ADDITIONAL SYSTEM SPECIFICATION DETAILS

  1. General Specifications
    1. The PCTLR – 2007 is a trailer mounted high pressure pumping unit. The unit is comprised of a high pressure pumping system, recirculating mixing system, all required controls and instrumentation and a hydraulic system to drive fluid handling and mixing equipment.
    2. The high pressure pumping system consists of two diesel engines, two automatic transmissions, and two triplex pumps. The fluid handling system consists of centrifugal pumps for recirculation, boost and mix water. Manifold consists of necessary piping, valves and connections to perform cementing jobs.
    3. The triplex pumps are horizontal single acting plunger pumps and consist of fluid end and power end. The fluid ends are made of alloy steel and are recommended for pumping cement, acid, water, drilling fluids and other well service fluids.
    4. The mixing system consists of a high energy jet mixing system, high rate recirculating pump and tub agitator. The diffuser aids in removing air entrainment from bulk cement. A densitometer is mounted in the recirculating line and the mix water is measured with a turbine flow meter. The one compartment 1 M3 (7bbl) mixing tank maintains the ability to mix cement on the fly with good density control and provides adequate residence time for good cement mixing.
    1. A 20 bbl averaging tank allows for greater residence time, more mixing energy and density averaging. The averaging tank along with the mixing tank allows the batch mixing of up to 25 bbl of slurry for squeeze and plug jobs and other purposes that require 25 bbl or less slurry.
    1. The displacement tank consists of two 1.59 m3 (10 bbl) working volume compartments with "barrel" marks. Tanks have full flow piping to rear of unit for ease of cleanup.
The system is capable of mixing 2.3 m3/min (14.4bpm) and densities up to 2.7 g/cm3 (22 lb./gal). The following are included as part of the equipment specification:
      1. Dust Eliminator
      2. Third centrifugal pump for dedicated boost
      3. Control panel labeled in English or Spanish
      4. Control panel gauge units in English and Metric except for the high pressure gauges, which are not available in dual scale
      5. 1502 103 MPa (15,000 psi) treating iron and discharge manifold
      6. Triplex fluid ends, (1) pump w/3.5" Dia plungers and (1) pump w/4.5" Dia plunger
Note: Other plunger sizes are available.
  1. Environment Parameters
    1. Temperature
Minimum operating  20° C ( 4° F) Maximum Operating 55° C (130° F) (dessert operation)
    1. Humidity
Relative: 95%
    1. Vibration/Shock
Maximum shock: 1.5g
  1. Operational Performance
3.1 Job locations The unit is designed for land operations. 3.2 Component Size
  • Width: no component is greater than 2.58m (102 in.) Exception is the removable ladders that are greater than 102 in when deployed.
3.3 Pressure Range This unit has a maximum working pressure of 71.7 MPa (10,400 psi) w/3.5” plunger pump. This unit has a maximum test pressure of 103 MPa (15,000 psi) with 3.5” plunger pump. 3.4 Flow Rate Maximum theoretical total flow rate is 3.3 m3/min (21 BPM) 3.5 Density Range of Slurry Maximum slurry weight is 1.0   2.7 g/cm3 (8.33 22.6 lb/gal) 3.6 Slurry Mixing Capacity Range Mixing range will be 0   2.3 m3/min (0   14.4BPM) 3.7 Automatic Control Density Tolerance When mixing in automatic control mode the density ranges can be controlled to within +/- 0.01 to 0.024 g/cm3 (±. 083 to .200 lb./gal) of indicated densitometer reading during near steady state operations. This assumes reasonable steady output of bulk delivery system. 3.8 Continuous Working Time at Rated WP of 70 MPa (10,200 psi): 2 hours 3.9 Continuous Working Time at Maximum Flow Rate: >1 hour
  1. Power System
Two (2) diesel engines drive two (2) high pressure triplex pumps via automatic transmissions and flexible drivelines. 4.1 Diesel Engines CAT C13, Tier II emissions is available). Rated Power 365 kw (475 hp) Rated Speed 2100 rpm Lube oil pump and filter and cooling system Fuel pump and filter system 4.2 Engine Accessories Mode of Starting: Electric starter Cooling: Engine jacket water is a closed loop circulating system with air to water radiators. Air filter (dry element type) Engine governor Mechanical /variable speed Throttle actuator Stop actuator Emergency kill actuator for air intake shutdown Stainless steel muffler with flexible stainless steel connection Air compressor – one included Alternator – one included
  1. Power Distribution System
5.1 Transmissions Allison 4700 OFS automatic transmission, complete with fill tube, dip stick gauge, torque converter, and 1800 series output flange. Gear ratios as follows: 1-st gear 7.63 2-nd gear 3.51 3-rd gear 1.91 4-th gear 1.43 5-th gear 1.000 Gear ratios are selected manually, Reverse   Blocked out
5.2 Transmission Accessories
  • Torque converter to go in lock up mode: 0.96 efficiency
  • Oil pan with level gauge and filler tube
  • Oil Filter (spin on), positioned for easy access
  • Engine driven power take offs are used for driving hydraulic pumps and triplex pump lube pump.
  • An engine mounted water to oil tube and shell cooling system is used to cool the transmissions at maximum sustained horsepower output at 120º F ambient temperature without exceeding maximum allowable temperatures.
5.3 Drivelines Heavy duty drivelines are used between the transmissions and triplex pumps. They are built with heavy duty universal joints using 1800 series components.
  • Installation of drivelines is such that the manufacturer's maximum recommended angle is not exceeded.
