unitedoilservices.comunitedoilservices.com/.../uploads/2020/08/cementing.pdf · 2020. 8. 20. · The S190H470 Double Pump Cementing trailer comprises of the following components:

Description Model S190H470 Double Pump Cementer/Recirculating Mixing Trailer developed by SETCO is the most advanced, accurate computer controlled cement mixing system available. The quality of design, component selection, and quality manufacture makes it a benchmark in the industry.

The high energy mixing system can mix the most difficult slurries. The pump unit can be utilized for a variety of pumping services including acidizing, cementing, pressure testing and fracturing within the limits of the available horsepower. The inline triplex pump installation makes the maintenance and service of pumps easier.

This system is designed for minimum maintenance and operating in extremely harsh environment with temperatures ranging from -15℃ to 55℃ and relative humidity up to 90%.

Components The S190H470 Double Pump Cementing trailer comprises of the following components:

(1) 30t Semi-Trailer Chassis (2) Detroit S60 used engine, 500HP each w/air compressor (2) ALLISON 4700 used transmission (1) HT400 X 4" Dia. Plunger rebuilt Triplex Pump (1) HT400 X 4 1/2" Dia. Plunger rebuilt Triplex Pump (1) 8bbl mixing tank (1) 20 bbl displacement tank (1) sjs 6x5 centrifugal pumps (slurry recirculation and transfer pumps) (1) sjs 4x3 centrifugal pump (mix water or displacement fluid) (1) slurry Mixing system (1) Wireless Data Acquisition System (2) power take off, for /closed-loop hydraulic system driven (1) Air reservoir, 20 gal (1) Fuel day tank 200 gal

Specifications The SD190H470 trailer is comprised of high-pressure pumping system, high energy

recirculating mixing system, and all required controls and instrumentation.

The high pressure pumping system consists of two diesel engines, two automatic transmissions, and two triplex pumps. The fluid handling system consists of centrifugal pumps for recirculation, boost and mix water. Manifold consists of necessary piping, valves and connections to perform cementing jobs.

Hydraulic system takes power from the auxiliary diesel engine, and drives fluid handling and mixing equipment, include in tow centrifugal pumps and agitators.

Triplex pumps are horizontal single acting plunger pumps and consist of fluid end and power end. The fluid ends are made of three-piece forged steel and are recommended for pumping cement, acid, water, drilling fluids and other well service fluids.

Fluid ends size: driver side 4" Dia. Plunger; passenger side 41/2” Dia. Plunger

Mixing system consists of a high-energy jet mixer, high rate recirculating pump and tub agitator. The diffuser aids in removing air entrainment from bulk cement. A densitometer is mounted in the recirculating line and the mix water is measured with a magnetic pic up through pump drive shaft. The 8bbl mixing tank maintains the ability to mix cement on the fly with good density control.

The displacement tank consists of two 10 bbl working volume compartments with "barrel" marks. Tanks have full flow piping to rear of unit for ease of cleanup.

Control panel labeled in English only; panel gauge units in U.S and metric.

Operational Performance Weight 27 Tons (net) | 28 Tons (including HP irons)

Dimension

Trailer Chassis The trailer chassis is a customer build, heavy duty, oil filed use, 30t anti-trailer.

Power System Two (2) diesel engines drive two (2) high-pressure triplex pumps via automatic transmissions and flexible drivelines.

Diesel Engines

Model: Detroit S60 -14l

Rated Power:500HP@2100RPM

Lube oil pump, filter and cooling system Fuel pump and filter system

Mode of Starting: Electric starter

Cooling: Radiator and Fan.55deg c

Heavy-duty air filter, dry element type Emergency kill for air intake shutdown

muffler with flexible rubber connection

Air compressor

TECHNICAL SPECIFICATION Spec. of Tractive Pin 2’’ (50) Model No. of Tire Meridian 11.00-20 Saddle Height Without Load 1390mm Loading gear OSMAN Axle OSMAN KOC 14T (2NO.S) Span of Tires 1300MM Others 12V and 24V electric system

Power Distribution System

Transmissions Allison 4700 automatic transmission, completes with fill tube, dip stick gauge, torque converter, and 1810 series output flange.

Gear ratios as follows:

1st gear 7.63 3rd gear 1.91 5th gear, 1.00

2nd gear 3.51 4th gear 1.43

Gear ratios are selected manually, Reverse - Blocked out

Transmission Accessories Oil pan with level gauge and filler tube

An engine mounted water to oil tube and shell cooling system

Drivelines Heavy-duty drivelines are used between the transmissions and triplex pumps. They are built with heavy-duty universal joints using 1810 series components.

