Cementing Seahawk Skid Operator Manual V1.1

Employee Development CenterTraining Media GroupTomball, Texas

OPERATOR MANUALVersion 1.1

SE A h Aw k CEMENTiNG Sk iD

Volume: 1 of 1 Manual Status: ACTiVE Locator Code: 503 JD Edwards P/N: 85193 Origin: BJ Services

Seahawk Cementing Skid Operator Manual - Version 1.1

Copyright © 2007 BJ Services Company

Published September 2007 by:BJ Services CompanyTraining Media Group11211 FM 2920Tomball, TX 77375

Notice of RightsAll rights reserved. No part of this manual may be reproduced or transmitted in any form without the prior written permission of BJ Services Company.

AcknowledgmentsThis manual could not have been written without the help, support, and coordination of many different departments and individuals within BJ Services Company. Some of those people include: (alphabetically listed)

Seahawk Design Team Ken Arnold - Mechanical Engineering Blake Burnett - Instrumentation Engineering Rick Jones, P.E. - Mechanical Engineering Yongnam Kang - Instrumentation Engineering Jeff Martinez - Instrumentation Engineering Training Media Group Bill Fiffick, Manager William “Mac” Fraser, Program Developer (Author) Reginald “Reggie” Gité, Media Specialist Pat Strike, Senior Media Specialist

Training Standard Practices Group Antonio Moreira District Operations Julius P. “Rick” Lee - Senior District Operations Supervisor (Houma, LA District) Bernard “Benny” Savoie - Field Supervisor (Houma, LA District)

To report errors or request more information, please send and e-mail to: [email protected]

TA B LE O f CO N T EN T S

i. introductionIntroduction ......................................................................................................................ixObjectives ...........................................................................................................................xOverview of Procedures .....................................................................................................xi

ii. Unit DescriptionFunctional Description ...................................................................................................... 3Unit Overview ................................................................................................................... 4Specifications ..................................................................................................................... 5Unit Performance .............................................................................................................. 7Operating Ranges .............................................................................................................. 8Component Identification ................................................................................................. 9The MCM 2000 .............................................................................................................. 15

Main Display Screen .................................................................................................. 19ACC Display Screen .................................................................................................. 20Liquid Additive Display Screen ................................................................................... 22

Programming the MCM 2000 ........................................................................................ 23Resetting Stages & Engineering Time .......................................................................... 23Lan Port Check ........................................................................................................ 25Slurry Recipe Control ................................................................................................ 29

Clearing the Job Program .................................................................................... 29Programming Batch Mode ................................................................................... 32Programming Continuous Mixing Slurry Recipes ....................................................... 36Slurry Recipe Review ......................................................................................... 39

Data Cassette Setup ................................................................................................... 43Configure Cassette Record ................................................................................... 43Set Job Head .................................................................................................... 47Set Job Length ................................................................................................. 54Set the Sample Rate ........................................................................................... 56Set Job Information (Customer Information) ............................................................ 58Set Job Information ( Job & Well Information) .......................................................... 61Initialize the Cassette ......................................................................................... 65Initialize the Virtual Cassette ............................................................................... 66

iii. Seahawk OperationStarting the Seahawk .................................................................................................. 69Priming the Seahawk ................................................................................................. 73

Low Pressure Piping .................................................................................................. 73Mix Water & Slurry Pumps ........................................................................................ 78Pacemaker II Pumps .................................................................................................. 86

Density Control Valve Check ................................................................................... 91Pressure Test Pumps & Lines ................................................................................... 92

Set Working Pressure Limit ........................................................................................ 92Set the Direct Gear.................................................................................................... 95Conducting the Pressure Test ...................................................................................... 97

Mixing in Batch Mode (Batching Up) .......................................................................... 102Mud Cup Test ............................................................................................................... 109Mud Cup Correction .................................................................................................... 111Mixing While Pumping (Mixing on the Fly) ............................................................... 115Shut Down Procedures .................................................................................................. 119Displacement ................................................................................................................. 126Clean Up Procedures ..................................................................................................... 134

iV. AppendixTroubleshooting ............................................................................................................ 139

Cummins QSM 11.0 Liter Deck Engine ..................................................................... 139Allison HD-4700-OFS Transmission ......................................................................... 141Pacemaker II Pumps ................................................................................................ 142Agitator ................................................................................................................. 142Mixing Tub ............................................................................................................ 143Mix Water Pumps ................................................................................................... 143Slurry Pumps .......................................................................................................... 144General Hydraulics .................................................................................................. 145Hydraulic Systems - Motors ...................................................................................... 146Hydraulic Systems - Pumps ...................................................................................... 147

Process Flow Diagram ................................................................................................... 148MCM 2000 Software Tree ............................................................................................ 149

V. GlossaryGlossary ......................................................................................................................... 153

A GUiDE TO READiNG ThiS MANUAL

To help you, the reader, take notice of various important items and section divisions, we have included the following elements.

SECTiON DiViSiONSThe manual is broken into five major sections, each identified by a Section Divider with its name and a graphic on the page. Each of those sections is then broken into Major Subjects, Minor Subjects, and Sub-Elements. The Major & Minor subject headings will be centered on the page, and Sub-elements will be left justified on the page. These elements will be in the following sizes and fonts:

M A J O R S U B J E C T SMinor Subjects

Sub-Elements

NOTE BOxESNote boxes will help explain a step or procedure more in depth, define a critical step, or bring your attention to an important safety issure. All note boxes will be the same color and in the same font. Note boxes will look like this:

ARROwSThroughout the manual there are various graphics to help you relate to a particular step or draw your attention to a specific component on the unit. Arrows and other “component identifiers” will be in yellow and include a number bubble corresponding to a numbered step or component. They will look like this:

Note: Note boxes will call your attention to important information.

Example Component1

iiNTRODUCTiON

viii

Seahawk Cementing Skid • Operator Manual • Version 1.1

This page is intentionally left blank.

ix

introduction

iNTRODUCTiON

This manual is designed to be used in conjunction with field training to teach Service Supervisors how to properly operate the Seahawk Cementing Skid

The information in this manual has been compiled by the BJ Media Group from BJ Standard Practices manuals, information gathered from experienced operators and design engineers, and other technical data.

Unit customization and installation will vary depending on area conditions and other factors. District Training and Safety personnel and the BJ Services Mechanical Engineering Department can help identify proper procedures on the various differences.

Efforts have been made to cover the majority of configurations and modifications, and whenever they are known, they will be mentioned in this manual.

Operators must be competent and thoroughly understand proper operation, maintenance, cement mixing and pumping, and the BJ Services Standard Practices concerning safety and job operations prior to conducting cementing operations for a customer.

x


OBJECT iVESBy studying and practicing the procedures described in this manual and actively participating in on the job training and instruction, an operator of a Seahawk Cementing Skid should be able to:

• Performpre-jobmaintenanceinspectionoftheunit.

• Performprocedurestoreadytheunitforpumpingprocedures.

• PerformonsitejobdutiesforoperatingaSeahawkCementingSkidwithintheneedsofthe particular job.

• Performpost-job maintenance inspection of the unit.

BJ Services Equipment Operators and Service Supervisors should understand the seven competencies:

1. Health, Safety & the Environment

2. Emergency Response

3. Maintenance

4. Pre-Job

5. Job Execution

6. Post-Job

7. Interpersonal Skills

xi

introduction

OVERViEw Of PROCEDURES

PRE-JOBAs the operator of the Seahawk, you will be expected to check the unit and all other necessary equipment.

You will do the mandatory walk-around inspection of the Seahawk Cementing Skid and check that you have the proper connections, proper safety gear and any other items needed to do the job.

As a check of Seahawk Cementing Skid, you will need to start the deck engines, engage the hydraulic system, and roll the pumps to assure proper operation.

SAfETy MEETiNGPrior to conducting any job, meet with the necessary rig and/or service personnel to conduct a pre job safety meeting. Make sure you are aware of any special circumstances concerning the job. Additionally, be aware of any other work going on in or around your area of operation that may have an impact on you and your crew’s safety, general job operation and completion, or customer satisfaction.

JOB PREPARATiON & RiGUPThe rig up and unit installation is to be done according to the Standard Practices Manual. (QHSE Database)

Thoroughly inspect the area of the rig or barge you will be working in ensuring all lines and connections are in working condition and ready to use. Ensure all lines are properly hobbled and secured, and that all connections have been properly tightened.

As the treating line is rigged up, ensure all connections have been cleaned, oiled, and properly tightened.

Suction/Drainage hoses should be cleaned, oiled, and connected. Discharge hoses should be properly tied or chained down and secured with hose hobbles if necessary.

xii



IIUNiT DESCRiP TiON

2



3

Unit Description & Overview

f UNCTiONAL DESCRiP TiONThe Seahawk is a 700 hydraulic horsepower unit (HHP) in nominal mixing mode (850 HHP in kill mode). The Seahawk Cementing Skid is designed to mix and pump various slurry designs at specific densities for various types of cementing services.

The main components of the Seahawk mixing system include the slurry recirculating pump, mixing module, de-aerator, mixing tub and agitator, density control valve, and mixing water control. In addition, the Seahawk is equipped with two Pacemaker II triplex pumps tasked with pumping various fluids and cement slurries.

Dry cement and mix water are blended in the mixing module. The mix water enters the mixing bowl through a high velocity jet from the mix water pump. The dry cement is delivered to the Seahawk from the pressurized surge tank to the mixer through the bulk density valve at 10 psi to 15 psi. The recirculated slurry also enters the mixer by the recirculating cement nozzle at a very high velocity. The tub agitator mixes and shears the cement to provide an evenly blended slurry. As the slurry leaves the tub through the recirculating pump, a portion of the slurry is pumped through the densimeter/flowmeter and returned, or recirculated, to the tub through the recirculating pump. The slurry is then delivered to the Pacemaker II triplex pumps for delivery downhole. The density readout on the MCM 2000 module displays the present weight of the slurry.

If batch mixing is required, other units can be used to supply batch mixed slurry to the Seahawk by connecting directly to the Pacemaker II triplex pump manifold or the auxiliary suction manifold.

Digital Representation of the Seahawk Mixing System

4


The Seahawk is a skid mounted cement mixing and pumping unit capable of accurately mixing and pumping a cement slurry while measuring and maintaining a proper consistant density over a wide range of performance requirements. The unit is equipped with an integral recirculating mixing system, and two triplex Pacemaker II pumping systems.

The Seahawk’s recirculating mixing system utilizes recirculated slurry, a mixing tub, and an agitator to thoroughly mix the slurry. The mixer provides consistent slurry and density control to within plus or minus 0.1 PPG, over a wide range of mixing rates and slurry weights. Mixing rates of 10 BPM have been achieved with slurry weights of 13 PPG, and rates of 4 BPM have been mixed at 22 PPG. All job parameters are monitored and controlled continuously by a BJ Services “Pendant Brain Box” system.

UNiT OVERViEw

The Seahawk is equipped with two Pacemaker II triplex pumps each rated at 550 hydraulic horsepower. The pumps are driven independently by two Cummins in-line six cyclinder diesel engines through two Allison automatic transmissions. The standard unit is equipped with both 4.5 and 3.5 inch plungers along with integral high pressure manifolds rated for 10,000 PSI. Pressure to 15,000 PSI can be achieved with proper selection of plunger size and manifold rating. The twin pump design allows for greater pumping rate variability and provides a 100% backup of the pumping system.

5


SPECifiCATiONS

MAJOR COMPONENTS

COMPONENT DESCRiPTiON

Deck Engine (2) Cummins QSM (11.0 liter) 500 BHP @ 2100 RPM Peak Torque - 1600 ft.lbs. @1450 RPM

Start System Air Starter

Transmission (2) Allison HD - 4700 - OFS

Triplex Pumps (2) BJ Services Pacemaker II Pumps (4.5” and 3.5” plungers)

Displacement Tank (1) 20 barrel capacity with two compartments 10 barrels each.

Slurry Recirculating Pump (2) Hydraulically driven 6”x4”x13” centrifugals.

Mixing Water Pumps (2) Hydraulically driven 4”x3”x8” centrifugals.

Slurry Agitator Variable speed hydraulically driven (120 rpm max).

Mixing Tub 7 Barrel Capacity

Densimeter/Downhole Flowmeter 4” Mass Meter - Coriolis Type

Bulk Supply Pressurized Surge Tank - 90 ft3 (2.5m3) capacity

Density Control ACC II with Manual Backup

6


SPECifiCATiONS (continued)

iNSTRUMENTS AND CONTROLS

CONTROL COMPONENT

Hardware Control BJ Services “Pendant Brain Box” system

Cement Control ACC- II Automated Cement Control

Mixing Control MCM 2000 Operator Interface Module (Mixing Control Module)

Software Job Master Software

Engine Control Dual ECM and UEC III

SkiD DiMENSiONS

DIMENSION MEASUREMENT

Length 25 ft. 3 in. (7.7 m)

Width 8 ft. 0 in. ( 2.4 m) or optional 10 ft dimension (3 m)

Height 12 ft. 6 in. (3.8 m)

Dual Pumping Skid 45,500 lbs (20,638.5 kg)

Mixing Skid 9,500 lbs (4,309.1 kg)

Surge Tank 4,800 lbs (2,177.2 kg)

Total Gross 60,800 lbs (27,578.4 kg)

The Seahawk has a modular construction capable of being disassembled into free standing assemblies that can be installed through a 5’ x 7’ (1.5 m x 2.1 m) opening.

