps via the
torque converter and the transmission shaft.
2.1.1 Diesel Engine

z Model: CAT C13
z Rated horsepower: 350 Kw (475 HP)
z Rated rotating speed: 2100 rpm
z Starting mode:air starter
z Cooling mode:fan and radiator exchanger
z Air filter: dry air filter
z Muffler:spark-arrest stainless muffler with flexible stainless pipeline
2.1.2 Transmission
Allison 4700OFS automatic transmission, complete with filling tube, dipping
stick gauge, torque converter, and 1800 series output flange.
z Gear ratios:
1st gear: 7.63

2nd gear: 3.51
3rd gear: 1.91
4th gear: 1.43
5th gear: 1.00
Note: Select gear ratios manually. Reverse gear is blocked out

z Torque converter efficiency: 0.96 in blocked mode.
z Oil pan, with oil level gauge and filling tube.
z Oil filter (spin on), positioned for easy access.

z Side power take-off port: used for driving the hydraulic pumps and the
lubricating pump of the triplex plunger pump.
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z Oil cooling device: The heat exchanger mounted on the engine is used
to cool the transmission oil to allowable temperature range.
2.1.3 Transmission Shaft
The transmission shaft for heavy-duty applications is mounted between the
transmission and the triplex plunger pump. The transmission shaft includes
heavy-duty universal joints and 1800 series flange elements.
z The mounting angle of the heavy-duty transmission shaft should meet the
maximum mounting angle recommended by the manufacturer.
z The transmission shaft should have a metal guard assembly complete with
easy greasing access.
z Maintenance: Add 3 shots every 3 month at the universal joint and slip joint.
2.2 Triplex plunger pumps

2.2.1 Brief introduction
SERVA TPB600 is a reciprocating, positive displacement, horizontal

single-acting, triplex plunger pump which is rated at 600 Brake
Horsepower input maximum. TPB600 is designed for intermittent duty well
service applications such as acidizing, cementing, fracturing, well killing,
gravel packing, etc.
Model TPB600
Power End
Type Single acting Triplex
Configuration Horizontal in line
Stoke 6" (152.4 mm)
Max Rod Load 100,000 lb (45,360 kg)
Max input Horse
600 BHP (447 kw)
Power
Fluid End
Max Pressure Displacement
Plunger Size
PSI (kg/sq cm) Gal(Liter)/Rev
3 1/2" (88.9) 10,400 (731) 0.75 (2.8)
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4" (101.6) 7,960 (560) 0-98 (3.7)

4 1/2" (114.3) 6,290 (442) 1.24 (4.7)
Gear Box
Ratio 4.61:1
Maximum input RPM 2100 RPM
Rated Horse Power 600 HP
Coupling Spicer 1800 series drive flange
Weight
With Gear Box 4,600 lbs (2086 kg)
Table 2.1 specification of TPB600 pump

* For more detailed specification and operation procedure, please refer
to the manual of the TPB 600 triplex pump.
2.2.2 Power End Lubrication System

The PTO mounted on the side of the Allison transmission drives the positive
displacement gear pump, which is designed to lubricate the power end of the
triplex plunger pump. The power end lubrication system comprises of:
z Lube oil reservoir, 45 gal capacity

z Power end lube pressure regulator. Should relieve at about 175 psi when
cold and pressure (measured at the operator console) should fall as unit
warms up.
z Power end lube oil filter. Clean filter every 3 months. Replace filter if
damaged.
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PARTS LIST
Item Qty Parts number description
1 2 lube oil tank
2 1 X04-04-311 pump
3 1 X04-04-309 dandem pump
4 2 X04-00-565 relief valve
5 2 X04-00-563 Filter
6 2 X04-00-688 breather
7 2 B01-15-312 dipstick
8 2 X04-00-564 suction filter
9 2 X04-00-637 check valve
10 Hydraulic hose
2.2.3 Plunger Packing Lubrication System
The packing lubrication system is an air over oil supply system. The lube tank
is pressurized to 0.14-0.2MPa (20-30psi). To operate, open the Air supply
shut-off valve (item 3) to pressurize the tank to designed pressure via the
pressure regulator (item 2). Then open the packing lube shut-off valve
(item5, 7) and adjust the lube flow to each pump packing through the
regulators (item 6, 8). Each pump packing has its own flow control valve to
regulate the flow rate of the lubrication oil. To release the pressure from the
tank just close the Air supply shut-off valve.
Caution: Dont open the packing lube tank cap to fill or check the lube
oil level before the pressure is released.
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10 10
Figure2.1---Packing lube
1)Packing lube oil tank: volume of pressure vessel is 35 L, lube oil is 13#
hyperbola extreme pressure or SAE 15W40 engine oil.
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2)Adjusting valve: lube oil pressure adjuster, part number: X04-00-633, to

reduce air sources system pressure to pressure it needs, about 0.3-0.4MPa
(10-60 PSI).
3)Pressure release switch: 1/4 pressure release ball valve, part number: X04-
00-634
4)Pressure gauge: indicate lube oil tank pressure, part number: X04-01-888,
working range: 0-60 psi
5)Ball valve: part number: X04-01-667, plunger packing lube system switch to
open or close lube oil.
6)Plunger packing lube oil volume adjusting valve: part number: X04-00-651,
to adjust lube oil volume.
7)Ball valve: part number: X05-02-327, centrifugal pump packing lube system
switch to open or close lube oil.
8)Centrifugal pump packing lube oil adjusting valve: part number: X04-00-635,
to adjust lube oil volume of Centrifugal pump packing.
9)Cover and dipstick: indicate lube oil tank oil level. note: add lube oil after
pressure released only.
10)Check valve: part number: X04-00-652, stop mud entering into lube oil
lines after packing seal damaged.
2.3 Metering Tank

A two (2) compartment 20bbl total capacity (10bbl each compartment)
metering tank. Each compartment should be equipped as follows:
-Enumerated level markers in metric units (1bbl)
-Stainless steel structured of compartment and manifolds
-152.4mm6butterfly valve and 127mm(5in.) lines at the discharge end
of the metering tank to ensure that fluid velocity going to booster pump and
plunger pump meet the requirement of system.
-Return release lines to release plunger pump into the metering tank
-3 overflow lines connected relief lines and discharge lines
-Orientation of relief fluid
-76.2mm(3in.) disinjection valve, connecting with overflow lines, for fluid
discharge of the above two compartment.
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- Victaulic couplings design for manifold, easy to install and dismantle.
Figure2.2---metering tank and piping

(a) Injection control valve-control fluid direction to which side of the metering
tank.
(b)Discharge lines control-lead fluid in high pressure discharge manifolds to
either side of metering tank.
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(c)Metering tank
(d) Fresh water injection lines and control valve-load fresh water to metering
tank through fresh water pump. When outside pressure of mud injection lines
is insufficient, the fresh water pump can load fluid to the metering tank at a
specified flow rate.
(e)Air controlled butterfly valve handles (6 eas) located left front and right front
of plunger pump, left and right of metering tank, drain valve and switch valve,
respectively.
(f) Relief lines and drain lines connected with bottom lines through quik
adapters to lead fluid to temporary compartment.
2.4 Mixing system
2.4.1 Introduction to the Mixing System
The mixing system consists of the following components:
z Mixing two compartment tank
z Cementing metering valve
z High-energy mixer
z Diffuser
z Agitating system
z 56 centrifugal recirculation pump
z Non-radioactive densitometer
z 43 centrifugal mix water pump
z Water Y strainer
z 3 turbine flow meter for measuring mix water flow rate
z 56 centrifugal transfer pump
z Piping system and valves
2.4.2 Low pressure piping
2.4.2.1 Feature
z Rated working pressure of the suction manifolds is 1.2Mpa (175psi) fitted
with butterfly valves, flanges, couplings, unions, lines and other accessories.
z The mixing water pump takes on fluid from external sources or the
displacement tank through a manifold with 4 union connections. The pump
can discharge fluid into the mixer or displacement tank.
z Recirculating pump takes on fluid from the bottom of mixing tank, and will
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be discharged into mixing tank via the densitometer for on-line measurement
and into high energy mixer for recirculating.
z The suction manifold of transfer pump is designed to take on fluid from
averaging tank or displacement tank. Fluid from the booster pump will be
discharged into the suction of the triplex pump for boosting.
z The suction manifolds of the triplex plunger pump can take fluid from
either the transfer pump or gravity fed from the line connecting the
displacement tank.
2.4.2.2 Water pump circuit
Figure2.3---Schematic of water pump suction and discharge

The following highlights the important features of the water pumping
system:
a. The 4x3 mix water pump receives fluid from either external source
via valve #2 or from the displacement tank.
b. The 4x3 pump discharges fluid to either the mixer via valve #6 or
to the displacement tank via valves#3, #4 or #5.
c. During the displacement process, the 4x3 pump may be used to
transfer displacement fluid to the displacement tank by taking fluid
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from an external source via valve #2.

2.4.2.3 Recirculation, transfer & displacement tank circuit
Figure2.4---Schematic of slurry and displacement fluid process

piping
The above schematic illustrates all the piping connections and valves of
the low Pressure mixing and pumping system. The following highlights the
major features:
a. No. 1-13 valves are air operated.
b. Recirculation pump only receives fluid from the primary mixing tank.
c. The recirculation pump normally discharges slurry to the High energy
mixer two primary recirculation connections for recirculating and back
to mixing tank via the densimeter for online measurement. In the case
of a transfer pump failure, it is also possible for the recirculation pump
to supply slurry to the triplex pumps by opening valve #9 (at a reduced
rate).
d. The transfer pump receives fluid from either the averaging tank or the
displacement tank, valve #7 or valve #10 respectively.
e. The transfer pump normally discharges fluid only to the triplex pumps
but in the case of a recirculation pump failure, can discharge to the
mixer by opening valve #9.
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f. Displacement fluid can be either gravity feed to the triplex pumps by

opening valves #4 &/or #3 or pressure feed by using the transfer
pump and opening valves#7, #5 &/or #6.
g. The mixing tanks, displacement tanks and piping can be drained after
the job to gravity discharge pipe at the rear of the unit by opening the
following valves #1,#2,#5,#7, #8and #10 and the petition valve(#13)
between the mixing tank and the averaging tank. To completely
drain the system, the mix water pump (4x3) suction must be opened
as well as opening the drain cocks of the centrifugal pumps.
2.4.2.4 Recirculating and mixing manifold
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Figure2.5--- mixing manifold
PARTS LIST
item Qty Part number Description

PUMP,CENTRIFUGAL,5x6,SPLINED,W/STL
1 1 P06-00-106
WEAR PLATE,OIL SEAL,CW
PUMP,CENTRIFUGAL,5x6,SPLINED,W/STL
2 1 P06-00-106
WEAR PLATE,OIL SEAL,CW
ACTUATOR,FOR BUTTERFLY VALVE 2"
3 4 V06-67-707
THRU 6" VANE MODEL TYPE 200 HD
FLOWMETER,ASSY,DENSITOMETER,LCD
4 1 X04-05-420 READOUT,RESET SWITCH,W(4) 1/2" CLEAN
OUT PORTS
5 1 Y STYLE PIPING STEEL
COUPLING,5",VICTAULIC,STYLE
6 4 X04-00-432
75,O.D.=140
7 2 X04-02-427 4"NPT CAMLOCK QUICK COUPLINGS
8 2 X04-02-432 4"CAMLOCK QUICK COUPLINGS MODOL
9 1 B10-07-010 VALVE,BUTTERFLY 3",ASSY
10 1 B10-07-016 VALVE,BUTTERFLY,4" W/HANDLE
11 2 X04-00-433 COUPLING,4",VICTAULIC,STYLE 77
12 1 X00-01-573 COUPLING, 3" VICTAULIC
2.4.2.5 Water pump manifold
Figure2.6---Water manifold
PARTS LIST

1 1 X04-00-410 PUMP,CENTRIFUGAL,4x3x13,
2 6 X00-01-573 COUPLING, 3" VICTAULIC
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3 1 X04-00-112 VALVE,BALL 2",FULL OPEN,Q11F-16P

4 1 B10-07-008 STRAINER 3",STEEL,W/3/16" HOLES
FLOWMETER,TURBINE,3",MODEL
W6/3000B,W/MAGNETIC PICKUP 2-PIN,K-
5 1 X00-01-596
FACTOR 53,3"VICTAULIC GROOVE,W/
15" 2-PIN CABLE
6 1 B10-07-010 VALVE,BUTTERFLY 3",ASSY
COUPLING, 2 1/2" VICTAULIC,PIPE OD
7 1 X00-01-574
2.875"
GAUGE, DUAL PSI-KPA 300PSI,S.S
CASE,BOTTOM
8 1 X04-00-546
CONNECTION,1/4"NPT,GLYCERING
FILLED
9 3 X04-00-681 VALVE,BALL,Z3/4"
10 1 X04-03-082 SQUIRT GUN
11 2 X04-00-112 BALL VALVE,2
12 1 X04-01-265 RELIEF VALVE
2.4.2.6 Displacement tank manifold
Figure2.7---Displacement tank manifold
PARTS LIST

1 1 X04-02-431 4"CAMLOCK QUICK COUPLINGS
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2 2 B10-07-016 VALVE,BUTTERFLY,4" W/HANDLE

3 3 X04-00-122 VALVE,BUTTERFLY 5"
4 2 X04-00-432
75,O.D.=140
COUPLING,6",VICTAULIC,STYLE 77,,PIPE
5 2 X00-01-963
O.D.=168.3
6 2 F32-29-888 VALVE,BUTTERFLY 6"
7 1 X04-00-433 COUPLING,4",VICTAULIC,STYLE 77
8 2 B10-07-252 UNION FEMALE(WELDING),4"
9 B10-07-251 UNION COVER,4"
10 2 F32-29-888 VALVE,BUTTERFLY 6"
ACTUATOR,FOR BUTTERFLY VALVE 2"
11 7 V06-67-707
THRU 6" VANE MODEL TYPE 200 HD
12 2 X04-00-432
75,O.D.=140
2.4.3 Fresh water centrifugal pump

Mission 4 X3 fresh water centrifugal pump specs:
Suction port: 101.6 (4in.)

Discharge port: 76.2 (3in.)
Flow rate at 110psi pressure: 1.65 m3/min (10.4bpm)
Maximum pressure:1.19MPa170PSI
This fresh water centrifugal pump will be designed to take fluid from an
external source or the metering tank via a 101.6 mm (4in.) union connection,
pump this fluid to the mixing tub or the metering tank.
d c b a
Figure2.8---Water centrifugal pump
a) In an extremely hot weather, every other three weeks or pump
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operation exceeding five hours every day, bearing stuff need to be

greased, grease nipples at ends of the bearing stuff.
b) Shaft seal and packing-The main shaft seals are mechanical seal, no
need to lubricate (no lubricant points in packing). However, it is not
allow the pump work at a dry condition. When mechanical seals are
failure, backup sealing system is usually used, i.e. packing seal. Notes:
packing is in loosening condition when no using this packing. When the
mechanical seal is failure, use packing only. When the mechanical seal
system is working normally, if packing seal is too tightened, packing is
over heat resulting in friction. The packing can not work normally any
more. Due to packing seal as temporary seal only, repair or replace
mechanical seal system as soon as possible.
c) Pumping fluid-pumping fluid after the completion of cementing

operation, keep open status until the next cementing operation.
d) Suction manifold-There is two fresh water supplies available, one from
an external water source, another from the metering tank, for details
refer to lines layout.
2.4.4 Circulation centrifugal pump

6 x 5 circulation centrifugal pump specs:
suction port: 152mm(6in.)
discharge port: 127mm(5in.)
Flow rate at 64psi pressure: 3.7 m3/min (23bpm)
Maximum pressure: 0.49MPa70PSI
The circulation centrifugal pump takes fluid from the mixing tub, and metering
tank through the mixing tank. The circulation centrifugal pump discharges fluid
to the mixing tub for circulation, or to suction manifold of triplex plunger pump.
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d c a b
Figure2.9---Circulation centrifugal pump
Notes: This circulation centrifugal pump is equipped with a bunch of lip-

shaped seal rings (packing). This centrifugal pump is compatible with packing,
lip-shaped seal rings and mechanical seal rings. The lip-shaped seal ring has
a good seal performance, but it is hard to replace comparing to packing. The
mechanical seal ring is not suitable for sealing slurry.
a) Packing lubrication lines-lubricate packing.

b) Shaft output end lubrication-grease nipples at the bearings stuff, these
bearings to be lubricated in regular intervals in terms of working time
and operating temperature. Generally, grease the bearing stuffs using
grease gun every other three months.
c) Water drain port-drain remained liquid in the pump after the completion
of operation. If there is remained liquid in the pump during shutdown
time, it will affect the operating performance of the pump, particularly,
the remained liquid freezes and damages to the pump in winter.
d) Fill up water lines-if there are some problems occurring during the
operation, dilute the mud using the fill up water lines. In addition, wash
and clean all lines after finishing job to avoid blockage in lines.
2.4.5 Booster centrifugal pump

6 x 5booster centrifugal pump specifications:
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Suction: 152mm(6in.)
Discharge: 127mm(5in.)
Flow rate at the pressure of 64psi: 3.7 m3/min(23bpm)
Maximum pressure: 0.49MPa (70psi)
The booster centrifugal pump takes fluid from the mixing tank, balance tank
and metering tank. The booster centrifugal pump unloads fluid to the mixing
tub for circulation, or unloads fluid to the suction manifolds of the triplex
plunger pump.
Notes: Generally, the circulation centrifugal pump and booster pump are
functioned as dedicated pump only. However, if one of two pumps fails,
another pump can replace the failure pump to work, or the pump can perform
the operation two pumps take, with the decrease of flow rate.
2.4.6 Mixing parts
The slurry mixer is a recirculating type designed to provide high energy

mixing. Basically, it consists of high energy mixer, diffuser, mixing tank, mixing
blades, circulating pump and fresh water pump. The mixer maximizes
wetness of dry bulk cement and fresh water. The high energy the mixer needs
is from fresh water centrifugal pump and circulation centrifugal pump. The
diffuser removes air in the dry bulk cement, and removal of dust in the mixing
tank. The mixing tank (1.27m3/7bbl) allows mud stay a certain time to fully mix
and uniform the mud. The deep tank is designed to attain a good pump
pressure head, and to minimize effect of vortex and volution. The mixing
blades driven by hydraulic motor effectively enhance quality and uniform
density of mud. The mixing capacity of this system is 0~2.3m3/min (14.4bpm)
with slurry density ranging from 1.0~2.7g/cm3(8.33~22lb./gal). The mixing tub
lines take fluid to the suction of the circulation centrifugal pump via 152.4mm
(6in.) lines. The suction of the triplex plunger pump takes fluid through 4 in.
manifolds and 102mm (4in.) butterfly valve.
k
e
d
g
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c f
Figure2.10---Mixing parts
a) Diffuser, part number: B10-11-050-- removes air in the dry bulk cement,
and minimize air in the slurry, and removal of dust in the mixing tank
during normal operating condition.
b) Dry bulk cement metering valve, part number:B10-17-300--

measurement of dry bulk cement delivery in a safe and reliable manner.
The metering valve can reliably measure dry bulk cement delivery even
in a lower delivery, no blockage of delivery lines. The dry bulk cement
valve has a very good linear performance (much better than butterfly
valve). With 0.17-0.21Mpa (25-30psi) delivery pressure, valve position
within 2~5, the dry bulk cement delivery can ensure system in a normal
working condition. If dry bulk cement delivery pressure is dropping (air
compressor cannot meet system demand), open cement metering
valve further. If it is necessary to open the dry bulk cement valve up to
80% position, it demonstrates that dry bulk cement tank is empty, or
delivery lines is blocked, or air compressor pressure is not sufficient.
During mixing operation, do not wet or wash the dry bulk cement
valve, you can wash and clean it after remove from this unit.
c) Fresh water adjusting valve part number: B10-12-028--Adjust fresh

water flow rate during mixing operation, turn counterclockwise to open
fresh water metering valve, turning 10 to 12 threads to fully open it.
Remember in mind: the fresh water metering valve is left hand thread,
when rotating counterclockwise, the valve rod rotates inside-to open
valve. The fresh water metering valve is linear performance, and fresh
water flow rate is always same per a thread, with flow rate of 0.15
m3/min(40gal/min) in a different water pressure, maximum flow rate of
1.9 m3/min(500gal/min). The fresh water metering valve cannot stop
fresh water completely.
d) Mixing tank- 7bbl capacityw/c 1 set agitator
e) Balance tank-20bblw/c 2 set agitators
f) Mixing manifold
g) Fresh water master valve-a butterfly valve, open or close fresh water
for mixing. This valve can stop fresh water completely.
h) Balance tank agitator motor part number: X04-00-515- effectively
improve mixing quality.
i) Mixing tank agitator motor part number: X04-01-616
j) Elbow pipe for discharge air, part number: B10-11-014
k) Mixer,water jet, part number: B10-12-100
2.4.7 Cement metering valve
4
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2 6 7 8
Figure2.11---Element of dry bulk Cement Valve
1) Dry bulk cement delivery hoses port5 hoses
2) Dry bulk master control valve: part number: X04-00-122, 5 butterfly

valve, dry bulk cement delivery lines switch. Slowly open this valve to
reduce the initial impact pressure of dry bulk cement at the beginning of
operation. Fully open this valve and the dry bulk cement delivery is
controlled by proportional dry bulk cement after stable movement of the
dry bulk cement.
3) Breather valvepart number: X02-00-158, when vacuum degree of the
dry bulk cement valve is high, the breather valve automatically open to
breather air to prevent water drop from spraying to the dry bulk cement
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valve for condensation.

4) Encoder: part number: X04-01-659, dry bulk cement valve opening
position sensor, acquisition signal transmitted to computer control
system.
5) Needle valve: part number: V06-30-524, to adjust sensitivity of dry bulk
cement cylinder, if the dry bulk cement cylinder is too sensitive, close
the need valve to reduce hydraulic fluid flow rate through this valve.
6) Dual-acting cylinder. It is used to control the cement metering valve.
Operation and maintenance guidelines of dry bulk cement:
Check the dry bulk cement for smooth movement before operation.
Remove gravel and foreign matters from dry bulk cement during operation,
with dry bulk cement delivery system pressure of 0.175--0.210MPa.
The valve position hands indicating within 2 ~ 5 during operation. While
indicating within 9 ~10, dry bulk cement is almost empty or blocked.
Clean dry bulk cement valve after finishing job.
Do not wash dry bulk cement valve after finishing job.
When washing other parts of this equipment, prevent water from spraying
to the valve core of the dry bulk cement valve.
Remove the valve core of the dry bulk cement at regular interval to clean
contamination. Assembly again after dry, no grease added to its surface.
Grease bearings after 80~100 hours operation or half year operation.
Double-acting cylinder pressure of the dry bulk cement is 4.2 MPa. The
pressure is adjusted to 6MPa if it is not smooth movement.
2.4.8 Spare parts list of mixing system
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Figure2.12---dry bulk cement valve
Figure2.13---High energy mixer
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Figure2.14--- RA56 centrifgal pump
PARTS LIST
NO PATT DESCRIPTION QUA
1 A170014000 O-RING,70014000 GB3452.1-82 1
2 X04-01-651 SEAL OIL ID=22 OD=35 022035/GB13871-1992 1
3 X04-01-652 POLYPAC SEAL ID 3 1/4" x OD 4 1/4" x H=0.25 1
4 A135513600 O-RING,35513600 GB3452.1-82 1
5 A135501900 O-RING,35501900 GB3452.1-82 2
6 X13-70-232 O-RING,70 DURO,NITRILE 1

IMPELLER,RA56 CENTRIFUGAL PUMP, 9 1/2"DIA-
7 V06-30-045 1
6VANE-OPEN,CW
O-RING,SEAL VITON UNIFORM SIZE 256,70
8 V06-60-879 1
DURO,1/8"x5-3/4"ID
O-RING,SEAL VITON UNIFORM SIZE 242,70 DURO,1/8"x
9 V06-60-811 1
4"ID
O-RING,SEAL VITON UNIFORM SIZE 272,70
10 V06-60-944 2
DURO,1/8"x9-1/2"ID
11 V06-54-820 SEAL,OIL,2"IDx2 3/4"ODx1/2"W 4
12 B10-12-127 SEAL,MAT.-2/RUBBER 1
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SEAL,OIL 2" DIA SHAFT FITS 3.189" BORE, 15/32"

13 V06-45-615 1
WIDE, METAL ENCASED
14 X04-02-505 RING 5",VICTAULIC 2
15 X04-02-502 RING 2 1/2",VICTAULIC 1
16 X04-02-503 RING 3",VICTAULIC 1
17 B10-07-028 SEAL WASHER,6" 1
18 B10-07-006 SEAL WASHER,3" 1
20 X04-01-659 ENCODER,DRY CEMENT,ASSY 1
21 X00-00-545 SENSOR,PRESSURE,2",FIG 1502,15000 PSI,4-20 mA 1
22 X00-04-203 SENSOR,PRESSURE,2",FIG 1502,15000 PSI,4-20 Ma 1
23 X00-03-326 VALVE,4 WAY SOLENOID,24V 1

FUSE,10A 250V,AGC SERIES,GLASS
24 X00-03-797 5
BODY,FASTACTING
FUSE,15A 32V,AGC SERIES,GLASS BODY,FAST
25 X00-03-798 5
ACTING
26 X00-03-799 5
ACTING
27 X00-03-774 5
ACTING
2.5 Hydraulic System
2.5.1 introduction
The hydraulic system of this equipment consists of separate two systems, one
set of hydraulic system (closed loop) driving three sets of centrifugal pumps,
another set of hydraulic system (opened loop) rotating blades and assistant
pump for MAC system. Each of the hydraulic system is equipped with
hydraulic fluid tank, dipstick, ports and heat exchanger.
The closed loop hydraulic system will be equipped as follows:

z Recirculation centrifugal pump
z Booster centrifugal pump
z Fresh water centrifugal pump
The opened loop hydraulic system will be equipped as follows:

z agitator in the mixing tub
z agitator in the balance tank
z double-acting cylinder of dry bulk cement cylinder
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Figure2.16--- Schematic of hydraulic system
PARTS LIST
No Qty Part number Description
1 1 B01-20-200 hydraulic oil tank
2 1 X04-00-532 return filter
middle pressure filter, 10m oil
3 3 X04-00-533
compensate pump
4 3 X04-00-508 EATON46 plunger variable pump
5 2 X04-00-509 hydraulic motor, centrifugal pump
6 1 X04-04-503 relief valves ( 0.4-2.5)
7 2 X04-00-574 relief valves, agitator motor
8 2 X00-01-616 motor, agitator
9 1 X04-00-515 motor, agitator
10 3 X04-00-548 control valves
pressure gauge, (0-10000PSI) double
11 7 X00-02-625
scales
12 1 X00-01-617 manual valve, cylinder controlled
13 1 X00-03-326 soleniod valve, dry bulk cement valve
pressure gauge, (0-1000PSI) double
14 3 X04-00-687
scales
15 1 X00-00-483 dry bulk cement cylinder
16 2 X00-03-489 oil pump
17 3 X04-02-320 agitator oil pump,mixing tub
18 1 Adapter body,return oil
19 1 X04-05-261 Heater exchanger
20 1 X04-00-133 Valve,relief,YF-L10B,0.5-7MP
21 1 Included item 19 Motor,exchange
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2.5.2 Hydraulic system operation
The rpm of three hydraulic motors driven by centrifugal pumps in the closed
loop hydraulic system can be ranged from zero to maximum through the
combined valves (10) in the control panel. The maximum rpm of three
centrifugal pumps can be limited by a group of relief valve (6), these valves
have been set before the departure from factory, the maximum rpm of fresh
water pump is 2900 rpm, circulation pump and booster centrifugal pump rpm
are 2100 rpm and 1900 rpm, respectively. The continuous operating pressure
of the closed loop hydraulic system reaches to 35MPa (5000psi), its working
pressure indicated by pressure gauge (11) on the control panel.
The hydraulic motor (8) and (9) rpm of agitator of the mixing tank and balance
tank in the opened loop hydraulic system is controlled by the throttle valves
(7) with relief valve on the control panel, with rpm range of 0-300 rpm. The
relief valve setting value of agitator in the mixing tank is 11.5 MPa.
The dry bulk cement cylinder (15) is manually controlled by relief valve or
automatically controlled by computer system. The manual relief valve setting
value is 5 Mpa, working pressure indicated by pressure gauge (14) through
instrument panel.
When oil return filter (2) is contaminated, the flow rate drops or fluctuation of
flow rate. Pay more attention to filter indicator is necessary, the filter is
changed every three months.
When hydraulic system is not working properly, the operator shall carry out
inspection listed in .
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2.5.3 Troubleshooting for hydraulic system
Troubles symptom Troubleshooting

empty oil or low oil level add oil and check for leakage
hydraulic system incorrect hydraulic fluid change hydraulic fluid
dont work filter blocked replace filter element
hydraulic fluid is not check lines for deformed, bended or
smooth blocked
pump dont work check pump drive unit for damage
unstable air in hydraulic system check pump suction for leakage
performance low oil temperature Preheat time for hydraulic system
lower oil level add hydraulic fluid
system working low engine rpm keep engine rpm above 1800 rpm
slowly cold engine oil preheat time for system
hydraulic fluid is not check lines for deformed, bended or
smooth blocked
overheat relief valve bypassing check system and relief valve pressure
hydraulic fluid hydraulic fluid
low oil level heat
foaming Incorrect oil replace oil
Low oil level or dirt/air check suction for leakage
leak
noise made by low oil level, incorrect oil or replace oil or add oil
pump air bubbles
oil inlet blocked clean filter
2.6 Air system

2.6.1 introduction
The air system consists of an external air source, air storage, oil and water
separator, valves and air cylinders, etc. air system pressure of 0.70.8Mpa.
The air system provides the power for air controlled gear-shifter actuating
hydraulic-mechanical transmission, engine throttle control, engine shutdown,
engine emergency shutdown and over load prevention of the plunger pump.
The external source start engine shall meet the following requirement, 0.7MPa
pressure, minimum flow rate of 14.3 l/s.
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Figure2.17--- schematic of air system scheme
PARTS LIST

1 1 X04-02-237 air storage,19GAL
2 2 X04-01-124 safety valve
3 1 X04-01-117 release switch,Z3/8
4 1 X04-00-647 oil and water separator
5 1 X04-01-125 ball valve,1
6 2 X04-02-967 air start motor,C13
7 2 X04-00-247 start controller
8 2 X04-00-631 muffler, start motor
9 22 V06-30-747 butterfly valve control valve
10 22 V07-67-707 butterfly valve actuator,2-6"
11 1 X04-05-301 AIR TRUMP,ELECTRICAL
2.6.2 Air system Operation
1. Switch off pressure-releasing switch (4) upstream oil and water

separator (5).
2. Check all of control valves in the control stand for reposition.
3. Turn on release switch.
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4. Operate butterfly valve controller (11) in the metering tank to control

open or close of air operated butterfly valve.
Figure2.18---Air reservoir
Figure2.19---Element of Oil fogger
a) Air storage, parts number:X04-02-237 & adjuster-capacity,parts

number: X04-01-124: 70L, the adjuster for air system pressure, with setting
value of 110 psi.
b) Main control valve of air system, parts number:X04-01-117-- switch off
all air system.
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c) Oil fogger & filter-lubricate air system.
The compressed air enters the air storage through two position and three
way valve, a safety valve in the air storage outlet. The oil and water separator
will dry the compressed air, then the dry compressed air will be taken to all
control valve through connection block to perform actuators.
2.6.3 Maintenance & Repair

Drain air storage at regular intervals, otherwise, the wet air will be taken
into all air operated elements to get corrosion.
Drain and add oil to oil and water separator, and oil fogger very often,
check oil for deterioration to ensure that air operated elements work in a good
condition.
2.7 High-Pressure Discharge System
The fluid end of each triplex plunger pump is jointed with 50.8mm (2
in.) API 1502 connection. And the discharge port of each pump has a 50.8mm
(2 in.) API 1502 integral plug valve. The manifolds of the two triplex plunger
pumps are arranged together so that it may discharge slurry indivadually or
simultaneously to the same or different discharge port.
The leak-off pipeline which locates at the other end of the triplex plunger
pump is connected with the pressure releasing pipeline leading to the
metering tank.
Two 50.8mm (2in.) X 25.4mm (1 in.) API 1502 integral plug valves control
the pressure release pipeline. Each pump has a such plug valve.
Each triplex plunger pump has a pressure transducer and has a 105 MPa
(15,000psi) pressure gage, which are used to measure the discharge manifold
pressure. The master discharge valve is also a 50.8mm (2 in.) API 1502
integral plug valve, which is mounted between the discharge manifold and the
wellhead manifold.
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Figure2.20--- High-Pressure Discharge System
PARTS LIST
Item Qty Part number Description
0001 2.00 B01-13-101 Release lines
0002 2.00 F1A-11-705 Plug valve 1" 105MPa,2" FIG1502 FXM

90 elbow 2"FxM,FIG1502, c/w nuts &
0003 5.00 F3L-13-234
clips seat
0004 1.00 B01-13-166 Pop joint 1502FM L=1493
0005 1.00 V06-37-685 Male union, 2" FIG1502

plug valve 2" FIG1502 FXM SP150WU-
0006 5.00 F1A-11-687
2X2
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0007 14.00 V06-37-694 2"clip seat
0008 14.00 V06-37-695 2"out clips
0009 12.00 V06-37-680 wing nut,2"FIG1502
0010 2.00 V06-78-022 Tee,2" 1502 FMF w/o union cap
0011 1.00 V06-78-028 Tee,2" 1502 MFM
0012 16.00 F4P-10-229 2" union seal ring
0013 2.00 F2A-18-192 safety valve 2" FIG. 1502
0014 2 B01-13-106 release pipes
0015 1.00 X05-91-163 Tee,2",style "Y",FIG 1502
0016 3.00 B01-13-003 U-bolts,M12*350
0017 1.00 B01-13-128 support
0019 2.00 X04-00-572 clamp 2"
0020 2.00 B01-16-232 spheric joints
0022 2.00 X00-00-545 pressure sensor
0023 2.00 X00-04-266 diaphragm
0024 1.00 B01-13-107 release pipes
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3.Operation
The PCS-621A cementing skid can be operated easily in either manual or
automatic modes. This section is of manual covers manual operation
however many of the same procedures are required for automatic mixing. The
following instructions outline the recommended procedures for performing a
cementing job or pumping job with PCS-621A Cementing skid. The operator
should be thoroughly familiar with these procedures before actually attempting
to perform a job.
3.1 Setup procedures
1. Park the vehicle on a relatively level location at jobsite
2. Hook up the mixing water pump suction manifold to the water supply,
using the 4 hose with 4 union.
3. Hoop up the discharge to the well, using 2 1502 manifolding supplied.
4. If the job requires pumping the displacement fluid, connect the mud
manifold to the displacement tank filling line.
3.2 Check the systems for readiness
Check the oil level of the engines.
Check the oil level of the transmissions.
Check the fuel tank level.
Check the battery.
Check the oil level of the packing lubrication reservoir.
Check the hydraulic reservoir level.
Check the water level of the cooling radiator.
Check each running parts for abnormal condition that could injure
operator or damage the unit when starting the engine.
Check the water tank for contaminates or other solid remains. Keep
the water clean.
Check the inside of the mixer (dry bulk area) and be sure it is clean.
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3.3 Turn on the computer power supply and the input job parameters
Turn on the system master control air valve.
Turn on the power supply.
Turn on the master power switch (console).
Turn on the computer and go to the JOB DESIGN screen (F5). Check the
following job parameters and reset if necessary.
9 Select the slurry design number 1, 2 or 3 and enter the following data
9 Slurry yield, m3/sack (ft3/sack)
9 Mix water requirement, l/sack (gal/sack)
9 Weight of each sack of cement, kg (lbs/sack)
9 Water specific gravity (fresh/salt water)
9 Slurry density, g/cm3 (ppg)
9 Desired slurry mixing rate, m3/min (bpm)
3.4 Simulator check of system and slurry design parameters
Following the instructions of ACM-III manual, do the simulator job.
3.5 Starting System Procedures (Step by Step)
3.5.1 Starting and operating the engine
The operation and maintenance manuals for the diesel engines are shipped to the user
together with the skid. Read the manual carefully before starting up the engine. Follow
the procedures listed below when operating the engines.
Open the valve of the water inlet.
Position the control valves of the mix water pump, re-circulating pump and the
booster pump to off position.
Turn off the agitator and blower control valve.
Open the master recirculation butterfly valve (below the mixer).
Turn off the 5butterfly valves installed at the outlet of the averaging tank.
Open the air supply valve to the lube tank and the manifold valves to supply oil
to the pumps. This will start the lubrication flow to the centrifugal pumps
packing.
Check the hydraulic system gauge of water pump; be sure it is working
normally.
Put Allison transmissions in neutral.
Start the triplex diesel engines. Observe oil pressures of the engines,
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transmissions and triplex pumps. Check the gauges of re-circulating pump and
the booster pump system to be sure that the systems are working normally and
the system pressures are normal.
Keep the diesel engines running at idle for 4~5 minutes.
3.5.2 Check Instrumentation, Cement Metering Valve Calibration and Centrifugal
pumps
3.5.2.1 Cement metering valve:

Manually adjust the bulk cement metering valve with the hydraulic valve and check if
the feedback valve position from the operation screen agrees with the actual valve
position. Recalibrate the valve position until they match each other.
3.5.2.2 4x3centrifugal pump, 3 flow meter and prime pumps:

Close the discharge valve of the mixing tank and open the water suction valve.
Open the water metering valve to about 20% open.
Start the 4x3 centrifugal pump with the control located on the console.
Increase the RPM of the engine to the max rpm.
Add fresh water to the mixing tank until the water reaches 1/2 of the agitating
blades. Observe the water flow rate being displayed on the computer operation
screen while filling the tub.
Turn off the water master valve and keep the engine running at high idle speed.
In the meanwhile keep an eye on the closed-in pressure of the centrifugal pump.
The pressure should be 160psi (1.1 Mpa) or higher.
Open the ball valve on the water supply line to flush it out.
Decrease the RPM of the engine until it reduces to idle speed.
Open the discharge valve of the mixing tub and prime the triplex plunger pump.
Add water to the tub until it reaches the 1/2 of the agitating blades and keep the
level. Close the discharge valve of the mixing tub after the triplex plunger pump
has primed.
Stop the water mixing pump.
3.5.2.3 5x6 recirculating centrifugal pump and slurry densitometer:

Open the master recirculation valve (below the mixer)
Stroke the hydraulic control for the recirculating pump to start the pump.
Check the hydraulic pressure and observe the recirculating flow rate in the
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mixing tub.
Check the closed-in pressure of the 6x5 pump. It should read about 60 psi
when the engine is operating at 2100 rpm is normal.
Check the densitometer readings on the operator interface panel, run screen
(F1).
The densitometer reading should be 8.0~8.34PPG.
3.5.2.4 Starting the mixing process:

Check if bulk cement tank is pressured and the bulk operator is ready for the
job.
Verify if the master bulk cement valve is closed.
Check if the job design number displayed on the screen is correct.
Put computer in MANUAL mode if it is not already there.
Start the computer operation and data recording by entering START CODE and
pressing the ACCEPT CHG F1 key.
Increase the engine speed to max working rpm.
Turn on the agitator to approximately 1/3 speed (100 rpm). The agitator
should be operated at the maximum speed without causing excessive
splashing and possible vortexing within the slurry.
Start the recirculating pump and increase its RPM to maximum working speed.
Then increase the RPM of the engine to normal working speed.
Caution: Do not start the water mixing pump right away. The job starts after
batch mixing the first tank of slurry.
Open the cement metering valve to 20% position. The bulk cement delivery
hose should become hard due to the pressure applied.
Gradually open the main control valve of the dry bulk cement delivery system
and check the delivery conditions. The color of the mixing tub should be
changing into gray and there exists some dust in the tub. You will be batch
mixing the first tank.
Observe the slurry density increasing from the F1 running screen.
3.5.2.5 Start the continuous mixing process and operating

After the density reaches the desired density, start the mixing water pump and
open the master water valve.
Density control: For manual control, adjust the cement metering valve to
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maintain density. Make only small changes at a time and wait to see the results.
Large changes will cause the density to make large changes in values. When
controlling the slurry density, the cement metering valve is the preferred means
(rather than changing mixing water rate). Also note that it is not advisable to
change both the cement metering valve and the mix water in order to adjust the
slurry density. Changing two variables at once makes density control very
difficult. It is better to set the mix water at a fixed value and only control the bulk
cement. Tub level should be controlled by the pumping rate out of the mixing
tank.
Adjusting the desired density: the desired density can be change in small
increments by pressing the bump keys, F6 (for reducing density) and F8 (for
increasing density).
Lead slurry to Tail slurry changes: When the mixing of the lead slurry is
almost finished, the operator can get ready to change to the final tail slurry.
Press the DESIGN NO. # key, enter the next slurry design (usually #2) and
press the return arrow key. The system is now ready for the change but it has
not been started until the ACCEPT CHG F1 key is pressed.
Ending mixing process: After all the cement has been mixed, the ABORT F7
key is pressed to stop data recording.
3.5.2.6 Cleaning unit after job:

After the mixing part of the job is finished, add additional mix water to the
mixing tank and recirculate water to clean the mixer while the cement slurry is
being displaced down the well.
Thoroughly clean and flush the unit and the piping systems after each cement
job.
After the engine has been working hard, let the engine run at idle speed for a
few minutes before stopping.
Drain the piping system and centrifugal pumps to avoid freezing in cold winter.
Drain the air reservoir.
Note any items that need to be repaired, adjusted or maintained and report to
the persons responsible for maintenance.
4. Circuit System
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4.1 Power Supply Circuit
The power supply of the entire electrical system is 24 volts direcet current.It is
necessary for the user to supply the equipment with alternating current outside, which
will meet the 24 volts direct current for the system exchanged from 220 volts alternating
current by the switching power supply.
The power supply outside for the equipment should meet the following
requirements:voltage range is between 110VAC and 242VAC,frequency range is
between 47Hz and 63Hz.
The output of the switching power supply is 600W.The switching power supply can
produce quantity of heat during it working.When using the switching power,its seal
outer covering warms up,which is the normal phenomenon and will not affect its
use.We suggest you to cut off the power supply outside for the equipment when you
finish using it,avioding it in the condition of no output or no load.
4.2 Overpressure Protection Circuit
The function of overpressure protection is completed by the computer.The computer
acquires the pressure of the triplex pump,when the pressure value exceeds the value
which set by the user ,the computer output a signal of overpressure protection
immediately ,then the driving relay will cut off the signal of engine throttle in order to
turn the engine to the idle condition.At the same time,the overpressure alarm light on
the operation panel will flash to remind of the operator.
When the overpressure occurs,in order to return to the natural working condition,you
should press the key of unlock on the computer display,then the connecting of engine
throttle is on the natural condition,and you can change its speed.
4.3 Meter and illumination

The electrical meters on the operation panel have background illumination ,which can
ensure you see the value which meters display distinctly in the condition of dark.
4.4 Density Automatic Control Circuit

Density automatic control consists of water
flow,cement valve position metering, cement
electromagnetic valve control,dendity metering.
Water Metering
Metering the water flow by the water
flowmeter,then transmit the water flow signal to
the computer.
The figure shows the flowmeter.It is a turbine
flowmeter.When water is passing the
flowmeter,it will make the turbine which is inside
of the flowmeter circumgyrating.The vane of
turbine circumgyrates,incising the sensor
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P/N:B01-00-073 REV: A
magnetic field,produces electrical pulse signal.The computer acquires the pulse
signals,then it will calculate the real-time water flow value.
Cement Valve Position Metering
The present opening degree of the cement valve is translated into electrical
signal by the valve position coder which is transformed to the computer.When
the computer receives the present opening degree of the cement valve,its
program will real-time calculate the perfect opening degree of cement valve.
Cement Electromagnetic Valve Control

The electromagnetic valve is a electrical control liquid valve,which accepts the control
signals from the computer,in order to control the directions of hydraulic pressure of the
bidirectional oilcan which driving the cement valve running.As a result,the computer can
control the opening of the cement valve.
According to the figure above ,you can easily understand control relationship and flow
among computer,cement electromagnetic valve, bidirectional oilcan,cement valve.
The figure is the practicality photo of cement electromagnetic valve which has been
installed.
Density Metering
The non-radioactive densitometer is made
up of two parts,density sensor and dendity
transmitter.The density sensor is mounted
on the slurry mixing recirculation piping.It
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P/N:B01-00-073 REV: A
transmits the real-time density signal to density transmitter(which is also called
secondary meter),dendity transmitter can display present density value itself.At the
same time,it can transform the signal from the density sensor to standard signal which
the computer can accept and transmit the signal to slurry mixing computer.The
following figure shows the connection relationship between density sensor and density
transmitter.
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SJS LIMITED
P/N:B01-00-073 REV: A
Density Transmitter Density Sensor
Flowmeter Electrical
Item Part NO. Description

FLOWMETER,TURBINE,3",MODEL W6/3000B,K-FACTOR
1 X00-03-492 53.3"VICTAULIC GROOVE,11"FROM TOP OF GROOVE
TO TOP OF GROOVE
2 X00-04-203 SENSOR,2 PIN MAG PICKUP
3 X00-04-201 CABLE,50 INCH SIGNAL,W/WEATERPROOF ADAPTER
4 B10-08-784 CABLE ASSY,C1(WATER FLOW)
5 X00-03-729 PLUG,6 PIN,FEMALE
6 X04-03-996 PLUG,FEMALE,2 PIN,FOR PICKUP
7 X04-03-614 CABLE,6 WIRENESS,BLUE JACKET,BRAID SHIELD,22AWG
49
SJS LIMITED
P/N:B01-00-073 REV: A
Cement Valve Position Encoder Electrical Assembly
50
SJS LIMITED
P/N:B01-00-073 REV: A

1 X26-22-051 ADAPTER,1/2"NPT
2 X00-05-149 GASKET,FOR X00-03-728
3 X00-03-728 RECEPTACLE,6 PIN MALE,FLANGE MOUNT
4 X00-03-902 COVER,RECEPTACLE,FOR X00-03-728
7 X00-03-783 TERMINAL,MALE,QUICK SLIDE TYPE,22-18AWG
TERMINAL,FEMALE,QUICK SLIDE TYPE,22-18AWG,
8 X00-03-782
PACKAGE QTY 100EA
Electromagnetic Commutated Valve Electrical

1 X00-03-326 VALVE,4 WAY SOLENOID,24V
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P/N:B01-00-073 REV: A
2 X26-22-051 ADAPTER,1/2"NPT
3 X00-05-149 GASKET,FOR X00-03-728
4 X00-03-728 RECEPTACLE,6 PIN,MALE,FLANGE MOUNT
7 X00-03-783 TERMINAL,MALE,QUICK SLIDE TYPE,22-18AWG
TERMINAL,FEMALE,QUICK SLIDE TYPE,22-18AWG,
8 X00-03-782
PACKAGE QTY 100 EA
CABLE,6 WIRENESS,BLUE JACKET,BRAID
9 X04-03-614
SHIELD,22AWG
RED
BLUE BROWN
BLUE
BLACK
GREEN
ORANGE
YELLOW
BLACK
RED
BROWN
RED BLUE
GREEN
ORANGE
YELLOW
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WHITE
PURPLE
GREEN
ORANGE
BROWN
BROWN
RED
ORANGE
YELLOW
GREEN
BLUE
PURPLE
GREY
WHITE
SHIELD WIRE
RED
YELLOW
BLUE
GREY BOX,WIRE,DENSIMETER
Densimeter Electrical
FLOWMETER,TRANSMITTER,WITH DISPLAY,WITH JACKETED
1 X00-03-493
CABLE(CPLTJ1A010).RFT9739D5SUA CEQ7615
2 X26-22-052 BUSHING,3/4"NPT
3 X00-05-149 GASKET,FOR X00-03-728
5 X00-03-728 RECEPTACLE,6 PIN,MALE,FLANGE MOUNT
CABLE,ONE PR 18 AWG,TWO PR 22 AWG,ONE TRIPLET
8 X02-00-317
22 AWG SHIELDED
9 X00-03-752 CORD GRIP,0.500",(0.312"-0.375")
10 X26-02-487 BUSHING,3/4"NPTM-1/2"NPTF
11 X00-03-496 FLOWMETER,SENSOR,W/(4) 1/2" CLEAN OUT PORTS
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Pump Pressure Sensor Electrical

TRANSDUCER,PRESSURE,2",FIG 1502,15000PSI,4-
1 X00-00-545
20mA
2 X04-01-399 PUMP PRESSURE SENSOR FIX BOX
CABLE,6 WIRENESS,BLUE JACKET,BRAID
4 X04-03-614
SHIELD,22AWG
5 X00-03-752 CORD GRIP,0.500",(0.312"-0.375")
6 X00-03-851 SEAL,RING,0.500"
7 X00-03-749 CORD GRIP,PLACTIC LOCKNUT,0.500"NPT
5.OIL SPECIFICATION AND DOSAGE
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SPEC. DOSAGE(L)
FAN RADIATOR TABLE 1 About 50
CAT C13 ENGINE LUB.OIL TABLE 2 34
FUEL OIL TABLE 3 91.7L/Hr
ALLISON 4700OFS LUB.OIL DEXRON-3 45
FUNK,GEAR BOX LUB.OIL SAE 15W-40
170(MAIN SKID)
HYDRAULIC OIL TABLE 5
170(POWER SKID)
LUB.OIL,AIR
ISO VG32 0.5
SYSTEM
GREASE TABLE 7
TRIPLEX POWER END 380
TABLE 6
PUMP,TPA600 PACKING LUBRICATION 50
CENTRIFUGAL
PACKING LUBRICATION SAE 15W40 50
PUMP,5X6
TABLE 1:
RECOMMEND TO USE: 50/50% GLYCOL COOLING MIX FLUID
THICKNESS OF ANTIFREEZEGLYCOL
TEMPERATURE THICKNESS
-15C5F) 30% ANTIFREEZE +70%WATER
-23C-9F) 40% ANTIFREEZE +60% WATER
TABLE 2:
RECOMMEND TO USE: SAE 15W40
VISCOSITY,LUB.OIL,ENGIN TEMPERATURE
E LOW CF) HIGH CF)
SAE 0W20 -40(-40) 10(50)
SAE 5W30 -30(-22) 30(86)
SAE 5W40 -30(-22) 40(104)
SAE 10W30 -20(-4) 40(104)
SAE 15W40 -15(5) 50(122)
TABLE 3:
SPECIFICATION,FUEL OIL ,ENGINE
SPEC. NAME
USA ASTM D975 NO.1-D,NO.2-D, NO.4
ASTM D396 Low Sulphur NO.1,NO.2
ASTM D2880 Gas Turbine NO.1-GT, NO.2-GT
LIGHE FUEL0#-10#-20#
CHINA
according to local temperature
TABLE 5:
HYDRAULIC OIL:
SUMMER 68# ANTIATTRITION OIL OR
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HM-46# ANTIATTRITION OIL
WINTERCOLD AREA HV-32# LOW CONCRETING OIL
WINTERFREEZING AREA HS-32# LOW CONCRETING OIL
TABLE 6:
Mobil Shell
Mobilube SHC
Compose gear lubricating oil Spirax s 75W-90
75W-90
Spring or Mobilube hd 80W-
Spirax hd 80W-90
TPA600 Power autumn 90
Noncompose
end lub. Mobilube hd 85W-
lubricating summer Spirax hd 85W-140
140
oil
Mobilube hd plus
winter Spirax hd 80W-90
75W-90
Tonna V lub oil
32F above Vactra lub oil 4#
#220
TPA600 Fluid
temperature Tonna V lub oil
end lub. 32F above Vactra lub oil 2#
#68
SAE 15W40
TABLE 7:
SPEC. TEMPERATURE
TRANSMISSION SHAFT
BUTTERFLY VALVE GREASE #3,CHANG
-15C-120C
FAN BEARING,ENGNIE CHENG RUN FENG
VALVE,PLUG
56

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Operation and Maintenance Manual Double Pump Skid B01!00!073 - A英文说明书

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Part Number: B01-00-073 Rev #: A

Operation & Maintenance Manual

CAUTIONS AND PRECAUTIONS .............................................................................................4

DEFINITION OF ABBREVIATION USED ................................................................................6

Cautions and Precautions

This manual covers main structure, specifications of components,

Definition of Abbreviation used

PCS-621A twin pump cementing skid developed by SJS is the most

Figure1.1---assembly, twin pump cementing skid

The plunger-pumping skid comprises of the following components:

1.2 Ambient parameters

1.3 Working performance

1.4.1 Pressure range

2 hours continuous operation @ rated working pressure of 70MPa.

1.4 Dimensions and Weights

Gross weight, w/o Iron (dry): 18.9 t(39,400lb)

1.5. Core technology description

2.1 Power system

2.1.1 Diesel Engine

1st gear: 7.63

Note: Select gear ratios manually. Reverse gear is blocked out

z Oil pan, with oil level gauge and filling tube.

z Oil filter (spin on), positioned for easy access.

2.2 Triplex plunger pumps

SERVA TPB600 is a reciprocating, positive displacement, horizontal

4" (101.6) 7,960 (560) 0-98 (3.7)

Table 2.1 specification of TPB600 pump

2.2.2 Power End Lubrication System

z Lube oil reservoir, 45 gal capacity

2.2.3 Plunger Packing Lubrication System

2)Adjusting valve: lube oil pressure adjuster, part number: X04-00-633, to

2.3 Metering Tank

- Victaulic couplings design for manifold, easy to install and dismantle.

Figure2.2---metering tank and piping

2.4.2.2 Water pump circuit

Figure2.3---Schematic of water pump suction and discharge

from an external source via valve #2.

Figure2.4---Schematic of slurry and displacement fluid process

f. Displacement fluid can be either gravity feed to the triplex pumps by

2.4.2.4 Recirculating and mixing manifold

Figure2.5--- mixing manifold

item Qty Part number Description

2.4.2.5 Water pump manifold

item Qty Part number Description

3 1 X04-00-112 VALVE,BALL 2",FULL OPEN,Q11F-16P

2.4.2.6 Displacement tank manifold

Figure2.7---Displacement tank manifold

item Qty Part number Description

2 2 B10-07-016 VALVE,BUTTERFLY,4" W/HANDLE

2.4.3 Fresh water centrifugal pump

Suction port: 101.6 (4in.)

Figure2.8---Water centrifugal pump

a) In an extremely hot weather, every other three weeks or pump

operation exceeding five hours every day, bearing stuff need to be

c) Pumping fluid-pumping fluid after the completion of cementing

2.4.4 Circulation centrifugal pump

Figure2.9---Circulation centrifugal pump

Notes: This circulation centrifugal pump is equipped with a bunch of lip-

a) Packing lubrication lines-lubricate packing.

2.4.5 Booster centrifugal pump

2.4.6 Mixing parts

The slurry mixer is a recirculating type designed to provide high energy

b) Dry bulk cement metering valve, part number:B10-17-300--