Installation of drivelines is such that the manufacturer's maximum recommended angle is not exceeded.

Each driveline is equipped with a metal guard assembly complete with greasing access.

Manufacturer name & model: Spicer 1810 series, US

High Pressure Pumping System

Triplex Pumps The HT400 triplex pumps are good for high-pressure well service. Each pump is equipped with an integral gear reduction box. The triplex pumps are designed to pump cement slurries, sand-laden fluids, crude oil, acids, mud and other oil well servicing fluids. The pumps have the following specifications.

Model HT 400 Power End

Type - Single acting Triplex

Configuration - Horizontal in line

Stoke - 8" (203.2 mm)

Maximum Rod Load - 170,000 lb (79,230360 kg)

Maximum input Horse Power - 600 BHP

Fluid End Plunger Size Max Pressure PSI (Mpa) Max Flow m3/min(bmp)

4" (101.6) 14,000 (96.5) 1.20 (7.6)

4 1/2" (114.3) 11,200 (77.2) 1.52 (9.6)

Gear Box

Ratio - 8.6:1

Maximum input RPM - 2400 RPM

Coupling - Spicer 1810 series drive flange

Performance

Note: The data above isbased on 90%ME and 100%VE and 380HP hydraulic horsepower——Intermittent servicing only.

Power End Lubrication System The power end lubrication system contains: Pump

Bypass valve

Required plumbing and hoses Heat exchanger

Pressure gauge Temperature gauge Full flow filter Suction strainer

Plunger Packing Lubrication System The plunger lubrication system is provided by a pressurized oil supply system. The packing lubrication system contains:

Lube oil reservoir Distribution manifold

Required plumbing and hoses Pressure gauge

Pressure regulator

Flow control valves for each plunger with setting locks

Inch (㎜) Gallon/rev (Liter/rev)GPM

(LPM)PSI

(MPa)GPM (LPM)

PSI (MPa)

GPM (LPM)

PSI (MPa)

GPM (LPM)

PSI (MPa)

GPM (LPM)

PSI (MPa)

4” 1.31 41.8 14000 91 7,150 167 3,896 223 2,918 319 2,042-101.6 -4.94 -158 -96.5 -344 -49.3 -632 -26.8 -844 -20.1 -1206 -14.14 1/2” 1.65 53 11200 115 5,658 211 3,079 282 2,306 404 1,610-114.3 -6.25 -200 -77.2 -435 -39 -799 -21.2 -1068 -15.9 -1527 -11.1

380(283)) 380(283)346(257)HHP(Kw) 380(283) 380(283)

Plunger dia Displacement per revDISPLACEMENT AT PUMP STROKES PER MINUTES/PINION RPM

32 / 275 70 / 598 128 / 1099 171 / 1469 244 / 2100

Fluid Handling System

Fluid Displacement Tank The displacement tank is a custom built stainless steel construction. It has a working volume of 20 bbl and consists of two 10 bbl compartments each having graduated markers measuring in increments of 0.5 bbl.The discharge ports from the displacement tank are 152.4mm (6 in) butterfly valves leading into a 127 mm (5 in) pipe that provides good velocity for gravity flow to boost pump and triplex pumps. A flow back release line is provided to allow the triplex pumps pressure to be discharged into the displacement tank. Standpipes provide overflow protection with (3 in) butterfly valves located under the displacement tank. These valves are connected to drain hoses to direct over-flow to desired location. Drain valves are

76.2 mm (3 in) and connect to the over-flow line. They allow the draining of each tank compartment. The piping manifold is designed with sufficient couplings to allow complete disassembly of the piping.

Low-pressure piping The suction manifold has a working pressure rating of 1.6MPa. The manifold

includes various butterfly valves, which are convenient to operate, and various flanges, couplings, union connections, pipe and fittings that are easy to connect.

Fluid from the mixing tank connects to both the recirculating & boost pumps or to the suction manifold for the two triplex plunger pumps. Fluid from the recirculating pump can be pumped into mixing tank via the densitometer and slurry mixer and into the suction manifold of the triplex pumps.

The suction manifold of the triplex pumps is supplied by either the transfer pump or gravity fed from the line connecting the displacement tank.

All remote valves are air actuated.