7


UNiT PERfORMANCE

COMPONTENT PERfORMANCE VALUE

Pacemaker II Triplex Pumps10,000 PSI working pressure (4.5” plungers)

15,000 PSI working pressure (3.5” plungers)

Fuel Tanks The Seahawk has no onboard fuel tanks. Fuel is supplied externally.

Rated Hydraulic Horsepower850 HHP (kill mode)

700 HHP (nominal mixing mode)

Transmission Speed Ratio

1st - 7.63 : 1 (in lockup)

2nd - 3.51 : 1

3rd - 1.91 : 1

4th - 1.43 : 1

5th - 1.00 : 1

Plunger Stroke 4 Inches (10.2cm) (on both pumps)

Rod Load Maximum 160,000 lbs force (72,574.78 kg force)

Pump Gear Reducer Ratio 4.06:1

Available Plunger Size Standard Fluid Ends 3 ½” 4”, 4 ½” and 5”

PlungeR Size vS. Rate & PReSSuRe (PeR PuMP @ 450 RPM)PLUNGER SizE MAx RATE MAx PRESSURE

3 ½ 5.0 15,000

4 6.7 12,500

4 ½ 8.3 10,000

5 10.2 8,000

8


COMPONENT MiN NORM MAx

Engine Speed (Idle) N/A 700 rpm 750 rpm

Engine Speed (Full Load) N/A 2100 rpm 2150 rpm

Engine Oil Pressure (Idle) 25 psi N/A N/A

Engine Oil Pressure (@1200-2100 rpm) 30 psi 50-70 psi N/A

Engine Water Temp. (°F/ °C) 160 °F (71 °C)

170-190 °F(77-88 °C)

200 °F(93 °C)

Engine Oil Temp. (°F/ °C) 180 °F(82 °C)

180-190 °F(82-88 °C)

210 °F(99 °C)

Air Inlet Restriction (in./cm. of H2O) N/A 12 in (30.5 cm) 20 in (50.8 cm)

Transmission Oil Pressure (psi) 100 psi 120-175 psi 220 psi

Transmission Oil Temp. (°F/ °C) 220 °F(104 °C)

220-270 °F(104-132 °C)

270 °F(132 °C)

Pump Oil Pressure (psi) 40 psi 40-120 psi 120 psi

Pump Oil Temp. w/ standard oil (°F/ °C) 70 °F(21 °C)

155 °F(68°C)

160 °F (71 °C)

Pump Oil Temp. w/ synthetic oil (°F/ °C) 60 °F(16°C)

155 °F(155°C)

200 °F(93 °C)

Hydraulic Reservoir Temp. (°F/ °C) 60 °F(16°C)

180 °F(82 °C)

220 °F(104 °C)

OPERATiNG RANGES

9


1

2

3

875 64


1 Displacement Tank Selector

Controls the valve directing fluid into the displacement tanks from the bleed manifold.

2 Control Console Houses the MCM 2000 and Dual ECM control panels.

3 Manual Mix Water Valve Control Manually manipulates the flow of water from the mix water pumps.

4 Valve Control Panel Controls all pneumatically operated valves throughout the unit.

5 Pendant Brain Box Houses the electronic & computer controls for the Seahawk.

6 Surge Tank Controls Operates the positive pressure surge can which is located seperate from the unit.

7 Manual Density Valve Controls

This joystick can be used when you need to overide the MCM 2000 to manually open or close the Density Control Valve.

8Auxiliary Hyrdraulic

System SelectorAllows the operator to switch between the B & C the Auxilliary Hydraulic Systems.

COMPONENT iDENTifiCATiON

10


1

2

3

4

5

6


1 Water Valve Position Feedback Monitor

Monitors the position of the water valve and sends this information to the MCM 2000.

2 Water Control Valve Controls the flow of water into the mixing tub.

3 Vacuum Breaker Allows the operator to eliminate a vacuum that may form in the line, preventing water migration into the bulk line.

4 Bulk Density Control Valve Controls the flow of dry cement into the mixing tub.

5 Bulk Density Valve Feedback Monitor

Monitors the position of the bulk density valve and sends this information to the MCM 2000.

6 Manual Bulk Valve Used to manually control the flow of dry cement to the mixer.

11


Mixing Tub Side ViewMixing Tub Top View

6

5

4

3

2

1

7 8


1 Tub Level Sensor/Probe

Monitors the fluid level in the mixing tub and sends this information to the MCM.

2 Auxiliary Hydraulic System Selector Valve

Allows the operator to select between the B & C auxiliary hydraulic systems.

3 Mixing Tub 7 BBL tub where slurry is de-aerated and mixed.

4 B-Side Mix Water Pump Pumps the mix water into the mixing tub.

5 Mixing Tub Drain Allows the the mixing tub to be drained for cleanup.

6 Drain or Mix Water Overboard Suction

Used for overboard suction of mix water or to drain the mixing tub or displacement tank for cleanup.

7 De-Aerator Removes air from the slurry during mixing.

8 Mixing Tub Agitator Hydraulic Motor Powers the paddles in the mixing tub.

12


2

3

45 6

7

9

10

8


1 B-Side Power Box Provides power for the B side of the Seahawk.

2 Pump Drain or Auxiliary Suction

Used to drain the Pacemaker pump for cleanup. It can also be used as a hookup for auxiliary suction.

3 Pacemaker Pump II Triplex pumps used to displace fluids downhole.

4 Displacement Tanks Holds the mix and meter fluids for pumping.

5 Auxiliary Hydraulic System Filters Filters the hydraulic f luid for the auxiliary hydraulic system.

6 Non-Stick Reservoir Holds non-stick chemical applied prior to mixing to aid in cleanup.

7 Defoamer Reservoir Holds chemical defoamer.

8Slurry Sample Valve

and Hose Used to pull slurry samples.

9 Hydraulic Valve Servo Junction Boxes

Houses the hydraulic servo valve junctions for the auxiliary hydraulic system and the ACC II.

10 Data Cassette Housing Houses the data cassette for the MCM 2000.

1

13


1

2

45

6 78

9

11 1210

3

COMPONENT DESCRiPTiON1 Mass Flow Meter Measures the rate of f low and density of f luid.

2 Flow-Meter Transmitters Transmits f low rates from the f low-meters to the MCM 2000.

3 B-Side Slurry Pump Pumps fluid in the manifold and is controlled by B-side power.

4 C-Side Slurry Pump Pumps fluid in the manifold and is controled by C-side power.

5 Instrumentation Bulkhead Provides ports for further instrumentation hookup.

6 Displacement Tank Drain Allows draining of the displacement tanks for cleanup.

7 Plunger Lube System Provides grease lubrication for the plungers of the Pacemaker pump.

8 Hyraulic Fluid Reservoirs Holds hydraulic f luid for the hydraulic systems.

9 C-Side Power Box Provides power for the C-side of the Seahawk.

10 Bleed Manifold Allows bleed off of pressure on the pump into the displacement tanks.

11 Discharge Manifold Used to control discharge from the unit.

12 Hydraulic Return Filters Filters hydraulic f luid returning to the hydraulic f luid reservoirs.

14


1

2

3 4 5

6

7


1 Transmission Filters Filters transmission fluid.

2 Engine Oil Fill Point where the engine oil is added.

3 Engine Oil Level Dipstick Checks the level of the engine oil.

4 Fuel Filter Filters the diesel fuel.

5 Engine Oil Filter Filters the engine oil.

6 Pacemaker Pump Lube Oil Filter Filters the Pacemaker pump lube oil.

7 PTO Selector Engages and dis-engages the PTOs for the hydraulic pumps.

8 Batteries Provides power to the instrumentation.

8

15


ThE MCM 2000

The MCM 2000 uses a standard 3 position switch. The switches and their corresponding knobs are number 1-16 starting with switch one (1) and the corresponding knob located on the panel at the bottom and to the left.

Switches 1 through 5 (LAS 1-5) Uses 1 PID per additive. MAN - (UP) - Output (or target rate) of each additive is adjusted by turning the knob above it. OFF - (MIDDLE) - No output to pump control. AUTO - (DOWN) - Pump output is controlled via PIDs to match a programmed target rate.

Switch 6 (TUB LEVEL) Used for selecting automatic tub level control. The knob defines the target in % of tub, allowable values are 50 to 95 %. The system attempts to hold the tub level at the target level. OFF - (UP) - Standard tub level control. OFF - (MIDDLE) - Standard tub level control. AUTO - (DOWN) - Tub level control using the knob for set-point value.

Switch 7 (wATER VALVE) Used to control flow of the primary liquid into the mix tub. This valve is normally used in the PID of MIX LVL control. MAN - (UP) - Direct control of the water valve, using knob 7 to open and close the valve. OFF - (MIDDLE) - Valve is closed. AUTO - (DOWN) - Valve opens and closes according to the set target.

Knob is used to manually adjust the tub level if “AUTO TUB LEVEL” is turned OFF. The tub level can be controlled (mixer tub level) by increasing or decreasing target water inlet rate by the percent shown at bottom of display column. The rate adjustment is +25% to –25%

6 71 - 5

16


Switch 8 (DENSiTy CONTROL VALVE) Used to control the entry of dry cement into the Mixing Chamber. This is used to control slurry density.

MAN - (UP) - Direct control of Mixing Chamber with the knob. OFF - (MIDDLE) - Mixing Chamber is closed. AUTO - (DOWN) - Mixing Chamber is available for automatic density control.

Switch 9 (BULk VALVE) Used to control the entry of dry cement into the Surge Tank from the Main Bulk Supply.

MAN - (UP) - Direct control of gate with the knob. OFF - (MIDDLE) - Mixing Chamber is closed. AUTO - (DOWNN) - Mixing Chamber is available for automatic level control.

Switch 10 (AGiTATOR) Mixing tub agitator control. There is no feedback control linked to the agitator, so the rate of speed is displayed.

ON - (UP) - Provides knob control of the agitator speed. OFF - (MIDDLE) - Agitator is OFF, there is zero output to the control. ON - (DOWN) - Agitator will run at full speed with no knob control.

8 9

NOTE: A PID, or Proportional Integral Derivative, is a mathmatical equation that a processor utilizes to tune a loop in a closed loop system. It is important to record all PID values when the unit is initially received in order to document all factory settings. The MCM 2000 has 16 PIDs that are accessed under the PID Routine Menu. Additionally, it is important to note that

PiDS ShOULD NEVER BE ChANGED By AN OPERATOR AND ONLy ADJUSTED By qUALifiED ELECTRONiC

TEChNiCiANS OR By BJ iNSTRUMENTATiON ENGiNEERS.

10

17


Switches 11 & 12 (Mix wATER PUMP) The B & C mix water pumps can be used to pump either to the Displacement tanks, or from the Displacement tanks to the Water Valve that regulates flow into the mixing tub. MAN - (UP) - Knob controls speed - No rate will be displayed.

OFF - (MIDDLE) - Mix Water Pump is OFF. MAX - (DOWN) - Goes to MAX pump speed. NO knob control.

Switch 13 & 14 (SLURRy PUMP) Both may run at the same time, but typically only one pump is used during all mixing and pumping. The pump rate is PID driven to hold a constant RPM. The RPM is set in a utility window. The system will try to maintain a constant pump speed; however, if the engine speed won’t support the target rate it is your responsibility. This switch has NO knob control.

STANDBY - (UP) - B and/or C side pump(s) is ON at a low idle (apx. 850 RPM but can be adjusted in utilities menu 4/6). OFF - (MIDDLE) - B and/or C side pump(s) are OFF. AUTO - (DOWN) - B and/or C side is ON at the set pump speed (apx. 1475 RPM but can be adjusted in utilities menu 4/6).

13 - 14

Note: Loss of speed pickup on slurry pump will cause pump to go to maximum hydraulic speed which may cause higher pressure on supercharge than normal.

11 - 12

Note: When not moving fluids the pumps MUST be turned OFF to prevent overheating

18


Switch 15 (WATER METER) Used to select either Mag Meter or Turbine use. BACKUP - (UP) - Selects the Turbine. OFF - (MIDDLE) - Selects the Mag Meter. MAIN - (DOWN) - Selects the Mag Meter. Switch 16 (DOWNHOLE RATE) Used to select the component that will read the downhole rate. STROKES - (UP) - Uses plunger size and speed to measure downhole rate. (from UEC III) OFF - (MIDDLE) - Uses the mass flowmeter for downhole rate. METER - (DOWN) - Uses the mass flowmeter for downhole rate.

15 16

Note: If you use STROKE for downhole rate, the system will totalize off Mag pickup on Pacemaker pumps and will ignore Mass Flowmeter for downhole rate. The system will also

ignore BATCH / DOWNHOLE switch for ACC operations.