  • Each driveline is equipped with a metal guard assembly complete with greasing access.
  1. High Pressure Pumping System
6.1 Triplex Pumps The Serva TPA 600 triplex pumps are good for high pressure well service. Each pump is equipped with an integral gear reduction box. The triplex pumps are designed to pump cement slurries, sand laden fluids, crude oil, acids, mud and other oil well servicing fluids. The pumps have the following specifications.
  • Type of pump: horizontal triplex single acting reciprocating plunger
  • Maximum Input Brake Horsepower: design capacity 447 kw (600HP)
  • Hydraulic Horsepower: performance w/engine spec (estimated) 283 kg (380HP)
  • Pressure rating
88.9 mm, (3.5 in) Dia plunger: 71.2 MPa (10,400 psi) 114.3 mm (4.5 in) Dia plunger: 43.4 MPa (6,290 psi)
  • Flow Rate at Rated WP (limited by estimated Hydraulic Horsepower):
w/3.5" Dia @ 10,400 psi: .16 m3/min (1.0 bpm) w/4.5"Dia @ 6,290 psi .26 m3/min (1.7 bpm)
  • Maximum flow rate
3.5" Dia plunger (1) Pump 1.27m3/min (8.0 bpm) 4.5" Dia plunger (1) pump 2.0 m/min (13.0 bpm) Total 3.3 m3/min (21. bpm) theoretical Volumetric Efficiency (estimated) 0.97 Mechanical Efficiency (estimated) 90%
6.2 Power End Lubrication System Positive displacement pumps driven by PTOs mounted to the Allison transmissions supply the lubrication system for the triplex pump power ends. The power end lubrication system contains: Lube oil reservoir Pressure relief valve Required plumbing and hoses Pressure gauge Temperature gauge Full flow filter Suction strainer 6.3 Plunger Packing Lubrication System The plunger lubrication system is provided by a pressurized oil supply system. The packing lubrication system contains: Lube oil reservoir Distribution manifold Required plumbing and hoses pressure gauge pressure regulator Flow control valves for each plunger with setting locks
  1. Fluid Handling System
7.1 Fluid Displacement Tank The displacement tank full capacity is approximately 25 bbl. and has a working volume of 20 bbl. It consists of two 1.59 m3 (10 bbl) compartments each having graduated markers measuring in increments of 1 bbl. The tank and piping manifold is constructed of steel with reinforced structures. The discharge ports from the displacement tank are 152.4mm (6 in) butterfly valves leading into a 127 mm (5 in) pipe that provides good velocity for gravity flow to boost pump and triplex pumps. A flow back release line is provided to allow the triplex pumps pressure to be discharged into the displacement tank. Standpipes provide overflow protection with (3 in) butterfly valves located under the displacement tank. These valves are connected to drain hoses to direct over-flow to desired location. Drain valves are 76.2 mm (3 in) and connect to the over-flow line. They allow the draining of each tank compartment. The piping manifold is designed with sufficient couplings to allow complete disassembly of the piping. Low pressure piping:
  • The suction manifold has a working pressure rating of 1.2 MPa (175 psi). The manifold includes various butterfly valves, which are convenient to operate, and various flanges, couplings, union connections, pipe and fittings that are easy to connect.
  • Fluid from the mixing tank connects to both the recirculating & boost pumps or to the suction manifold for the two triplex plunger pumps. Fluid from the recirculating pump
can be pumped into mixing tank via the densitometer and slurry mixer and into the suction manifold of the triplex pumps.
  • Remote valves that are required for normal operation are air actuated.
  • The suction manifold for the transfer pump is supplied from either the displacement tank, averaging tank or the mixing tank. The suction manifold of the triplex pumps is supplied by either the transfer pump or gravity fed from the line connecting the displacement tank and the transfer pump.
  • A 76.2mm (3in.) fill manifold for filling the displacement tank from an external mud or water supply is equipped with 76.2mon (3 in.) butterfly valves, and 76.2mm (3 in.) union joints. An over pressure relief valve is included to protect the system from receiving fluid with too much pressure.
7.2 Cement Mixing System The mixing system is a high energy recirculating slurry mixer type. It consists of a high-energy eductor mixer, diffuser, mixing tank, agitator and recirculating and mix water pumps. The mixer design maximizes wetting of all cement by forcing the dry bulk cement into a high energy confluence of 4 annular water jets, 4 annular slurry jets and a central slurry jet. The mix water centrifugal pump and the recirculating centrifugal pump provide most of the high energy. The diffuser aids in removing air entrainment from the bulk cement and eliminates dust in the mix tank. The 1.27 m (7bbl) mixing tank allows adequate residence time for good mixing and averaging of density with varying bulk cement delivery. The deep tank design provides good pump head and minimizes vortexing and cavitation. A hydraulic driven paddle agitator provides improved mixing and a more homogenous slurry. The mixing capacity range is 0   2.3 m3/min (14.4bpm) with mixing density range of 1.0 2.7 g/cm3 (8.33 22 lb./gal). The mix tub piping delivers fluid to the suction manifold of the recirculating centrifugal pump via 152.4 mm (6 in) piping. The triplex pump suction normally receives fluid from a 4 in. manifold and 102 mm (4 in) butterfly valves. 7.3 Mixing Centrifugal Pump The 4x3 mixing centrifugal pump will meet the following specification. Suction: 101.6  (4 in) pipe size Discharge: 76.2  (3 in) pipe size Flow rate at 110 psi: 1.65 m3/min (10.4 bpm) Maximum closed-in pressure: 1.17 MPa (170 psi) The mixing centrifugal pump takes on fluid from external sources or the displacement tank through a manifold with 101.6 mm (4 in) union connections. The pump can discharge fluid into the mix tub or displacement tank. 7.4 Recirculating Centrifugal Pump The dedicated 6X5 recirculating centrifugal pump has the following specifications. Suction: 152 mm (6 in) pipe size Discharge: 127 mm (5 in) pipe size Max. flow rate at 64 psi: 3.7 m3/min (23 bpm) Maximum closed-in pressure: 0.49 MPa (70 psi) The recirculating centrifugal pump is capable of receiving fluid from the mix tub and from the displacement tank via the mix tank. The recirculating pump can discharge fluid into the mix tub for recirculating or into the suction manifold of the triplex pumps.
7.5 Boost Centrifugal Pump The dedicated 6x5 boost centrifugal pump has the following specifications. Suction: 152 mm (6 in) pipe size Discharge: 127 mm (5 in) pipe size Flow rate at 64 psi: 3.7 m3/min (23 bpm) Maximum closed-in pressure: 0.49 MPa (70 psi) The boost centrifugal pump is capable of receiving fluid from the mixing tank, averaging tank and from the displacement tank. The boost pump can discharge fluid into the mix tub for recirculating or into the suction manifold of the triplex pumps. Note: The recirculation and boost pumps are dedicated pumps for their respective functions but in case there was a problem with either pump, the other pump can take the place of the inoperative pump or can take both functions at the same time at a reduced rate.
  1. Hydraulic System
The hydraulic system consists of independent systems: one for closed hydraulic pumps and the other for agitator open loop systems. Each system contains its own 160 liter (42 gal) stainless steel reservoir with sight gauge, filtration system, and heat exchanger. The closed loop system is powered by an auxiliary 260 HP skid and drives the following components: Recirculating pump Boost centrifugal pump Mixing water centrifugal pump. The open loop system is powered by the main cementing skid engines and drives the following components: Mix tub agitator Averaging tank agitator Automatic Control Mixer (ACM) power for Metering Valve actuator
  1. High Pressure Discharge Manifold
Each of the triplex pump fluid ends has 50.8nim (2 in) API type 1502 threads. Each pump discharge has 50.8min (2 in) 1502 integral plug valves. The two triplex pumps are manifolded together and configured so as to be capable of discharging singularly or simultaneously to the same outlet or different outlets. A flow back manifold (connected to the opposite side of the pump) connects to the pressure release line with an open end connected to the displacement tank. Two 50.8min (2") X 25.4mm (1") 1502 integral plug valve, one for each pump, controls the release line. Each of the pump discharge lines has a pressure transducer and 105MPa (15,000 psi) pressure gauges. A master discharge valve, 50.8 min (2 in) type 1502 integral plug, is located between the manifold and the discharge pup joint. The discharge manifold/valves are mounted firmly by a heavy duty mounting system.
  1. Operation and Display System
10.1 Operator Console The Operator console is a custom built stainless steel cabinet with a protective stainless steel cover. The instrument panel is stainless steel with permanently engraved labeling in English. The location of the console allows the operator a full view of the various instruments and gauges of the console. 10.2 Deck Instrumentation
  • The engine gauges includes tachometers, oil pressure gauges, water temperature gauges, voltmeter, and warning lights that indicate low engine oil pressure and high water temperature.
  • The transmission gauges includes the main oil pressure, lock up clutch indicator light, oil temperature and fluid level gauge.
  • The triplex pump gauges includes oil pressure gauge, oil temperature, and an oil gauge. The pressure and temperature gauges are switch gauge type and activate a warning light whenever a certain level is reached. An over pressure warning light indicates over pressure for the triplex pump discharge pressure.
  • A transducer mounted on the triplex fluid-end is connected to a pressure gauge measures discharge pressure. A proximity switch at the input to the triplex pump measures pump displacement rate.
  • The hydraulic system has pressure gauges for each pump circuit and an oil temperature gauge mounted in the console.
  • Console mounted pressure gauges are liquid filled with dual scale face reading in standard U. S. units and metric units.
  • Most gauges and instruments read in both standard U. S. units and metric units.
  • Mixing pump is equipped with a flow meter and pressure gauge.
  • The recirculating/boost pump is equipped with a pressure gauge.
10.3 Density Control The cement mixing system can be operated in a manual or automatic mode. In manual mode the operator uses a manually operated hydraulic control valve to control the cement metering valve. In the automatic mode, an electro-hydraulic control system operates the cement metering valve. The electro-hydraulic system is controlled by an industrial process controller/computer. The slurry density can be quickly reduced by the use of a bypass line (connected to the recirculation pump suction).
ADDITIONAL SYSTEM SPECIFICATION DETAILS
Mixing: Mix Water Metering Valve approximate maximum capacity: 1.9 m3/mm (436 gal/min) High Pressure Triplex Pumps: Estimated Pump Performance: (Based on Estimated Hydraulic Horsepower of 380 HP)
Serva TPB 600 w/ 88.9 mm (3.5 in) Dia plunger

GEAR

m3/min (gpm)

MPa (psi)

1

.163 (42)

(10,400)

2

.408 (108)

(6,025)

3

.640 (169)

(3,850)

4

.926 (246)

(2,645)

5

1.29 (340)

(1,914)

Serva TPB 600S w/ 114.3 mm (4.5 in) Dia plunger

GEAR

m3/min (gpm)

MPa (psi)

1

.27 (70)

(6,290)

2

.67 (176)

(3,697)

3

1.05 (278)

(2,340)

4

1.53 (406)

(1,602)

5

2.1 (562)

(1,158)

High Pressure Discharge Manifold and Valves:
  • All components are made of API type 1502 components and have a rating of 103 MPa (15,000 psi) at cold working conditions.
  • The triplex pumps have working pressures that are less than 103 MPa (15,000 psi). See individual pump specifications for operating pressure limits.
Hydraulic Systems
  • Hydrostatic Transmissions (Mix Water, Boost and Recirculating Pumps)
  • 41.4 MPa (6000 psi) maximum
  • 37.9 MPa (5500 psi) continuous
    • 20.7 MPa (3000 psi) Maximum Tank Agitator
Options: a. Standard engines for this trailer are USEPA Tier II certified. USEPA now requires Tier II certified engines for US locations. Tier I engines are still available with some cost savings.
Options not included but recommended:
    1. Displacement tank agitators – used when liquid additive system is used or when mixing spacers prior to cementing. This is a good option for spacer mixing even if there is no liquid additive system.
    2. ServaView remote data recording and display software. Standard unit is wired to accept ServaView.