All the butterfly valve used on this unit should be sanam style type 12N

Cement Mixing System Introduction The mixing system is a recirculating slurry mixer type. It consists of a slurry jet mixer, diffuser, mixing tank, agitators and recirculating and mix water pumps. The mixer design maximizes wetting of all cement by forcing the dry bulk cement into and between the fresh water and the recirculating slurry. The mix water centrifugal pump and the recirculating centrifugal pump provide most of the high energy. The diffuser aids in removing air entrainment from the bulk cement and eliminates dust in the mix tank. The 8bblmixing tank allows adequate residence time for good mixing and averaging of density with varying bulk cement

delivery. A hydraulic-driven paddle agitator in each tank provides improved mixing and more homogenous slurry. The mix tub piping delivers fluid to the suction manifold of the recirculating centrifugal pump via 6” piping.

The cement mixing system can be operated in a manual or automatic mode. In manual mode the operator uses a manually operated hydraulic control valve to control the cement-metering valve. In the automatic mode, an electro-hydraulic control system operates the cement-metering valve. The electro-hydraulic system is controlled by an industrial process controller/computer.

Control system The Control System consists of simatic computer, 3” non- radioactive densitometer, cement metering valve, encoder and cementing software.

The bulk cement is pneumatically delivered to the cement metering valve. The proportional cement metering valve controls the flow rate of the bulk cement to the recirculating mixer.

Mix water along with recirculated slurry mixes the dry bulk cement into slurry. The slurry is then discharged into the mixing tank via an air separating diffuser. The newly mixed slurry is homogenized with the existing slurry by a tank agitator and then is re-circulated by the recirculation centrifugal pump back to the mixer. The 3” densitometer located on the circulating piping system detects the actual density and feeds it back to the computer. When the primary mixing tank becomes full, it flows over a weir into a second tank for averaging and final discharge to a downhole pumping unit.

Performance Mixing capacity: 0-2.3 m3/min (0～14.5 BPM) Density range: 1-2.6g/cm3

Density control accuracy:±0.024g/ cm3

Densitometer: Micro motion or E+H F300 3” non-

Cement Metering valve Patented off-center bulk cement metering valve

Mixer: Halliburton type recirculation mixer.

Mixing water Centrifugal Pump The sjs 4x3 mixing centrifugal pump will meet the following specification. Model: sjs 4X3,Mechanical seal Suction: 4” pipe size Discharge: 3” pipe size Flow rate at 110 psi: 1.65 m3/min (10.4 bpm) Maximum closed-in pressure: 1.17 MPa (170 psi) The mixing water centrifugal pump takes on fluid from external sources or the displacement tank through a manifold with 101.6 mm (4 in) piping and union connections. The pump can discharge fluid into the mix tub or displacement tank.

Recirculating Centrifugal Pump The recirculating centrifugal pump has the following specifications.

Model: sjs –serva Lip seal type Suction: 6” pipe size

Discharge: 5” pipe size

Max. Flow rate at 64 psi: 3.7 m3/min (23 bpm) Maximum closed-in pressure: 0.49 MPa (70 psi)

The recirculating centrifugal pump is capable of receiving fluid from the mixing tub and discharge fluid back into the mix tub for recirculating.

Power Unit and Hydraulic System The transmission mount power take off includes 10 bolt Chelsea or Muncie pto, gear box and hydraulic system.

Gearbox: Muncie (10 bolt)

Hydraulic System Hydraulic system consists of 2 independent systems: one for closed loop hydraulic pumps and the other for agitator open loop systems. The system contains of stainless steel reservoir with sight gauge, filtration system, heat exchanger, hoses and the other complete accessories.

The hydraulic systems take power from the auxiliary diesel engine, and will drive the following components:

Recirculating pump (close loop) Mixing water centrifugal pump.(close loop) Mix tub agitator (open loop)

High Pressure Discharge Manifold All the discharge connector and piping are 2”, fig 1502

Rated working pressure of the exhaust manifold and the union: 105MPa (15,000psi)

Rated working pressure for the plug valve and relief valve: 105MPa (15,000psi)

Two triplex pumps can be manifold together so as to be capable of discharging simultaneously to the same outlet.

A flow back manifold (connected to the opposite side of the pump) connects to the pressure release line with an open end connected to the displacement tank.One2" X1" 1502 plug valve control the release line.

Each of the pump discharge line has a safety valve.

Each of the pump discharge lines has a pressure transducer and 105MPa (15,000 psi) mechanical pressure gauges.

The discharge manifold/valves are mounted firmly by a heavy duty mounting system.