19


Main Display Screen PSI #1 PSI #2 NDEN DEN TIME

0.0 0.0 0.0 0.0 0.0

METER BPM 0.0 STG 0.0 TOT 0.0

F3 BPM 0.0 STG 0.0 TOT 0.0

PSi #1 Pressure transmitted from UEC-2 or UEC III (unit B) via serial communication.

PSi #2 Pressure transmitted from UEC-2 or UEC III (unit C) via serial communication.

DEN Aux density read out from micro motion flowmeter.

NDEN Nuclear density from nuclear densimeter if equipped

TiME Job time in minutes. Counter is started and stopped with the S/S key.

METER OR Discharge rate as defined by the D/H SWITCH #16 “ SELECTS DISCHARGE STROkE & SOURCE”. Possible source are: a) Rate F1 + F2 rates from UEC-II b) Slurry discharge rate from MicroMotion c) Simulated rate

STG Stage total of measured BPM

TOT Job total of measured BPM

f3 F3 rate input connector “Tank level B”, which is now defined as “Inlet Flow Rate”. This channel is intended to be used to measure the flow into the

displacement tank. This flow may be used to Ratio additives. If you are not doing this you may connect any flowmeter to this port to measure and

totalize it.

STG Stage total of F3

TOT Job total of F3

20


ACC Display ScreenBATCH DENS WATER GATE LEVEL

TARGET 0.0 0.0 0.0 0.0

ACTUAL 0.0 0.0 0.0 0.0

12.5 PPG -3.6% % %

ACC Status This field will display the label “BATCH” in stage zero (0). For other mix # or recipes it will show “SLURRY #” followed by the current stage number. The maximum number of recipes in this version of the program is fifty (50). It will flash the position of the “BULK GATE” switch when in the “OFF” or “MANUAL” position.

TARGET This field normally has the label, “TARGET”. When mixture change is indicated the message “NEW SLURRY = >” will display here with the indicated new mix number. Pushing the “STG” key will cause the current slurry change to

the indicate slurry number.

ACTUAL This field does not change.

12.5 This field shows the “ACTIVE” discharge rate (either the measured discharge or the simulated discharge rate) depending on the switch position. Down is measured,

up is simulated. Simulated discharge rate may be programmed as necessary via the corresponding selection screen on the ACC program menu.

DENS This field does not change.

0.0 Target mixture density that is calculated from active discharge rate, and job setup values for this stage.

0.0 Actual mixture density. Measured density. Value source is selectable in the Utilities menu.

PPG This field does not change.

21


ACC Display Screen (con’t)SLURRY #1 DENS WATER GATE LEVEL

TARGET 0.0 0.0 0.0 0.0

ACTUAL 0.0 0.0 0.0 0.0

12.5 PPG -3.6% % %

wATER This field does not change.

0.0 Target water rate is calculated desired water rate. It uses Target density ,the Active discharge rate, and other things to accomplish this.

0.0 Actual Water rate is measured mixture inlet water rate, as measured via the : Mix water flowmeter” port.

-3.6% Target water flow correction factor. When the “WATER VALVE” switch is the AUTO position, the knob will indicate an adjustment to the target-water flow rate. This adjustment can be from -25% to +25%. This field indicates any adjustment in effect.

GATE This field does not change.

0.0 Target gate position percentage. Calculated position (percent open) needed to deliver correct cement to mixing tub.

0.0 Actual gate position. Feed-back from gate.

% This field does not change.

LEVEL This field normally indicates the column labeled “LEVEL” for the displacement tank and the mixing tub levels as measured with the level probes in each tank. It will flash “DBIV” or “TXNU” depending on what source for the density was

picked in the Utilities menu.

0.0 When the Tub Level Control is in “AUTO” position this is the tub level target value.

0.0 Mixing tank level, percent full. Measured by probe in tank.

% This field does not change.

22


Liquid Additive Display ScreenSTG # 0 LAD 01 LAD 02 LAD 03 LAD 04 LAD 05

RATE 0.0 0.0 0.0 0.0 0.0

TOTAL 0.0 0.0 0.0 0.0 0.0

SETPNT 0.0 0.0 0.0 0.0 0.0

When no menu windows are displayed and the liquid additive screen is displayed as shown above, the four (4) function keys will directly bring up the PPU screen for the current stage and the additive one (1) through four (4) depending on the F-key pushed.

STG # Is the STAGE # currently being sent to JobMaster.LAD 01 These fields do not change.LAD 02LAD 03LAD 04LAD 05

RATE This field does not change.

Across 0.0 Measured rate in GPM (gallons per minute) for each pump. TOTAL Is the row label. It will be either “STAGE” for Stage Total or “TOTAL” for job total.

This row is toggled with the “TOT” key. All of the total variables for each additive are switched between the current stage total and the job total when the “TOT” key is pushed and this display is showing.

Across 0.0 Current Stage or Job total for each additive and pump.

SETPNT This field is a cycling row labeled each second the hole row changes to a new parameter. The available parameters are:

a) SETPNT for target rate b) RATIO for actual flowing ratio c) UNITS for target set-point units (ratio mode G/SK, flow mode GPM) d) MODE selected for each additive, default is RATIO

Across 0.0 Appropriate value or label for each additive based on SETPNT, RATIO, UNITS and MODE.

23


PROGRAMMiNG ThE MCM 2000The MCM 2000 may or may not hold total or stage total values from testing or prior jobs. The Job Monitor screen portion of the display will also still show old totals, and should have job time from the last job. You must clear this old data before JOBMASTER is linked to the Seahawk.

1 Push the RST key to enter the reset menu.

2 Push the zero (0) key to tell the system you are starting a new job and want to clear all TOTALS, STAGE TOTALS and the ENGINEERING TIME.

STG #0 LAD 01 LAD 02 LAD 03 LAD 04 RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

SELECT RESET OPTION

1> STAGE NUMBER 0> RESET ALL

2> ENGINEERING TIME

{STAGES} {=BOTH =} {TOTALS} {EXIT}

Resetting Stages & Engineering Time

1

2

24


PLEASE CONFIRM RESET

OFRESET ALL - NEW JOB

{ YES } < - SELECT CHOICE - > { NO }

3 Push the “F1” key to accept the change.

Note: Your Elapsed Job Time (or E-Time) and totals are all set back to zero and it’s OK to start the JobMaster computer at anytime now. In this state when JobMaster starts up you should be able to see a valid density or pressure reading from your panel. Verify that JobMaster has Communication. If there is no communication you should verify that the X - LAN is setup in the MCM 2000.

3

25


STG #0 LAD 01 LAD 02 LAD 03 LAD 04 RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

1 Before the start of the job you will need to check which LAN PORT has been setup. Press the PRG key to enter the MAIN MENU FUNCTIONS screen.

2 Press the number three (3) key for UTILITIES.

MAIN MENU FUNCTIONS

1> JOB OPERATIONS 3> UTILITIES

2> CALIBRATION 4> SELF TEST

( EXIT )

LAN Port Check

2

1

26


3 Press the F1 (MORE) key three (3) times to get to the SELECT UTILITY ROUTINE 4/6 screen.

4 Select the number one (1) key for SET LAN PORT USE.

SELECT UTILITY ROUTINE 4/6

1> SET LAN PORT USE

2> DUMP INTERNAL JOB DATA (LAN PORT)

(MORE) (BACK) (EXIT)


1> SET LAN PORT USE

2> DUMP INTERNAL JOB DATA (LAN PORT) (MORE) (BACK) (EXIT)

3

4

27



1> SET LAN PORT USE

2> DUMP INTERNAL JOB DATA (LAN PORT)


5 Check that the LAN PORT X OUTPUT has been selected. If the LAN PORT NORMAL is selected, change to the LAN PORT X OUTPUT by pressing the number two (2) on the keypad.

6 Press the program F4 (EXIT) key to get to the SELECT UTILITY ROUTINE 4/6 screen.

SET LAN PORT USE

1> LAN PORT NORMAL

2> LAN PORT X OUTPUT < = SELECTED

(EXIT)

6

5

28


7 If you want to get to the MAIN VIEWING SCREEN press the F4 key two (2) times or press the PRG (program) key to get back to this screen.

STG #0 LAD 01 LAD 02 LAD 03 LAD 04

RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

7

29


Programming a Job Before starting the job, you will need to program the cement pump. Some information will need to be

changed and some of the information will need to be verified for proper setup.

LAD 01 LAD 02 LAD 03 LAD 04

RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

Note: To avoid confusion during MCM 2000 programming, you may want to clear any previous slurry recipes still loaded in the MCM.

1 You may clear all slurry recipes already programmed in the MCM 2000 by pressing the PRG (program) key on the key pad.

2 The MAIN MENU FUNCTION screen will be displayed. Press the number one (1) key for JOB OPERATIONS.

MAIN MENU FUNCTIONS



(EXIT)

Clearing the Job Program

2

1

30


3 From the SELECT THE JOB PROGRAM OPERATION screen, press the number three (3) key for CLEAR JOB.

4 The next screen will give you the option to clear the job program. Press the F1 (CLEAR) key to clear any job program in the MCM 2000.

SELECT THE JOB PROGRAM OPERATION

1> SETUP SLURRYS 3> CLEAR JOB

2> REVIEW SLURRYS

(EXIT)

OPTION TO CLEAR THE JOB PROGRAM

MAKE SELECTION

(CLEAR) (EXIT)

4

3

31


5 After pressing the F1 (CLEAR) key you will return to the SELECT THE JOB PROGRAM OPERATION screen.



2> REVIEW SLURRYS

(EXIT)

32


1 At the SELECT THE JOB PROGRAM OPERATION screen, press the number one (1) key on the keypad for (SETUP SLURRYS).

2 The first option is to select the (SLURRY NUMBER). Use the key pad to select the mixture number. Press the F1 (ENTER) key to enter the target mix number selection.



2> REVIEW STAGES

(EXIT)

SLURRY # DENSITY CEMENT GATE BATCH 8.3 0.0

SLURRY NUMBER = (0-49)

(ENTER) (CLEAR) (MORE) (EXIT)

Note: 0 is for BATCH stages. Stage numbers

1-49 are used for continuous mixing.

2

Programming Batch Mode

1

33


3 The next screen prompts you to enter the (TARGET DENSITY) of the cement for this mix. Use the key pad to input this value. Press the F1 (ENTER) key to enter the value. (EX. 14 PPG)

4 The (CEMENT GATE PERCENT OPEN) prompt will come up next. After inputting the percent using the key pad, press F1 (ENTER) key to enter the value. The Seahawk has a Density Control Valve Chamber versus a knifegate. It’s reccomended setting is 45% open for Batch.

SLURRY # DENSITY CEMENT GATE BATCH 8.3 0.0

TARGET DENSITY = 14 lbs / gal


SLURRY # DENSITY CEMENT GATE BATCH 14 0.0

CEMENT GATE PERCENT OPEN = %


4

3

34


5 The next screen will be the (SELECT ADDITIVE) screen. There are 5 additive pumps to choose from. You will need to decide which additive needs to be set up. Use the key pad to make selection. Press the F3 (MORE) key to enter the selection that has been made.

6 The option (SELECT ADDITIVE) has changed to (SELECT MODE), F1 (ENTER) has changed to (FLOW) and F2 has changed to (RATIO). Choose which mode the pump is to be run in either F1 (FLOW) or F2 (RATIO).

SLURRY # ADDITIVE MODE SEPTNT 00 LAD 01 RATIO 0.0

SELECT ADDITIVE 1, 2, 3, 4, OR 5

(NEW MIX) () (MORE) (EXIT)


SELECT MODE

(FLOW) (RATIO) (MORE) (EXIT)

Note: In order for addititves to be added automatically the the

mix water during batch-up, the addititves must be set to ratio to gallons per thousand gallons of mix water.

6

5

35


Slurry # ADDITIVE MODE

00 LAD 01 RATIO

SET POINT =

(ENTER) (CLEAR) (NEXT ADD) (EXIT)

7 The last option is the (SET POINT). When operating in the (FLOW) mode, the (SET POINT) is the desired rate you wish to pump the chemical in gallons per minute. When operating in the (RATIO) mode, the (SET POINT) is the ratio you wish to pump at in gallons per thousand of fluid pumped or gallon per sack. Press the F1 (ENTER) key to enter the value.

SET POINT will be the last screen for setting up the first additive to be pumped. If more than one additive will be used, press the F1 (ENTER) or F3 (NEXT ADD) key to set up the next additive. By pressing the F1 (ENTER) or F3 (NEXT ADD) key, it will take you back to the SELECT ADDITIVE screen. Repeat the steps until all additives have been set up.

Slurry # ADDITIVE MODE SEPTNT 00 LAD 01 RATIO 0.0

SELECT ADDITIVE 1, 2, 3, 4, OR 5

(NEW MIX) () (MORE) (EXIT) 8 To setup the next mixture, press the F1 (NEW MIX) key on the keypad.

7

8

36


SLURRY # DENSITY CEMENT GATE BATCH 14 35

SLURRY NUMBER = (0-49)

(COPY) (CLEAR) (MORE) (EXIT)

1 Use the keypad to enter the (SLURRY NUMBER). Press the F1 (ENTER) key to accept this value.

2 To enter the (TARGET DENSITY), use the keypad and press the F1 (ENTER) key to accept this value.

Note: When entering the (SLURRY NUMBER)

using the keypad, the heading of (COPY) will change to (ENTER).

SLURRY # DENSITY YEILD CEMENT GATE BATCH 14 0.00 35

TARGET DENSITY = lbs / gal


Note: When entering the Slurry Setup, the unit

will always start in the Slurry number that the system is set to run.

2

Programming Continuous Mixing Slurry Recipes

1

37


3 Use the keypad to enter the (CEMENT YEILD). Press the F1 (ENTER) key to accept this value. This information can be found in the lab report.

4 To enter the (WATER REQUIREMENT), use the keypad and press the F1 (ENTER) key to accept this value.

SLURRY # DENSITY YEILD WATER 1 14 0.00 0.0

CEMENT YEILD = cu ft / sk


SLURRY # DENSITY YEILD WATER 1 14 1.18 0.0

WATER REQUIREMENT = gal / sk


4

3

38



SELECT ADDITIVE 1, 2, 3, OR 4



SELECT ADDITIVE 1, 2, 3, OR 4


5 To setup more mixtures press the F1 (NEW MIX) key on the keypad to repeat the steps until all stages have been setup.

6 Press the F4 (EXIT) key to get back to the SELECT THE JOB PROGRAM OPERATION screen.

6

5

39


1 From the SELECT THE JOB PROGRAM OPERATION screen, press the number two (2) on the keypad for Review slurry mixes.

2 The screen will show the (SLURRY NUMBER), (DENSITY), and (CEMENT GATE PERCENT). To move to next mix, press the F1 (NEXT) key to move to the next screen.



2> REVIEW SLURRYS

(EXIT)


lbs / gal %

(NEXT) (LAST) (ADDITIVE) (EXIT)

Slurry Recipe Review

Note: It is important to go back through the job to check and make sure all information has been entered correctly.

1

2

40


3 From this screen, (SLURRY NUMBER), (DENSITY), (YIELD), (WATER) will be displayed. Press the F1 (NEXT) key to move through the stages. Use the F2 (LAST) key to move back up through the mixes.

4 Press the F3 (ADDITIVE) key to check and ensure that the additives have been set up correctly.


lbs / gal %


SLURRY # DENSITY YIELD WATER 1 14 1.18 4.98

lbs / gal cu ft / sk gal /sk


4

3

41


5 This screen shows the four (4) liquid additive LAD setup. To move through the mixes use the F1 (+ SLR.00) key.

6 To get from the additive screens to the cement mix screens press the F3 (CEMENT) key.

ADD MODE SETPNT ADD MODE SETPNT

LAD 01 FLOW 0.0 LAD 03 RATIO 0.0

LAD 02 RATIO 0.0 LAD 04 RATIO 0.0

(+ SLR.00) ( ) (CEMENT) (EXIT)

ADD MODE SETPNT ADD MODE SETPNT

LAD 01 FLOW 0.0 LAD 03 RATIO 0.0

LAD 02 RATIO 0.0 LAD 04 RATIO 0.0

(+ SLR.00) ( ) (CEMENT) (EXIT)

5

6

42


7 To get to the SELECT THE JOB PROGRAM OPERATION screen press the F4 (EXIT) key.

8 Or press the PRG key to get to the MAIN MENU.


1) SETUP SLURRYS 3) CLEAR JOB

2) REVIEW SLURRYS

(EXIT)

8

LAD 01 LAD 02 LAD 03 LAD 04

RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

7

43


1 To set up the job data in the MCM 2000, press the PRG (program) key on the key pad.

2 The MAIN MENU FUNCTION screen will be displayed. Press the number three (3) key for UTILITIES.

STG # 0 LAD 01 LAD 02 LAD 03 LAD 04

RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

MAIN MENU FUNCTIONS



(EXIT)

Data Cassette Setup

Configure Cassette Record

2

1

44



1> SET UNIT LAN ID 3> DATA CASSETTE

2> SET CLOCK 4> 3305 UTILS


3 Push the F2 (BACK) key to back up one utility menu. (this will take you to MENU 6/6)

4 Push the number one (1) key to check or change the cassette configuration.


1> CONFIG CASS RECORD - OFF LINE - INHIB

2> ENGR SERIAL (RS232)


3

4

45


TOGGLE CASSETTE ACCESS

1> EXTERNAL CASSETTE IS OFFLINE

2> CASSETTE ON SERIAL NONE PORT


5 This screen tells us that the cassette drive is not available to the system. It could have been turned off by the operator, never setup, or possibly turned off by the system because of error detection.

6 To use the cassette drive it must first be assigned to a serial port. Push the number two (2) key until the display looks like this. (select the HART PORT)

5


1> EXTERNAL CASSETTE IS OFFLINE

2> CASSETTE ON SERIAL HART PORT


6

46


7 Once the serial line is assigned, push the number one (1) key to activate the port for the cassette drive. This will show the data cassette is valid and the system is ready to work with it.

8 Push the F4 (EXIT) key to exit this menu item and get back to the UTILITY 6/6 screen.


1> EXTERNAL CASSETTE IS ACTIVE

2> CASSETTE ON SERIAL HART PORT (EXIT)


1> CONFIG CASS RECORD - ON LINE - ACTIVE

2> ENGR SERIAL (RS232)


8

7

47


1 Push the F1 (MORE) key to advance to menu 1/6.

2 Press the number three (3) key for the data cassette menu.









Set Job head

1

2

48


3 You will see this menu item if the Job is running, or the S/S is on. Press the S/S to enter the paused mode.

4 You will see this menu item if the Job is in the not recording mode, or the S/S is paused.

Note: The preferred mode to be in when setting

up the data cassette is the S/S paused mode.

SELECT CASSETTE FUNC 1> HEAD 2> INIT

PERCENT OF CASSETTE USED 25%

APPROX TIME UNTIL FULL 3.2 HRS.

(S/S IS OFF) (CHG SAMPLE) (EXIT)

SELECT CASSETTE FUNCTION

1> SET JOB HEAD 3> FAST DUMP VIRTUAL

2> INT CASS RECORD 4> INIT VIRT CASS

(S/S ON) (CHG SAMPLE) (EXIT)

After pressing the number three (3) key to get to the data cassette menu you will see one of two basic forms for this menu.

Note: The preferred mode to be in when setting

up the data cassette is the S/S paused mode.

3

4

49


ENTER JOB TICKET NUMBER

1> JOB TICKET =

2> SERVICE REP =

(MORE) (CLEAR) (EXIT)



2> INT CASS RECORD 4> INIT VIRT CASS


5 Push the number one (1) key to enter the Job Information Utilities.

6 To enter the job ticket number press the number one (1) key.

Note: As an absolute minimum requirement

to initialize a cassette you must enter a job number.

5

6

50


7 Use the keypad to enter the job number and press the F1 (ENTER) key to accept job number.

8 To enter the name of the Service Representative push the number two (2) button to enter the name.

ENTER THE SERVICE REP NAME

1> JOB TICKET = 125695483

2> SERVICE REP =


ENTER THE JOB TICKET NUMBER

( )

ABCDEFGHIJKLMNOPQRSTUVWXYZ @#%()?:-

(ENTER) (CLEAR) (BKSP) (EXIT)

7

8

51



( )



9 Pushing the RST (reset) key will move five (5) characters to the right. If you go past the end you will come back on at the beginning (A).

10 To move to another character press the STG (stage) key. This will move one (1) character to the left.


( )



10

9

52



( )



11 Pushing the EVE (event) key will move five (5) characters to the left. If you go past the (A) you will come back on the other end of the line.

12 Press the TOT (total) key to enter the characters needed.


( )



12

11

53


13 After inputting the Service Rep. name, press the F1 (ENTER) key.

14 Press the F1 (MORE) key to set the JOB LENGTH and SAMPLE INTERVAL.


( )



Note: If you press the F-4 (EXIT) key before

pressing the F-1 (ENTER) key, it will not save your information.


1> JOB TICKET = 125695483

2> SERVICE REP = John Smith


13

14

54


1 The first information to enter is

the JOB LENGTH. Press the number one (1) key on the

keypad.

2 Use the keypad to select the new value.

SET JOB LENGTH OR SAMPLE RATE

1> JOB LENGTH = V2.9 HRS C 3.3

2> SAMPLE RATE = 7 SECONDS

(MORE) (DEFAULT) (EXIT)

SET JOB LENGTH

1> JOB LENGTH = 4.2 HRS

2> NEW VALUE =

(ENTER) (CLEAR) (EXIT)

The sample interval can be set by either entering the estimated job time by direct entry of the sample interval. These two items will cross calculate the other.

Set the Job Length

1

55


3 Press the F1 (ENTER) key to accept the new value.

4 Press the F4 (EXIT) key.

SET JOB LENGTH

1> JOB LENGTH = 4.2 HRS

2> NEW VALUE = 3

(ENTER) (DEFAULT) (EXIT)

SET JOB LENGTH

1> JOB LENGTH = 3 HRS

2> NEW VALUE =

(ENTER) (DEFAULT) (EXIT)

3

4

56


1 Press the number two (2) key to enter the SAMPLE INTERVAL value.

2 Use the keypad to select the new value. Press the F1 (ENTER) key to accept the new value.

SET THE SAMPLE RATE

SAMPLE RATE = 5 SECONDS

NEW VALUE =


Note: The minimal sample rate is 5 seconds.

SET JOB LENGTH

1> JOB LENGTH = V3.0 HRS C3.3

2> SAMPLE INTERVAL = 7 SECONDS


Set the Sample Rate

2

1

57


3 After accepting the new value press the F4 (EXIT) key.

4 Once the information has been entered, press F1 (MORE) key to get to the SETUP JOB INFORMATION screen.

SET THE SAMPLE RATE

SAMPLE RATE = 5 SECONDS

NEW VALUE =


SET JOB LENGTH OR SAMPLE RATE

1> JOB LENGTH = V2.9 HRS C 3.3

2> SAMPLE RATE = 7 SECONDS


4

3

58


1 Press the number one (1) key to enter the CUSTOMER NAME.

2 Setup the CUSTOMER NAME the same way that you setup the SERVICE REP. (steps 9-13 in ENTER JOB TICKET NUMBER section).

SET JOB INFORMATION

1> CUSTOMER NAME =

2> CUSTOMER REP. =


ENTER THE CUSTOMER NAME

( )



Set Job information (Customer information)

1

59


3 Press the F1 (ENTER) key when done entering the CUSTOMER NAME.

4 Once the CUSTOMER NAME has been entered press the number (2) key to enter the CUSTOMER REP.

SET JOB INFORMATION

1> CUSTOMER NAME = Big Oil Company

2> CUSTOMER REP. =


ENTER THE CUSTOMER NAME

(Big Oil Company)



3

4

60


5 Setup the CUSTOMER REP. the same way that you setup the CUSTOMER NAME.

6 Press the F1 (ENTER) key to accept the CUSTOMER REP. information.

ENTER THE CUSTOMER REP.

(Stan Stafford)



ENTER THE CUSTOMER REP

( )



6

61


1 Once the information has been entered, press F1 (MORE) key to get to the JOB TYPE and WELL / RIG # screen.

2 Press the number one (1) key to enter the JOB TYPE.

SET JOB INFORMATION

1> JOB TYPE =

2> WELL / RIG # =


SET JOB INFORMATION

1> CUSTOMER NAME = Big Oil Company

2> CUSTOMER REP. = Stan Stafford


Set Job information ( Job Type & well information)

1

2

62


3 Setup the JOB TYPE the same way that you setup the CUSTOMER REP.

4 Press the F1 (ENTER) key to enter the JOB TYPE.

ENTER THE JOB TYPE

( )



ENTER THE JOB TYPE

(Cement)



4

63


5 Once the JOB TYPE has been entered press the number (2) key to enter the WELL / RIG #.

6 Setup the WELL / RIG # the same way that you setup the CUSTOMER REP.

SET JOB INFORMATION

1> JOB TYPE = Cement

2> WELL / RIG #. =


ENTER THE WELL / RIG NUMBER

()



5

7 Once the information has been entered, press F1 (ENTER) to accept the information.

8 Press the F4 (EXIT) key to get back to the SELECT CASSETTE FUNCTION SCREEN.

7

ENTER THE WELL / RIG NUMBER

(Big Rig #1)



8

SETUP JOB INFORMATION

1> JOB TYPE = Cement

2> WELL / RIG # = Big Rig #1


64


1 Press the number two (2) key to start the initalization process.



2> INIT CASS RECORD 4> INIT VIRT CASS


initalize the CassetteNow that you have entered information into the Job Header fields you are ready to initialize the cassette. First verify that the cassette is in the drive unit.

After pressing the number two (2) key you will see the cassette initalization data being passed down to the cas-sette in a 13 - step process. If a step should repeat itself this is OK. If the system should lock into 1 step, it is possible that something may be wrong with the cassette system. It is possible that there is no cassette in the drive or the drive is disconnected due to a cable failure or a broken cable. If this is the case, you will need to abort the initalization and have a qualified technician troubleshoot the cassette unit.

65


1

66


1 Press the number four (4) key to erase and initialize the Virtual Cassette memory.



2> INIT CASS RECORD 4> INIT VIRT CASS


The last step in this process is to initialize the Virtual Cassette. This is a separate process because the Virtual cassette is totally independent of the physical cassette unit. This initialization process will erase any prior data now in memory. The Virtual cassette is a 1500 record history file with header information.

Note: This is a very fast operation. F3 can be used to dump the Virtual Cassette file.

1

When you are in this window the F1 key may be used to START or STOP the job clock. The F3 (CHG SAMPLE) key can be used to change the sample interval for the cassette data. The longer the interval is the greater the remaining time on the cassette. This also means that less data will be recorded.

initalize the Virtual Cassette

IIISEAhAwk OPERATiON

68


Note: It is vitally important that ALL steps in this section of the manual are followed as they are written from beginning to end regardless of how a process has been segmented and numbered. The instructions in this section were written sequentially, i.e. one step relies on the proper completion of the preceding steps. If a set of steps is extracted without regard to previous instruction, proper operation of the unit WILL be hindered.

69

Operating the Seahawk

1 After completing the pre-job checklist, verify that the 2 switches on the right side of the Seahawk control console are turned off.

2 On both sides of the Seahawk there is a UEC III Control Box. Each control box has three switches located on the left side of the box, and are marked “Console”, “UEC” (Universal Engine Control), and “TCM” (Transmission Control Module). Flip these 3 switches to the UP or ON position on both of the boxes.

S TA RT i N G T h E S E A h Aw k

11

2

Note: Applying power to the unit while the console power switches are in the ON position may create a power surge potentially damaging the Pendant Brain Box system.

70


3 Ensure the air from the rig to the unit is on and open to the unit and all connections are secure; the air from the unit to the Surge Tank is open and all connections are secure; the fuel lines from the unit to the external fuel tank are open and all connections secure; and that the external fuel tank is open to the unit.

4 Ensure the PTO toggle on both sides of the unit are in the “ENGAGE” position. This switch is located just below and to the left of the UEC III Control Boxes on either side of the Seahawk.

FUEL

AIR

4

71


5 Climb up to the work deck and turn on the 2 power switches on the Brain Box located underneath the console.

6 This will cause the MCM 2000 and the Dual ECM panels to light up. The “B” and “C” engine display should power up, and the MCM 2000 should begin going through its boot-up procedures.

6

5

72


7 Start with the “B” controller on the control module. Press the “RUN” key on the keypad. This will turn the fuel on to the “B” deck engine.

8 Press the “CNK” crank key momentarily to get the deck engine to start. Follow the same procedure to start the “C” side deck engine.

Check both engine’s water temperature and oil pressure before pumping the job to ensure both engines are with in the normal operating temperature and pressure ranges.

If a deck engine will not start after repeated attempts, ensure all power switches at the side power box are ON, all fuel lines from the external fuel tank are properly connected and open, and that the fuel pumps are operating (indicated on the ECM controller screen). If this fails to address the problem contact the necessary maintenance person.

7 8

73


P Ri M i N G T h E S E A h Aw k

Low Pressure Piping

Before priming up the Seahawk’s pumps, check MCM 2000 console.

1 Turn all knobs to the left. Check that all switches are in the OFF (middle) position.

1

74


2 Check that all switches on the valve control console are in the CLOSE position, and that the DOWNHOLE valve is in the BATCH position.

3 OPEN the Bleed Manifold, CLOSE the two discharge manifold valves, and OPEN the Splitter Valve.

3

2

3Splitter valve

Discharge Manifold valves

3Bleed

Manifold

Note: As a matter of safety and as required by BJ Standard Practices, ALWAYS OPEN BEFORE YOU CLOSE.

75


4 Fully open the Choke by turning the handle to the left, open the two 2x1 valves on the Bleed Manifold, and ensure the valves leading to the Pacemaker II pumps are open.

4

4

Choke

Bleed Manifold 2x1 valves

4

76


Raw Water

5 Open the corresponding valve to the Mix Water you will be using, and begin filling the displacement tanks with approximately 6 BBL of fluid each.

Mud

Rig Water

Note: Depending on how the unit is rigged up or plumbed, the location of the Rig Water and Raw Water may be different. If it has been determined that

the job will mix with Sea Water, a.k.a. Raw Water, then you must prime up using that type of water.

6 Open all of the valves on the Valve Control Console with the exception of the TUB SUCTION and DRAINS, which should be kept in the closed position. The DOWNHOLE valve should also be kept in the BATCH position.6

Note: Opening TUB SUCTION at this point may back fill your Mixing Tub and flood it. Opening the DRAINS may cause you to lose all of your water.

77


7 By opening all of the appropriate valves, water will flood the system ridding it of any large pocket of air. Watch the displacement tank for bubbles. When there are no more large bubbles, it will be necessary to totally rid the system of all air by priming the centrifugal, slurry, and Pacemaker II pumps.

7

78


1 OPEN the top two valves on the Displacement Tree.

2 Open the valve handle to diverts fluid into the “B” side displacement tank. Check that the displacement tank return line valve is open to the proper tank.

Mix water & Slurry Pumps

1

2

79


3 With the valves on the unit all open and the engine at idle, turn ON the B & C Mix Water Pumps.

4 Check the displacement tank to make sure that fluid is starting to flow into the tank. It may take a few seconds to get fluid through the mix water pump and plumbing to the displacement tank. When water enters tank, use the THROTTLE lever or THR UP key on both CONTROLLERS to bring the engines to full throttle.

3

4

80


5 Watch the tank for a good full stream of fluid going into it. This will be a sign that the air has been worked out of the system.

6 Use the THROTTLE lever or THR DOWN key on both CONTROLLERS to lower the engines’ RPMs to an idle or you can throttle down by pressing the INS NEU key.

6

5

81


7 Close the valves to the displacement tanks.

8 Close the valves on the displacement tree while leaving the bottom left valve OPEN.

7

ClOSe

OPen

82


9 Turn OFF the C-Side Mix Water Pump.

10 Close the C Mix Water Pump Suction on the Valve Control Console.

9

10

83


11 Throttle up the B-Side Engine to a high idle (anything below

900 RPM).

12 Open the Manual Mix Water, turn the Water Valve on the MCM to the MANUAL Position, and Open the water control valve. Control the rate of water to the Mixing Tub using the Manual Water Valve Handle. Fill the Mixing Tub about half full.

12

11

84


13 When the Mixing Tub is half full, OPEN the Slurry Tub Suction & Recirc Valve on the Valve Control Console.

14 OPEN the B & C Slurry Pump Valves, and then the DOWNHOLE Valve.

14

13

85


15 Turn the B & C Slurry Pumps ON.

16 Watch the tank for a good full stream of fluid going into it. This will be a sign that the air has

been worked out of the system. Keep the water rolling through the system at this point, and move into priming up the Pacemaker II Pumps.

15

16

86


1 Ensure the B-Side RPMs are below 900 RPM. (RPMs above 850 RPM will prevent the user from shifting from neutral into any gear.)

Pacemaker Pumps

2 With the water still circulating from centrifugal and slurry pump prime up, shift the B-Side Pacemaker Pump into 4th gear and throttle up until the water is moving around 5 BPM.

2

Once the mix water pumps, slurry pumps, and plumbing have been primed, the Pacemaker II Pumps and plumbing will be primed next.

87


3 CLOSE the B Suction while keeping the C Suction OPEN and the B & C Crossovers OPEN. (This will send water around the horn.)

4 After running the water for a few minutes, OPEN all DOWNHOLE PUMP Valves.

3

3

4

88


5 After rolling the water for a minute or two to help warm up the Pacemaker II Pumps, and once good flow is observed, use either the joystick or the throttle down (THR DN) key and bring the deck engine to an idle.

6 Shift the C-Side Pacemaker II Pump into 4th gear and throttle the C-Side Engine up until you are rolling the water at 5 BPM.

5

6

89


7 CLOSE the C Suction while keeping the B Suction OPEN and the B & C Crossovers OPEN. (This will send water back around the horn.)

8 After running the water for a few minutes, OPEN all DOWNHOLE PUMP Valves.

7

7

8

90


9 Once good flow is observed, use either the joystick or the throttle down (THR DN) key and bring the deck engine to an idle.

10 Turn OFF all Pumps, CLOSE all Valves, and position the Downhole Valve back to BATCH.

9

10

10

91


DENSiTy CONTROL VALVE ChECk Check the density control valve to assure it opens and closes. You can do this by either programming a

water stage into the MCM and running it, or by using the manual density control valve next to console to operate the density control valve, which we will review.

1 From the Manual Density Control Console, switch to ON/Manual and move the joystick while watching the valve move

2 Watch the ACC screen for the % (percent) open or closed.

Note: Never place any part of your body into the density control valve or mixer.

12

92


PRESSURE TEST PUMPS & LiNES

Before beginning any job, it will be necessary to perform a pressure test of the pumps and lines leading up to the wellhead. This process will require a number of steps beginning with programming both UEC controllers.

1 From the Main Viewing Screen of the UEC, press the program PRG (program) key to bring up the Main System Menu Screen.

ENG RPM GEAR PRESS PSI RATE BPM 0 INST_N 00 0.0(M 0)

N/L ENGINE OIL PRESSURE 0.0

1

Set working Pressure Limit

93


2 Press the number one (1) Key. This will bring up the Set Value Screen.

MAIN MENU

1> WORKING PRESSURE 3> DIAGNOSTICS2> UTILITIES 5> DIRECT GEAR

PUSH PGM OR EXIT KEY TO RETURN TO MAIN

2

3 Enter the new value using the keypad. Remember to set this value according to the maximum pumping pressure of the job.

SET WORKING PRESSURE LIMIT

WORKING PRESSURE 10000 NEW SETTING -

3

94


4 Press the ENT (enter) key to save the operator entered values.


WORKING PRESSURE 10000 NEW SETTING - 5000

4



Note: After setting up the “B” Side Controller you must set the “C” Side Controller for the same Working Pressure Limit. If you don’t, the “C” Side Controller will not shut down

when the Working Pressure Maximum is reached.

Note: Pressing the ENT (enter) key will also take you back to the Main Viewing Screen.

95


Set the Direct Gear

5 From the Main Viewing Screen press the PRG (program) key that will bring up the Main System Menu Screen.

6 Press the five (5) Key. This will bring up the DIRECT GEAR Screen.


N/L ENGINE OIL PRESSURE 60

MAIN MENU



5

6

96


7 From the DIRECT GEAR ACCESS Screen, press the number FIVE (5) key.

8 Notice that the TARGET GEAR has changed to D5.

DIRECT GEAR ACCESSPRESS = -10 ENG 1000 RPM

TARGET GEAR = D5 <push # of targ gear>

<PGM / EXT / CLR = ABORT> <ENT = SHIFT>

Note: Always watch the pressure when testing lines. Know your line and testing limits.


TARGET GEAR = N <push # of targ gear>



TARGET GEAR = 5 <push # of targ gear>


8

7

97


After the Overpressure Shutdown Values have been set for both engine controls and the Direct Gear the valves must be set to conduct the pressure test.

1

1 OPEN the corresponding Discharge Valve that leads to the wellhead.

Conducting the Pressure Test

98


2 CLOSE the Bleed Manifold valves and FULLY CLOSE the Choke by turning the handle to the right.

2

3

3 OPEN the B-Side Suction on the Displacement Tank, the Supercharge, B-Side Suction on the Downhole Pumps, the B-Side Slurry Pump, and Downhole valves.

Note: These instructions assume that the operator will be using the B-Side Slurry Pump. If the C-Side Slurry Pump is to be used, OPEN the corresponding valves leaving the B-Side valves CLOSED.

Note: It is important to note that the Choke does not provide a 100% positive shutoff. The 2x1 must be used to completely shut in pressure.

99


44 Turn ON the B-Side Slurry Pump.

5 Press the S/S button on the MCM 2000 to record the pressure test and start the E-time, and then start the pressure test by pressing the ENT (enter) key to move the pump into fifth (5) gear and start the pressure test.


TARGET GEAR = D5 <push # of targ gear>



TARGET GEAR = 5 <push # of targ gear>


5

100


6 Once you start to see pressure on the pumps and lines or the pump stalls out, press the INS NEU (instant neutral) key to take the pump out of gear. Check the pumps and line for any signs of a leak also look at the pressure to make sure it is holding.


N/L ENGINE OIL PRESSURE 60

6

7 If pressure continues to hold, indicating all pumps and lines are holding pressure and there are no leaks, select the displacement tank you will be returning fluid to, and begin bleeding off pressure by slowly opening the 2x1 valve on the Bleed Manifold inline with the Choke.

7

7

101


8 Slowly bleed the remaining pressure by turning the Choke to the left.

8

Note: When the 2x1 is opened pressure will immediately start to fall off and you will start getting returns into the desired displacement tank.

9 Water will then begin flowing back into the displacement tank. When all of the pressure is bled off. fully CLOSE the Choke and all valves on the Bleed Manifold.

9

102


1 OPEN the B-Side Mix Water Tank Suction and Pump Suction valves.

Note: The following instructions will assume that you will be using the B-Side Mix Water Centrifugal and Slurry Pumps.

1

MixiNG iN BATCh MODE(BatChing uP)

Before pumping downhole make sure the discharge being used is in the OPEN position. Ensure the valves and Choke on the Bleed Manifold are CLOSED. Set the ACC to slurry zero (0) which is BATCH mode, and begin circulating water.

2 OPEN the bottom-left valve on the Displacement Tree leaving the other 3 valves CLOSED.

2

103


33 Turn ON the B-Side Mix Water Pump.

4 OPEN the Manual Mix Water Valve.

4

104


5

5 Position the Water Valve on the MCM in the UP or Manual Position and use the corresponding knob to OPEN the water control valve. Observe the mixing tub level while controlling the flow to the tub using the Manual Mix Water Handle. Fill the Mixing Tub to apporximately 1/2 full with water. Once the desired level is reached, CLOSE the Manual Mix Water valve and turn OFF the Mix Water Pump.

6 OPEN the Slurry Tub Suction, the B-Side Slurry Pump, and the Recirc Valves.

6

Note: When not pumping fluid, the Mix Water Pumps must be turned OFF to avoid overheating of the pump and other potential damage.

105


7 Turn the B-Side Slurry Pump ON, and select Slurry Stage 0 (Batch Stage) by pressing 0 then STG.

7

7

8 Water should be circulating at this point.

8

106


Note: Now that water is circulating through the system, it is necessary

to fill the Surge Tank with Dry Bulk Cement.

9

9 Fill the Surge Tank to 50%-60% by first having someone open the Main Bulk Supply Line leading to the Surge Tank and then position the Bulk Valve on the MCM to MANUAL. OPEN the Bulk Control Valve using the knob above the toggle switch.

10 Ensure the Manual Density Control is in the Auto Position.

10

107


11 Turn ON the Surge Tank Aerator and Vibrator.

11

12

12 Using the regulator on the Manual Control Console, set the Surge Tank Control pressure to 25 PSI. (Actual tank pressure will be 11 PSI)

Note: The pressure shown on the Surge Tank Control Pressure guage does not

reflect the actual pressure in the Surge Tank. The actual pressure vs. gauge control pressure can be found in the table.

CONTROL PRESSURE GUAGE READiNG

ACTUAL SURGE TANk PRESSURE

21 PSI 9 PSI23 PSI 10 PSI25 PSI 11 PSI27 PSI 12 PSI30 PSI 13 PSI

108


15 The unit will start batching up to the pre-programmed weight.

16 When the batch weight is achieved, the chamber in Bulk Density Valve will CLOSE on its own and you will need to have someone SHUT the Main Bulk Supply line to prevent “packing off ” the line leading to the Surge Tank.

14 Move the Density Control Valve switch on the MCM & the Manual Density Control valve switch on the Manual Control Panel to AUTO.

13 OPEN the Manual Bulk Valve on the Mixing Module.

13

14

109


MUD CUP TESTBJ Services uses Pressured Mud Scales also know as Fluid Density Balance. Fluid Density Balance Scales are more accurate because it subjects the slurry sample to pressure which collapses the air bubbles negating most of their effect on the slurry density.

1 Collect a sample of slurry from the slurry sample line.

2 Fill the cup with slurry. Make sure to fill the cup all the way to the top.

Note: Pressured mud scales should be checked for accuracy before every cement job. They are the most important tool in assuring proper cement density and ultimately job success.

1

110


3 Place the lid cap on the cap. Press the lid down to seat it in the cup. Excess solution should be expelled from the check valve. If no slurry is expelled, more solution should be added to the cup. Tighten the lid cap onto the cup.

4 With some of the same slurry that was used to fill the pressurize mud cup, pressurize the cup using the plunger.

5 Place the pressurized mud cup in the mud cup stand and move the rider to the line that indicates the density of the slurry.

6 The bubble in the spirit level should be centered between the two lines.

Note: Be sure to clean the Mud Cup before placing it on the scale to gain a reading. Excess cement on the outside of the cup will lead to a false reading. Additionally, it is important to clean the Mud Cup and Plunger after every test to ensure accuracy in every use.

111


MUD CUP CORRECTiONThe pressurized mud cup reading and the density read out on the Seahawk should read the same. If this is not the case, conduct another Mud Cup Test. If the second test reading is the same or very close to the first, then the MCM must be recalibrated using the Mud Cup Correction instructions that follow.

1 Push the PRG key to enter the Main Menu.

2 Push the number two (2) key to enter the Calibrations Menu.

STG # 0 LAD 01 LAD 02 LAD 03 LAD 04

RATE 0.0 0.0 0.0 0.0 TOTAL 0.0 0.0 0.0 0.0

RATIO 0.0 0.0 0.0 0.0

MAIN MENU FUNCTION


2> CALIBRATIONS 4> SELF TEST

(EXIT)

1

2

112


3 Push the number three (3) key for CAL DENSITY. (calibration density)

4 Push the number one (1) key to select the CAL MDEN density calibration.

MAIN MENU FUNCTION

1> CAL MDEN ( MICROMOTION)

2> CAL NUC DEN

(EXIT)

SELECT CALIBRATIONS ROUTINE 1/2

1> CAL ANALOGS 3> CAL DENSITY

2> CAL ADDITIVES 4> PID ROUTINES

(MORE) (EXIT)

4

3

113


5 Push the F2 (MUD CUP) key to select the calibration with the Mud Cup.

6 Using the key pad enter the correct density for the new mud cup reading.

CALIBRATION WITH MUD CUP

MUD CUP SPAN = 12.6

NEW MUD CUP = 11.6


CALIBRATE DENSITY

1> UNIT SPAN 3> mV SPAN

2> UNIT ZERO 4> mV ZERO

(WATER) (MUD CUP) (DEFAULT) (EXIT) Note: Beware of pushing the F3 (DEFAULT) key here. This will return you to default calibration values for this device, eliminating any water correction you might have made.

5

114


7 When you have the correct value push the F1 (ENTER) key to enter the new value.

8 You should see the correct value in your density field now. Push the F4 (EXIT) key to exit or push the PRG (program) key to exit all menus.


MUD CUP SPAN = 12.6

NEW MUD CUP = 11.6



MUD CUP SPAN = 11.6

NEW MUD CUP =


When the desired weight is reached, and both the pressurized Mud Cup and the Seahawk cement pump density reading’s are the same, use the keypad to move to the next stage.

7

8

115


MixiNG whiLE PUMPiNG(Mixing On the fly )

Before starting downhole, make sure the discharge being used is in the OPEN position, and the Bleed Manifold is CLOSED. Set the ACC II to the desired slurry. Check that the MCM 2000 is in the data record mode and not paused. For this example we will use the “B” side of the unit.

Ensure the following switches on the MCM 2000 are in the correct position.

1 Tub Level - Auto

2 Water Valve - Auto

3 Density Control Valve - Auto

4 Bulk Valve - Auto

5 Agitator - ON

6 Mix Water Pump - MAX (This will only apply to the side you choose to use.)

7 Slurry Pump - Auto (This will only apply to the side you choose to use.)

8 Water Meter - Main

9 Downhole Rate - Meter

1 2 3 4 5 6 7 8 9

10

10 If you are using a Liquid Additive, engage the proper LAS for the corresponding stage to Auto.

116


Ensure the following switches on the Valve Control Console are in the correct position.

11 Mix Water Valves - OPEN (For the side you are using.)

12 Slurry Pump Valves - OPEN (For the side you are using.)

13 Downhole Pump Suction B&C - OPEN

14 All Displacement Valves - CLOSED

15 Downhole Pump Crossovers - CLOSED

11 12

1513

14

117


16 Ensure the Manual Density Control switch is in the OFF/AUTO position and set the Surge Tank Control pressure to 25 PSI. During the job, adjust the Surge Tank pressure to increase or decrease the bulk delivery from the main bulk supply.

Note: If there is little pressure coming from the main bulk supply to the surge tank, you may need to lower the surge tank pressure to allow more bulk to enter the tank from the main

supply.

17 Turn the Surge Tank Aerators and Vibrators ON.

16

16

17

17

118


19 Use either the joystick or the UP SFT key and move both pumps to the desired gear.

20 Use either the joystick or the THR UP key and bring both pumps to full throttle.

During the job you will need to monitor rates, pressures, cement delivery, tub levels, additives if being used and overall operation of the truck to assure proper operation and job requirements.

Note: In order to put the pumps in gear the engine speed must be below 850 rpm.

18 OPEN the DOWNHOLE valve.18

20

19

119


1 Continue mixing until the Surge Tank is empty. It may be necessary to increase the the pressure on the Surge Tank to ensure all dry bulk has been delivered to the Mixing Module.

2 When all dry bulk has been delivered, and you notice the slurry weight dropping off, CLOSE the Bulk Valve on the MCM.

ShU T DOwN PROCEDURES

When the cement delivery is finished, have someone CLOSE & JET the supply line from the Main Bulk Supply to the Surge Tank before the valve is closed on the Seahawk.

1

2

120


3

3 CLOSE the Manual Bulk Valve on the Mixing Module.

4 CLOSE the Recirc Valve.4

121


5

5 CLOSE the Water Valve on the MCM.

6 Slow your rate as much as possible so as not to outrun your mixing tub.

6

122


8 While watching the tub, continue pumping the tub level lower until you see the top of the screens in the bottom of the tub. When the level reaches the screens, press INST NEU on both pumps, and CLOSE the Downhole Valve.

7

7 Turn OFF the Agitators and any Liquid Additives you may be running at this time.

8

123


99 RE-OPEN the Recirc Valve.

10

10 Turn ON the Manual Mix Water Override.

124


11 Move the WATER VALVE switch on the MCM to the MAN (UP) position to OPEN the Water Valve giving control to the MANUAL WATER lever on the Manual Control Console. Use the MANUAL WATER lever to fill the tub with water until it is about 3/4 full.

12 Turn ON the Agitators and adjust the speed up so as to fully dillute

any remaining slurry in the tub.12

11

125


1313 Turn OFF the Mix Water Pumps.

14 CLOSE the Mix Water Tank and Pump Suction Valves.

14

126


DiSPLACEMENT

After all cement has been pumped and the various pumps have been washed up, it will be time to start dis-placing the cement to its proper position in the well. Begin by programing new Overpressure Values.

1 From the Main Viewing Screen, press the program (PRG) key to bring up the Main System Menu Screen.



1

127


2 Press the number one (1) Key. This will bring up the Set Value Screen.

MAIN MENU



2

3 Enter the new value using the keypad. Remember to set this value according to the estimated pressure at the point of plug bump.


WORKING PRESSURE 10000 NEW SETTING -

3

128


4 Press the enter (ENT) key to save the operator entered values.


WORKING PRESSURE 10000 NEW SETTING - 5000

4



Note: After setting up the “B” Side Controller you must set the “C” Side Controller for the same Working Pressure Limit to ensure the “C” Side shuts down when the Working Pressure Limit is reached.

Note: Pressing the ENT (enter) key will also take you back to the Main Viewing Screen.

129


5 Reset the Stages and Totals.5

6 CLOSE the Tub Suction and Recirc Valves.

6

130


7

7 OPEN the Supercharge, Displacement Suction, and Downhole Valves.

Note: In order to assure the proper tracking of displacement of the well, always start with the “C” side displacement tank.

7

8 Use either the joystick or the UP SFT key and move both pumps to the desired gear.

9 Use either the joystick or the THR UP key and bring both pumps to full throttle.

8

9

131


10 Fill and switch the displacement tanks accordingly.

12 Use either the joystick or the DWN SFT key and move both pumps to the desired gear.

13 Use either the joystick or the THR DWN key and bring both pumps to low throttle.

11 When pressure starts to rise rapidly, or when you are within 10 BBLs of total displacement volume, begin slowing your rate to approximately 3 BPM.

13

12

132


14 After one tank of displacement is pumped, alternately open the Downhole Pumps Suction Valves a few times to assure clean up of the plumbing. Displace until the cement plug bumps.

14

15 When differential pressure is reached, the Overpressure Shutdown Condition should bring the unit to Instant Neutral. You may also use the INS NEU key to shut down the pumps. Make sure that you have pumped 500 PSI of the preset differential pressure. If not, reset the Overpressure value and slowly pump until you reach 500 PSI over.

15

133


At the end of the job it may be necessary to watch pressure for a few minutes. If pressure holds, bleed the pressure off back to the same displacement tank, that is being pumped from and record the amount of fluid that flows back into the tank.

16 If pressure continues to hold, indicating all pumps and lines are holding pressure and the float equipment downhole is holding, select the displacement tank you will be returning fluid to, and begin bleeding off pressure by slowly opening the 2x1 valve on the Bleed Manifold inline with the Choke.

16

16

17 Slowly bleed the remaining pressure by turning the Choke to the left.

17

134


CLEAN UP PROCEDURESAfter the job it will be necessary to clean up the Seahawk cementing unit. Depending on customer require-ments along with State and local laws and regulations, cleanup must be done in an approved fashion.

The following items must be either washed or flushed with water. Each item must be checked for any cement resdue and proper operation.

1 Wash and clean the Mixer & Chamber and the De-Aerator making sure both components are clean and that there is no cement resdue or build-up.

2 Wash and clean the Mixing Tub to remove any excess slurry or dry cement.

De-aerator

Mixer & Chamber

2

135


3 Run clean water through the cement sample hose to make sure it is clean and clear of any cement.

4 Flush and clean all lines of the Seahawk Cement Pump. After pumping and flushing all lines check for any cement resdue. Be sure to operate all valves making sure they are operational.

3

136



IVAP P ENDix

138



139

Appendix

TROUBLEShOOTiNG

SYMPTOM PROBABLE CAUSE CORRECTIVE ACTION

Low oil pressure

Low crankcase oil level. Check level in crankcase and add oil to recommended level.

Improper oil viscosity (fuel in oil) Determine cause of fuel dilution and change oil.

Engine Control System Malfunction (sensor) Notify maintenance

Internal engine problem Notify maintenanceFaulty gauge Notify maintenance

High oil temperature

Oil level low Check level in crankcase and add oil to recommended level.

Oil level overfull Drain to proper levelEngine Control System Malfunction (sensor) Notify maintenance

Insufficient coolant flow through oil cooler

Flow may be restricted by debris. Clean oil tubes

Running rough and low power

Insufficient fuel Check fuel level and fuel systemInlet air restriction or exhaust back pressure

Check intake and exhaust plumbing

Engine Control System Malfunction Notify maintenance

EXCESSIVE EXHAUST SMOKE

Black or GraySmoke

Damaged or dirty air cleaner Repair or replaceImproper grade of fuel Replace fuelExcessive exhaust back pressure Check exhaust pipingThin air (high altitude)

Blue SmokeOil burning in manifold or turbo Notify maintenanceExcessive oil in crankcase Drain to proper level

White SmokeMisfiring cylinders Notify maintenanceAir in fuel system Notify maintenanceOctane rating of fuel too low Replace fuel

Cummins qSM 11.0 Liter Deck Engine

140



High engine coolant temperature

Radiator coolant fluid level low. Add fluid to proper level.Restricted radiator core passages Steam clean radiatorDirt buildup between radiator core and intercooler. Steam clean between radiator

Excessive load on engine Reduce loadSlipping fan drive belts Adjust tensionEngine Control System Malfunction (sensor) Contact Maintenance

Low fuel pressure

Fuel tank level low Add fuelFuel filter clogged. Service filterEngine Control System Malfunction (sensor) Contact Maintenance

Engine will not rotateNO or Low air supply to starter Check air connections & supply.Faulty cranking motor Replace starter

Low engine cranking speed

Low battery voltage Check charging system & charge batteries

Faulty cranking motor Replace starterFaulty cranking motor switch Replace switchImproper lube oil (cool climate) Replace with oil that meets standards

Engine cranks but will not start

Circuit breaker/electronic control malfunction Check electrical switches and system

Fuse blown or missing Check fusesOut of fuel Add fuelFuel filter or lines plugged Service filter and check linesEngine Control System Malfunction Notify maintenanceInternal engine problem Notify maintenance

Low or Fluctuating Lube Oil Pressure

Air leak in lube pump suction lines

Tighten all suction-line connections. Check hoses for leaks.

Filters dirty and clogged Replace filters and lube oilExternal lines to pump clogged Flush line and change oil

Relief valve clogged Clean relief valveLow relief valve setting Reset relief valveRelief valve stuck open Clean relief valveLow oil viscosity – diluted oil Replace lube oil

Relief valve adjustment incorrect, or damaged Adjust or replace relief valve

Cummins qSM 11.0 Liter Deck Engine (continued)

141

Appendix



Damaged pressure gauge Replace pressure gaugeLow oil level Add oil until adequate Level

Hot oil Check oil coolerWorn lube pump Replace lube oil pump


Transmission Hard to Shift

Transmission failure Repair transmissionHeat damage Repair transmissionPin out of shift level shaft (inside transmission) See transmission service manual

Transmission Runs Hot

Improper fluid levelCheck fluid level and add or remove fluid as necessary to achieve proper level

Heat exchange pump Check electrical connection for pump

Heat exchanger Check tube and shell cooler for no circulation either coolant or lube oil

Heat exchanger pump thermostat control Replace thermostat control

Transmission Main Pressure Low

Fluid filter plugged Replace filterTransmission lube pump Repair Transmission

Allison hD-4700-OfS Transmission

Cummins qSM 11.0 Liter Deck Engine (continued)

142


Pacemaker ii Pump



Air leaks in lube pump suction lines (indicated by frothy oil)

Tighten all suction line connections. Check hoses for leaks (oil drips, streaks, etc.).

Low oil level Check oil level and add oil as requiredHot oil Check the oil cooler and the cooling

fluid temperatureWorn lube oil pump Replace pumpPacemaker pump clearances too Check crankshaft and bearings. Repair

as requiredIncorrectly adjusted or defective relief valve

Check adjustment. Replace relief valve

Low viscosity oil or diluted oil Sample oil or replaceRelief valve stuck open Clean relief valveRelief valve set low Reset relief valveClogged relief valve Clean relief valveClogged lines exterior to pump Clean out lines and change oilDirty and clogged filters Change filter cartridges and oil

Lube Oil Temperature High

Insufficient coolant flow through the oil cooler

Flow may be restricted by debris. Clean cooler tubes

High engine coolant temperature Check engine coolant for excessive temperature, determine, and correct problem

Pump Inoperative Suction valves closed Open valvesPacemaker Pump Hammering or Excessive Vibration

Suction or discharge valve leaking Repair valve and re-checkSuction valve cover sucking air Repair leak and re-check

Agitator


Agitator Will Not Rotate

Check valve Check set pressure relief valve or replace check valve

Check flow control valve Replace valveBad hydraulic pump Replace pumpBad Hydraulic motor Replace motor

143

Appendix

Mixing Tub


Inability to Maintain Slurry Weight

Bridge forming in the Mixing Module Try the following: Close the mixer completely. Snap the water valve fully open. Quickly open and close the knife gate several times. If this does not work it will be necessary to remove the bottom sight glass and break the bridge

Loss of mix water flow Mix water flow restricted in the Mixing Module. Check the water jet for restriction

Slurry Foaming

Slurry foaming is usually caused by air entrapment. Air leaking around the mixer is the normal source

Check the mixer for air leaks and repair leaks. Add defoamer to control foaming

Slurry design Contact lab

Mix water Pumps


Mix Water Pump Inoperative

Pump locked up due to debris in the impeller

Inspect and clean pump

Hydraulic motor malfunction See Hydraulic Motor Troubleshooting Guide

Pump Operating Normally But Pumping Rate is Low

Mix water pump suction manifold is restricted

Check suction manifold for restrictions

Impeller worn or excessive clearance Check for impeller wear or improper clearance and replace impeller if necessary

Pressure gauge defective Check with known good gauge. Replace if necessary

Air in system Bleed system until air is removed

Pump Operating But Mixing Water Pressure Low

Pressure gauge defective Check with known good gauge. Replace if necessary

Pump speed improper Hydraulic motor not operating at sufficient speed. Determine motor problem

Screen clogged Clean out screen.

144


Slurry Pumps


Pump Will Not Run

Pump locked up due to debris in the impeller

Inspect and clean

Hydraulic drive motor failure Repair or replace motor. Review section 3.5 Hydraulic Systems Motors

Pump Operating but Cannot Achieve Full Rate

Low level in mix tank Increase level in the tankPump speed too slow Check hydraulic drive motor for

problemsPump speed too fast causing cavitation Pump can cavitate if run too fast.

Determine cause and correct. Slow pump speed. Review section 3.5 Hydraulic Systems Motors

Slurry is aerated Add defoamer to the slurry

Pump Operating but Recirculating Pressure is Low

Low level in mix tank Increase level in the tankPump speed too slow Check hydraulic drive motor for

problemsPump speed too fast causing cavitation Pump can cavitate if run too fast.

Determine cause and correct. Slow pump speed. Review section 3.5 Hydraulic Systems Motors

Slurry is aerated Add defoamer to the slurryWash out slurry jet in the Mixing Module Replace jetPump suction manifold restriction or leak Check suction manifold for restrictions

or leaksPump Operating but Recirculating Pressure is High

Slurry jet may be restricted Disassemble jet assembly and clean

Pump Packing Leaks

Packing needs adjustment Adjust packing and re-check for leakage

Packing worn Replace packing and re-check for leakage

Shaft sleeve worn Replace sleeve and packing and re-check for leakage

Pump Will Not Hold Prime

Suction manifold leak Repair leakAerated fluid Add defoamerSlurry design unsatisfactory Contact LabIncompatible defoamer Contact Lab

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Appendix


Noisy Hydraulic Pump or Motor

Air in system Check hydraulic oil level.Check for leaks.

Dirt in system Clean all lines and filters.Valve in line is not fully open Open valve completely.Worn or damaged pump or motor Replace or rebuild pump or motor.

Servo Valve Malfunctioning

Dirt in hydraulic system Clean system and replace filters.Worn or broken spool Replace spool.

Hydraulic pressure too low Manually operate valve in opposite direction for several seconds.

Loss of signal Check connections

Check Null positioning Null adjust the servo

Low / No Hydraulic System Pressure

Compensator is out of adjustment Readjust compensatorManifold relief valve out of adjustment Readjust relief valve set point.

Hydraulic reservoir empty Fill tank to proper level.

Pump suction line restricted Remove restriction or replace line if crimped.

Pressure line leaking Replace defective line or seal.

General hydraulics

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hydraulics Systems - Motors


Improper Motor Output Speed

Insufficient hydraulic system fluid will reduce motor speed

Fill reservoir level

Inadequate charge pressure Adjust charge system as necessary to obtain proper charge pressure

Inadequate pump output flow Check for proper pump speed and see that the pump is in full stroke. If not in full stroke determine why and correct

Low Motor Output Torque

Low system pressure at the motor will reduce torque generated by the motor

Measure system pressure at motor. If pressure limiter setting is low increase setting

Internal leakage will reduce system pressure

Check for internal leakage and repair or replace unit as required

System Operating Hot

System low on fluid Check fluid level in reservoir and add fluid until level is correct

Low charge pressure will overheat system Make necessary repairs to the pump to increase charge pressure

High system pressure will overheat system If the system pressure is high reduce loads on the system

Excessive Noise and or Vibration

Insufficient hydraulic f luid will lead to cavitation

Fill reservoir to proper level

Air in system will lead to cavitation Look for foam in reservoir and check for leaks on inlet side of system loop

Loose shaft coupling Replace loose shaft coupling or replace pump or motor

Improper shaft alignment Align shaft

Motor Will Not Turn Centrifugal Pump

Motor rotating inside coupler Replace coupling or motor shaftMotor not able to handle centrifugal pump load

Motor bypassing fluid. Check case flow is not excessive

147

Appendix

hydraulics Systems - Pumps


Noisy Hydraulic Pump

Low fluid level Check and add, if necessaryAerated fluid Check fluid levelContaminated fluid Drain fluid, f lush system, and replace

with good fluidRestricted pump suction Check pump suction filterPump operating at relief valve setting Verify motor is free to rotate and check

pump relief valve settingPump defective Replace pump

System Operating Hot

System low on fluid Check fluid level in reservoir and add if necessary

Low charge pressure will overwork system Make necessary repairs to the pumpHigh system pressure will overheat system If the system pressure is high reduce the

load on the systemPump operating at relief valve setting Verify motors are free to rotate and

check pump relief valve settingDefective fluid thermostat valve Verify valve is bad and replace valve

Air side of f luid cooler restricted or fouled Clean cooler with de greaser and high pressure water hose

Excessive Noise and or Vibration

Insufficient fluid will lead to cavatation Look for foam in reservoir and check for leaks on the inlet side of the system loops

loose shaft coupling Replace loose shaft coupling or replace pump or motor

Improper drive shaft alignment Align shafts

148


P RO C E S S f L Ow D i AG R A M

149

Appendix

MCM 2000 SOf TwARE TREE

150


VGLOSSARy

152



153

Glossary

AABANDONTo stop oil or gas production from a well when it becomes unprofitable.

ACCELERATOR A chemical additive that reduces the setting time of cement.

ADDiTiVEA material other than cement and water added to a cement after its manufacture to modify its properties.

ADMixTo add one material to another by mixing.

ALkALiAny base or hydroxide having the following properties: (1 ) solubility in water, (2) the power of neutralizing acids, and (3) the property of altering the tint of many coloring matters.

AMERiCAN PETROLEUM iNSTiTUTEThe leading standardizing organization on oil-field drilling and producing equipment; abbreviated API.

ANNULAR SPACESpace around a pipe in a well bore, the outer wall of which may be the wall of either the bore hole or the casing; sometimes termed the annulus.

ANNULUSSee Annular Space.

APiSee American Petroleum Institute.

AUTO LEfTIdentifying term used to specify which side of a truck is being talked about. This term is based on the driver’s viewpoint. Everything on the drivers left is auto left even when operating the truck. Other terms used are roadside, on side and “B” engine side when talking about the Seahawk. Duel pump units like the Slurrymaster or Seahawk

AUTO RiGhTThis term is used to describe which side of a truck is being talked about. Opposite of auto left. This term is based on the driver’s viewpoint. Everything on the right side of the truck as it is driven is auto right. Other terms used are curb side, offside and “C” engine side when discussing the Seahawk

GLOSSARy

154


BBALANCED PLUGA method of placing a plug: Pre flush, cement slurry, and spacer fluid are displaced down the drill pipe or tubing with mud until the cement level is about equal in the annulus and drill pipe or tubing. The pipe is then pulled, leaving the plug “balanced” in place.

BcSee Bearden unit of consistency.

BEARDEN UNiT Of CONSiSTENCyA standard value of measurement on the firmness of a cement slurry; abbreviated Bc.

BhCTSee bottom-hole circulating temperature.

BhSTSee bottom-hole static temperature.

BOTTOM-hOLE CiRCULATiNG PRESSUREThe pressure at the bottom of a well during circulation of any fluid. It is equal to the hydrostatic head plus the annular friction loss required to pump the fluid to the surface plus any back pressure held at the surface.

BOTTOM-hOLE CiRCULATiNG TEMPERATUREThe temperature of any fluid at the bottom of a well while it is being circulated; abbreviated BHCT.

BOTTOM-hOLE STATiC PRESSUREThe pressure at the bottom of a well after the well is shut in long enough to reflect ambient formation pressure.

BOTTOM-hOLE STATiC TEMPERATUREThe temperature attained at the bottom of a well after the well is shut in; abbreviated BHST.

BRADENhEADA type of casing head.

BRADENhEAD SqUEEzEThe process by which hydraulic pressure is applied to a well to force fluid or cement outside the well bore.

BREAkDOwN PRESSUREThe amount of pressure needed at the well head to rupture the formation in a fracture treatment or a squeeze job.

BRiDGiNG MATERiALFibrous, flaky, or granular material added to a cement slurry or drilling fluid to aid in sealing formations in which lost circulation has occurred.

155

Glossary

BULLhEAD SqUEEzEMethod of forcing well fluid into a formation ahead of the cement to contain the application pressure.

BUOyANCyThe apparent loss of weight of an object immersed in a fluid.

CCASiNGSteel pipe placed in an oil well as drilling progresses to prevent the wall of the hole from caving in during drill-ing and to provide a means of extracting petroleum if the well is productive.

CASiNG CEMENTiNGThe practice of filling the annulus between casing and hole with cement to prevent fluid migration between permeable zones and to support the casing.

CASiNG CEMENTiNG TEMPERATUREThe temperature of a cement slurry while it is being displaced at the maximum cementing depth in a casing cementing operation.

CASiNG hEADA heavy, flanged steel fitting that connects to the first string of casing and provides a housing for the slips and packing assemblies by which intermediate strings of casing are suspended and the annulus sealed off [also called a spool].

CEMENTA powder made of limestone, clay, and some other materials used as mortar and concrete.

CEMENT ChANNELiNGThe rising of cement between the casing and the bore hole wall when the slurry fails to rise uniformly through-out the annulus. CEMENTiNGThe application of a liquid slurry of cement and water to various points inside or outside the casing.

CEMENTiNG BASkETA collapsible or folding metal cone that fits against the walls of the well bore to prevent the falling of cement.

CEMENT PLUGA portion of cement placed at some point in the well bore to seal it.

CEMENT RETAiNERA tool set temporarily in the casing or well to prevent the passage of cement, thereby forcing it to follow another designated path. It is used in squeeze cementing and other remedial cementing jobs.

156


CEMENT SySTEMThe combination of materials which make up an oil-well cement slurry.

CiRCULATiNG PRESSUREThe pressure at a specified depth required to circulate a fluid in a well at a given rate.

CiRCULATiONThe movement of drilling fluid out of the mud pits, down the drill stem, up the annulus, and back to the mud pits.

CLiNkERThe finely powdered limestone and other matter fused together as the first stage in the manufacture of Portland cement.

COMPRESSiVE STRENGThThe degree of resistance of a material to force acting along one of the axes in a manner tending to crush it, usu-ally expressed in pounds of force per square inch of surface affected.

DDENSifyTo reduce or decrease the amount of mixing water in a slurry from normal to less than normal.

DiATOM (DiATOMACEOUS)(1) A microscopic plant that lives in water. (2) Dry land covered with a thick layer of diatom skeletons; this kind of earth is used for making dynamite and as a cement additive.

DiffERENTiAL PRESSUREThe difference between two fluid pressures; for example, the difference between the pressure in a reservoir and in a well bore drilled in the reservoir or between atmospheric pressure at sea level and 10,000 ft.

DiSPERSANTCement additive that reduces the initial consistency of cement slurries.

DRiLLiNG fLUiDAny substance, such as air or gas, water or oil base muds, circulated in a well during drilling operations.

DRy BLENDiNGThe process of admixing finely divided solid compounds.

EExTENDERAn additive put in drilling mud to increase viscosity without adding clay or other thickening material.

157

Glossary

ffALSE SETAn abnormal early thickening of cement slurry in which the slurry remains pumpable for the usual thickening time. The thickening may be reversible during the pumping history of the slurry.

fiLTERCAkEThe solid material deposited on a porous medium resulting from the filtration of the fluid part of a liquid-solid suspension.

fLUiD LOSS ADDiTiVEA compound added to the cement slurry or to drilling mud to prevent or minimize fluid loss.

fLy AShAn artificial pozzolan; residue of burnt coal.

fRiCTiON PRESSUREThe pressure (or head) lost by flowing water or other fluids as a result of the internal friction of the fluid and the friction between the moving fluid and the walls of the conduit.

GGiLSONiTEA naturally occurring solid hydrocarbon of the asphalt group whose granular form is sometimes used as a cement additive to prevent lost circulation.

GyPSUMA naturally occurring crystalline form of hydrous calcium sulfate.

hhEMATiTEAn iron oxide used as a weighting material in percentages by weight of cement.

hESiTATiON SqUEEzEA sub classification of squeeze cementing that can be used in either high or low-pressure applications.

hiGh-PRESSURE SqUEEzE CEMENTiNGThe forcing of cement slurry into a well at the points to be sealed with a final pressure equal to or greater than the formation break-down pressure.

158


hyDRATETo cause to combine with water.

hyDRAULiC CEMENTA cement that hardens or sets under water.

hyDROSTATiC hEADThe pressure exerted by a body of fluid at rest.

iiNNER STRiNG CEMENTiNGAlso called stab-in cementing, method by which the large-diameter casing string is cemented through drill pipe string into a special sealing sleeve in the casing shoe.

JJOiNTA single length (30 ft) of drill pipe, casing, tubing, or rod with threaded connections at both ends.

LLAMELLATEDComposed of or furnished with lamellae (thin plates composing the gills of a bivalve mollusk). Lamellated materials, such as mica and cellophane flakes, are used as cement additives to restore lost circulation.

LiGNOSULfONATEAn organic drilling fluid additive derived from by-products of a paper-makingprocess using sulfite; added to drilling mud to minimize fluid loss and to reduce the viscosityof the mud.

LiNERAny string of casing whose top is located below the surface.

LOST CiRCULATiONThe loss of quantities of whole mud to a formation, usually in cavernous, fissured, or coarsely permeable beds, evidenced by the complete or partial failure of the mud to return to the surface as it is being circulated in the hole. Lost circulation can lead to a blowout and in general reduce the efficiency of the drilling operation. It is also called “lost returns.”

159

Glossary

LOST-CiRCULATiON MATERiALA substance added to cement slurries or drilling muds to prevent the loss of cement or mud to the formation.

LOST RETURNSSee lost circulation.

LOw-PRESSURE SqUEEzE CEMENTiNGThe forcing of cement into the points in a well to be squeezed at a pressure not exceeding the formation break-down pressure.

MMUDThe liquid circulated through the well bore during rotary drilling and work over operations.

MULTiPLE-STAGE CEMENTiNGPlacement of cement slurry around the lower portion of a casing string followed by placement of successive upper stages through ports in a stage or port collar.

NNEAT CEMENTA cement with no additives other than water.

NEwTONiAN fLOwThe type of flow occurring in a liquid system in which shear rate is directly proportional to the shearing force. Mineral oils, for example, exhibit this type of flow at low shear rates.

NiTROGEN CEMENTiNGThe use of nitrogen to control increased hydrostatic pressure in annulus by injecting a precalculated volume of drilling fluid ahead of the cement slurry with nitrogen.

NON-NEwTONiAN fLOwFlow occurring a liquid system in which shear rate is apt directly proportional to the shearing forces.

160


OOiLMUDDrilling mud in which oil is the continuous phase; e.g., oil-base mud and invert-oil mud.

OUTSiDE CEMENTiNGA secondary cementing method conducted to fill the annulus completely; also called “top job” or “one-inch” job.

PPSMPrecision Slurry Mixer.

PAy zONEThe producing formation in an oil well.

PERfORATiONA hole made in the casing, cement, and formation through which formation fluids enter a well bore. Usually, several perforations are made at a time.

PERMEABiLiTyA measure of the ease with which fluids can flow through a porous rock.

PiDA mathmatical equation that a processor utilizes to tune a loop in a closed loop system.

PiLLA cement plug; a portion of cement placed at some point in the well bore to seal it.

PiTOTInstrument that allows one to measure the velocity of a fluid in relation to an immobile body or a moving body of a stable fluid.

PLUGAny object or device that blocks a hole or passageway (as a cement plug in a bore hole).

PLUNGERA sliding reciprocating piece driven by or against fluid pressure, especially a long valveless piston used as a forcer in a force pump, as a ram in a hydraulic press.

POPPET VALVEA device that controls the rate of flow of fluid in a line or opens or shuts off the flow of fluid completely.

161

Glossary

PORTLAND CEMENTThe product obtained by grinding clinker consisting essentially of hydraulic calcium silicates, to which no addi-tions have been made after calcination other than water and untreated calcium sulfate, except that additions not to exceed 1.0% of other materials may be interground with the clinker at the option of the manufacturer.

POzzOLANA natural or artificial siliceous material commonly added to Portland cement mixtures to impart certain desir-able properties. Added to oil-well cements, pozzolans reduce slurry weight and viscosity, increase resistance to sulfate attack, and influence factors such as pumping time, ultimate strength, and water tightness.

PRiMARy CEMENTiNGThe cementing operation that takes place immediately after the casing has been run into the hole; used to pro-vide a protective sheath around the casing, to segregate the producing formation, and to prevent the migration of undesirable fluids.

PUMPABiLiTyThe physical characteristic of a cement slurry that determines its ability to be pumped.

RRAMRecirculating Averaging Mixer.

RETARDERChemical compound used to prolong the thickening, setting, or hardening time of oil-well cements; the oppo-site of an accelerator.

REVERSE CiRCULATiONThe return of drilling fluid through the drill stem.

SSECONDARy CEMENTiNGAny cementing operation after the primary cementing operation. Secondary cementing includes a plug-back job, in which a plug of cement is positioned at a specific point in the well and allowed to set. Wells are plugged to shut off bottom water or to reduce the depth of the well.

SLURRyA plastic mixture of cement and water that is pumped into a well to harden; there it supports the casing and provides a seal in the well bore to prevent migration of underground fluids.

SPOOLSee casing head.

162


SqUEEzE CEMENTiNGThe forcing of cement slurry by pressure to specified points in a well to cause seals at the points of squeeze. It is a secondary-cementing method used to isolate a producing formation, seal off water, repair casing leaks, etc.

SURfACE PRESSUREThe pressure measured at the wellhead.

SURfACTANTA substance that affects the properties of the surface of a liquid or a solid by concentrating on the surface layer. Surfactants are useful because they ensure that the surface of one substance or object is in thorough contact with the surface of another substance.

TThixOTROPyThe property exhibited by a fluid that is in a liquid state when flowing and in a semisolid, gelled state when at rest.

TwO-STAGE CEMENTiNGPlacement of cement slurry around the lower portion of a casing string followed by placement of an upper stage through ports in a stage or port collar.

UUNiT Of CONSiSTENCyA standard value of measurement relating torque equivalent to degree of firmness of a cement slurry; replaced by the Bearden unit of consistency.

VViSCOSiTyA measure of the resistance of a liquid to flow.

VUGA cavity in a rock.

163

Glossary

wwAiTiNG ON CEMENTPertaining to or during the time when drilling or completion operations are suspended so that the cement in a well can harden sufficiently; often abbreviated WOC.

wEiGhTED SLURRySlurry to which a weighting material, such as hematite, has been added to the blend to make the slurry heavier than normal.

wELL BOREA bore hole; the hole drilled by the bit. A well bore may have casing in it or may be open (i.e., uncaged); or a portion of it may be cased and a portion may be open.

whiPSTOCkA long, steel casing that uses an inclined place to cause the bit to deflect from the original bore hole at a slight angle.

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Cementing Seahawk Skid Operator Manual V1.1