Operation and

Display System

Operator Console The Operator console is a custom built steel cabinet with a protective stainless steel cover. The instrument panel is stainless steel with permanently engraved labeling in English. The location of the console allows the operator a full view of the various instruments and gauges of the console.

Deck Instrumentation The main engine gauges includes tachometers, oil pressure, water temperature,

voltmeter, and warning lights that indicate low engine oil pressure and high water temperature.

The transmission gauges include the main oil pressure, lock-up clutch indicator light, oil temperature.

Auxiliary engine gauges and relative controls. The triplex pump gauges include lube oil pressure gauge, oil temperature, and an

oil level gauge. The pressure and temperature gauges are switch gauge type and activate a warning light whenever a certain level is reached.

A transducer and a mechanical diaphragm mounted on the triplex fluid-end are utilized to measure the discharge pressure.

The unit is equipped with an over pressure protection system. When the pressure of the pump reaches to a predetermined point, the computer system will output a command to engine throttle system to bring the engine to idle speed.

10” panel view for the parameter inputting and monitoring. The hydraulic system has pressure gauges for each pump circuit and an oil

temperature gauge mounted in the console. Console mounted pressure gauges are liquid filled with dual scale face reading in

standard U. S. units and metric units. Mixing water pump is equipped with a flow meter and pressure gauge.

Wireless Data

Acquisition System

Technical Specifications for Wireless Data Acquisition System 1. Radio Modem

(1) Operating Frequency License-free, 2.4-2.4835 GHz (2) Rated range 50 m (3) Output Power 500 mW maximum (4) Interface

RS232, Asynchronous, Full-duplex (5) Data Throughput (uncompressed)

1200 Baud - 115.2 Kbaud (115.2 Kbaud throughput measured assuming 75% frequency availability)

(6) Connector RS232 (7) Operating Modes

Point-to-point, Point-to-multipoint (8) Operating Environment

Temperature, -40° to 75°C (-40° to +167°F) Humidity, 0 to 95% non-condensing humidity 2. Computer

(1) Standard operating temperature is -29° to 40°C, need heater when below - 30°C.

(2) Lenoy (3) Vibration-resistant (4) Data acquisition software with latest version. Display and record job data in

real-time, replay history data in chart, create and print data reports, run screen in English or Chinese language. Customization is available.

3. Power Supply

(1) When using 24VDC input supply power for the radio modem by a 24VDC- 12VDC power switch, supply power for the computer by a 300W power inverter;

(2) When using 220VAC input, supply power for the radio modem by a 220VAC-12VDC power switch, supply power for the computer directly.

4. Cable Communication

Cable communication is also supported. Operators can use communication cable to connect the equipment and the wireless data acquisition system to transport data.

Cable transportation distance is from 10 to 50 m.

Unitization and Completion To keep the equipment completion, the following items should be included.

Tool Box. Lights and electric system. Air system Centrifugal pump Lubrication system Bracket for high pressure iron and universal joint. The instrumentation brand must be

followed as below:

Description Brand PLC&INSTRUMENTATION SIEMENS DENSITOMETER EMERSON (micro motion) or E+H GAUGES MARTIN DEKER,MORPHY,WAGNER

Computer LINOY -CPU:Inter core i5-2540M 2.6GHZ-4GBRAM DDRIII-1333 -IP65MIL-STD-810G-certification with all accessories -genune win7 -13.1”XGA sunlight-viewable LED 1024-768 -serial port

Painting The body loaded equipment will have the following finish and preparations:

All steel parts will be sand blasted to white metal

Primer will be zinc rich

Color will be polyurethane paint with catalyst

Red color. Brand: DUPONT. We paint it as per customer’s design.

Tools and Spare Parts Tools

Description Quantity Special tools for plunger pump 1 Seat puller c/w hand pump & accessories 1 Tools box 1

Spare parts Item Description Quantity

1 Engine 1.1 Master fuel filter, Detroit s60 2 1.3 Engine oil filter, Detroit s60 2 1.4 Air filter element, Detroit s60 2 2 Transmission 2.1 Element oil filter , transmission 2 3 Triplex pump 3.1 Packing, 4” fluid end 3 set 3.2 Packing, 4 1/2” fluid end 3 set 3.3 Centrifugal pump 3.4 Packing, 5X6 Centrifugal pump 2 set

Documents

unitedoilservices.comunitedoilservices.com/.../uploads/2020/08/cementing.pdf · 2020. 8. 20. · The S190H470 Double Pump Cementing trailer comprises of the following components: