SECTION

Section

15
Preface

Mixing System Problems and

FLECS Controller Operation
FLECS Controller Operation
FLECS stands for the Flexible Electronic Control System. The FLECS Manual (Part No.
101324382) provides specific information about this component as well as some operational
information. Much of the FLECS controller interface and operation is similar to that of the
Azonics 2500 controller. Additional information can be found at the FLECS controller technical
website:

http://halworld.halnet.com/HES/Hesps/hespspe/hespspe_fracacid/hespspe_fracacid_eqflecs/h
espspe_fracacid_eqflecs.asp

RCM® IIIr Mixer

The ELITE™ trailer is equipped with an RCM® IIIr mixer with an 8-bbl mixing tub. The volume
capacity of the premix side of the tub (from the bottom to the top of the weir) is 5 bbl. The volume
of the downhole side of the tub is 3 bbl. Access holes are located on both the premix and
downhole sides of the tub. Both access holes include covers that enclose the tub and prevent
splashing during mixing.

The RCM® IIIr mixer with rotary-jet water valve shown in Figure 5.1 (Page 5-2) is very similar
to the standard RCM® IIIr mixer, but the new mixer includes a built-in jet for metering water.
Although this model is more expensive than the standard mixer, which meters water with a 2-in.
ball valve, it is capable of jetting water into the mixer at a higher velocity, thereby increasing
mixing energy.

Figures 5.2 and 5.5 (Pages 5-4 and 5-7) are simple breakdowns of the parts necessary for
assembling the RCM® IIIr mixer with rotary-jet water valve. Table 5.1 (Page 5-8), shows the part
numbers and descriptions for each numbered location on the diagrams.

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The RCM® IIIr mixer with the rotary-jet water valve contains an inner sleeve with 27 jet holes
arranged in nine staggered vertical columns and three staggered horizontal rows. The total length
of holes is identical to the width of the drop-in insert, which is located in the center of the mixer.

A plug that can be rotated on either end is mounted snugly inside the sleeve. This rotating plug
is hollow with two rectangular cutouts. In the closed position, the solid portion of the plug covers
the 27 jet holes. When the metering plug is rotated, the rectangular cutout portion of the plug
covers the jet holes and allows water to flow through the plug, the sleeve, and the mixer in a
velocity jetting pattern.

dn000375

Figure 5.1—RCM® IIIr mixer with rotary-jet water valve

The metering plug and sleeve are contained within another sleeve that is permanently welded to
the mixer body. This outer sleeve contains a window opening that allows water to flow to the
center of the mixer. The metering plug slides within the sleeve, allowing the solid portion of the
plug to completely cover the jet holes.

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The rotary actuator, which is prebolted onto the end plate, is normally fully turned to the closed
position. When the endplate containing the rotary actuator is installed with the actuator in the closed
position, it will align with the metering plug in the closed position, holding the plug in place and
thereby closing the entire rotary-jet valve.

The rotary-jet valve uses two sizes of O-rings. Four small O-rings are mounted on the metering
plug, and four large O-rings are mounted on the sleeve. Grease holes and a grease ring are machined
into the sleeve, allowing grease to flow from the sleeve into the cavity between the sleeve and the
metering plug. Teflon® wear rings are included on each end of the metering plug to better support
the constant torque that the metering plug will encounter, increasing the life of the O-rings.

May 2005 Mixing System Problems and FLECS Operation 5-3

5-4
7 10 3 10 7
dn000376
Elite™ Cementing Trailer Manual

Note: Assemble after mounting

plate to acutator. (See Section E-E.)

14 5 14 4
13 6 13 5 9 2 9 13
E

Mixing System Problems and FLECS Operation

15
E
Top

15 4×
LOC 5 -1 has counterbored
holes for bolting actuator.
9° See Section E-E.
Section E-E

Front view

Figure 5.2—Parts breakdown of RCM® IIIr mixer with rotary-jet water valve (front and rear views)

May 2005
 Elite™ Cementing Trailer Manual

1 REF
(1/4 NC × 1)
(1/4 NC nut) Ring on mixer
with countersunk holes
(4 × 3/8 NC × 1 (.25)
with flat and
lock washer Flat washers for
10

spacers after
8
6

4
2
0
installation sheath
(1/4 NC × 1) (LOC 8) should
(1/4 NC nut) rotate in slot. 18

(1/4 NC jam nut) 8 REF

Section B-B
Detail A

11

See Detail A

8
dn000133

B
Side View

Figure 5.3—Side view of RCM® IIIr mixer with rotary-jet water valve

May 2005 Mixing System Problems and FLECS Operation 5-5

 4 15 REF

5-6
See section B-B

13 14 REF

8 REF
dn000134

B
12
Elite™ Cementing Trailer Manual

C C

12

Mixing System Problems and FLECS Operation

D
Install these bolts 1 REF
after actuator (LOC 4) TOP
is bolted to flange. TOP
See Section E-E. 14 9 9
(4× 3/8NC × 1 1/2 with 10 10 3
9 5
lock and flat washer) 3
7 7

See Detail A
F/installation
of LOC 6
5 -1
5 -2
2
2 Make sure when LOC 2
is installed that water inlet Make sure when LOC 2
hole is facing this opening. is installed that jet holes
SECTION D-D are facing this opening.
SCALE 3/4
D SECTION C-C
SCALE 3/4

May 2005
Figure 5.4—Top and cutaway views of RCM® IIIr mixer with rotary-jet water valve
 4 5

May 2005
15

11

Note: Assemble after

mounting plate to
Qty 4 actuator.
7 14
10
1
3
12
10 12
9
7
2

9
dn000377

5 8

6
Qty 4
13

Mixing System Problems and FLECS Operation

Figure 5.5—Parts breakdown of RCM® IIIr mixer with rotary-jet water valve
Elite™ Cementing Trailer Manual

5-7
Elite™ Cementing Trailer Manual

Table 5.1—Parts Breakdown of RCM® IIIr Mixer with Rotary-Jet Water Valve

Find SAP No. Qty Material Description

1 101207816 1 Weldment - mixer - cement - low profile - with cylinder and flanges -
rotary-jet water valve

2 101207817 1 Sleeve - jet - rotary-jet water valve - 27-hole pattern - 5/16-in. holes

3 101207818 1 Plug - metering - rotary-jet water valve - for 27-hole jet - symmetrical
design

4 101207819 1 Actuator assembly - rotary - 90° - rotary-jet water valve

5 101207868 1 Kit - endplates - rotary-jet water valve - for manual and automatic
operation

6 101207888 1 Indicator - handle stop with position scale - mounted right of water
inlet - rotary-jet water valve

7 101208095 2 Ring - wear - Teflon - for metering plug - rotary-jet water valve

8 101208098 1 Sheath - splash - mixer - 72° opening - 9 5/16 in. long

9 100001962 4 O-ring, 90 duro, 2 7/8 × 2 1/2 × 3/16 568-333, spec. 599.33001 spec.
70.72000

10 100001957 4 O-ring, 90 duro, 2 3/8 × 2 × 3/16 568-329, spec. 599.33001 spec.

70.72000

11 101216037 1 Insert, mixer, low profile, 4.5 in. ID, Nylatron, RCM® IIIr mixer with
rotary-jet water valve

12 100024702 2 Fitting, grease, 1/8 MPT, straight, stainless steel E10001 alemite
1961-S

13 Fastener 4 Screw, hex cap, 3/8 NC × 1 with flat washer, lock washer, and nut

14 Fastener 4 Screw, hex cap, 3/8 NC × 1 1/2 with flat washer, lock washer, and nut

15 100028236 4 Screw, hex socket, 5/16-18 NC × 3/4, spec. 70.43270

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Mixer Assembly Instructions

The following instructions describe the process of assembling the mixer. If these instructions are
not followed, the mixer could be damaged or may not work properly. Use Figures 5.2 to 5.5 (Pages
5-4 to 5-7) as guides for assembly.

Installing the Sleeve

1. Push the sleeve (2) into the cylinder on the weldment.
2. Align the 27-hole jet pattern and the 2-in. main inlet with the appropriate openings on the
weldment.
3. Push the sleeve through the weldment approximately 4 in. and install two O-rings (9) on
the end of the sleeve.
4. Apply grease to the O-rings and the surface around the O-rings.
5. Carefully push the sleeve back through the weldment and repeat the procedure on the other
side.
6. Carefully return the sleeve to its original position with it aligned according to Step 2. While
returning the sleeve to its original position, place your other hand through the top of the
weldment and compress the O-rings with your fingers as they pass by the leading edge of
the window opening. This will prevent the O-rings from tearing.

Note To reduce the chances of tearing, install O-rings separately on each end of the
sleeve so that they contact the window opening in the weldment as little as
possible.

Installing the Metering Plug

1. Install two of the O-rings (10) on the metering plug (3).
2. Lightly grease the O-rings and area around the O-rings.
3. Carefully slide the metering plug (3) inside of the sleeve (2).

Important Be careful when installing the metering plug inside the sleeve. Although the
inside diameter of the sleeve has a fine finish, the two O-rings could be damaged
if the installation is not performed slowly and carefully.

4. Push the metering plug all the way through the sleeve so that the grooves for the O-rings
on the other side are just barely visible.
5. Install the other two O-rings (10) on the metering plug (3).

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6. Apply grease to the O-rings and the surface around the O-rings.
7. Carefully slide the metering plug back inside the sleeve so as to minimize damage to the
O-rings.
8. Align the metering plug so that the solid portion of the center section covers the 27 holes.
The metering plug is symmetrical and can be correctly mounted in two of four possible 90°
rotations.
9. Lightly grease the Teflon® wear rings (7) both inside and out.
10. Install the wear rings (7) on either end of the metering plug.
11. Ensure the sleeve is aligned properly as in Step 2 of “Installing the Sleeve” (Page 5-9).

Installing the Endplates and Indicator

1. Locate the two endplates (5). The tabs on the sleeve are opposite and out of phase from each
other.
2. Facing the rotary-jet water valve from the 2-in. water inlet, properly mount the 1/4-in. thick
endplate (5) on the right side of the mixer. Rotate and flip the endplate as required so that
the tabs of the sleeve fit into the notches of the endplate.
3. Locate the indicator (6) and attach it to the ¼-in. thick endplate. Lock down the set collar
and the bolt to secure it in place.
4. Insert and finger-tighten the bolts through the weldment, endplates, and indicator. Lubricate
all bolts with Never-Seeze™ compound to prevent galling of the threads.

Mounting the Actuator Assembly

1. Secure the actuator assembly (4) in a vice with the mounting surface facing up.
2. Open the ¼-in. hydraulic bypass valve.
3. With Never-Seeze™ compound, lubricate the square bore of the actuator and the
socket-head screws.
4. With a square 5/8-in. piece of bar stock or similar tool, rotate the square bore of the actuator
counterclockwise, or left-hand rotation, until it stops.
5. Close the 1/4-in. bypass valve.
6. Mount the actuator assembly (4) to the 3/4-in. endplate. The endplate has two sets of mount-
ing holes for the actuator assembly. With the actuator assembly turned at a 9° angle as
shown in Section E-E of Figure 5.2 (Page 5-4), screw the actuator assembly to the endplate
with lubricated socket-head screws (15).

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Completing the Mixer Assembly

1. Carefully slide the assembled actuator assembly and endplate onto the weldment and
metering plug. The notches in the endplate should align with the tabs on the sleeve and the
side of the endplate labeled “top” should be facing upward.
2. Lubricate all bolts with Never-Seez® compound to help prevent galling.
3. Insert bolts through the weldment and endplate and finger-tighten them.
4. Ensure that the sleeve alignment is oriented as in Step 2 of “Installing the Sleeve” (Page
5-9).
5. Ensure that the metering plug alignment is oriented as in Step 8 of “Installing the Metering
Plug” (Page 5-10).
6. Tighten the bolts on either end of the rotary-jet water valve.
7. Secure the mixer assembly and open the ¼-in. hydraulic bypass valve.
8. Install the pointer that comes with the indicator (6), as in Detail A of Figure 5.3 (Page 5-5).
9. With a suitable wrench, rotate the metering plug clockwise or right-hand rotation 64° to
verify correct assembly.
10. Look through the 2-in. inlet to verify that water jets are opening from the top down as the
metering plug is rotated. If this does not occur as described, stop and investigate what step
was done incorrectly.
11. Return the rotary-jet water valve to the zero mark and close the ¼-in. bypass valve.
12. After installing the sheath (8), verify that it will open and relatch as designed.

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Elite™ Cementing Trailer Manual

Mixing Problems

Erratic Cement Delivery

Poor bulk delivery to the mixer is the most common problem that can affect a uniform slurry blend.
Any RCM® mixer, whether ADC® mixing system-controlled or not, requires a constant supply of
cement to help ensure consistent slurry density. Eventually, the slurry weight will be affected if the
bulk delivery is substandard. Common causes of poor bulk delivery include the following:

• The bulk tank has a faulty or worn compressor. Repair the compressor when it shows signs
of wear to prevent below-normal air pressure.
• The aeration pads in the bulk tank are dirty. Clean these pads periodically so cement will
be sufficiently aerated to avoid packing problems.
• The cement delivery lines are too long. Keep delivery lines to the unit as short as possible and
ensure that they have a minimal number of bends. If the cement must enter the unit from a long
line, equip the line with purges that can be used to open it in the event of a blockage.
• The cement blend has been stored in the bulk tank too long. If the cement is a weighted
blend or has been in the unit for some time, aerate the cement in the tank thoroughly to “fluff it
up” before the job begins.
• The venting system contains cement residue or is not fully operational. On offshore units
and land units equipped with a steady-flow bin, ensure that the venting system is clean and in
good operating condition before starting a job.

Below-Normal Recirculation Rate on a 6 × 5 Pump

For consistent mixing of the slurry blend, the energy inside the mixer must be sufficient. Most of
this mixing energy is created by the Halliburton 6 × 5 recirculation pump, and a rate of 13 to 16
bbl/min of recirculation flow should be maintained. The following problems can affect the
recirculation flow rate:

• The engine speed is too slow. The engine driving the 6 × 5 centrifugal pump should operate at
1,400 to 2,000 rev/min to help ensure good recirculation flow.
• The centrifugal pump is worn. Check the condition of this pump periodically. Maintain
proper impeller clearances, and replace the impeller if it is worn. Verify that the seals in the
pump are in good condition.
• The 6 × 5 pump suction line is restricted. If the system seems to recirculate water efficiently
but tends to slow down with heavier, more viscous fluids like slurry, the suction line may be
restricted. Check the sump area in the mixing tub and the suction line to the 6 × 5 centrifugal
pump, and verify that neither contains cement buildup.

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Aerated Slurry
Many slurries containing salts and other chemicals become aerated when they are recirculated or
stirred vigorously. The aeration may be caused by slurry properties or mechanical failure such as
leaking seals in the centrifugal pump. This slurry aeration can cause the centrifugal pump to lose
partial prime or stop pumping completely, allowing dry powder to accumulate in the mixing tub.
Take the following steps to recognize and help prevent slurry aeration:

• Ensure that the unit’s 6 × 5 recirculation pressure gauge functions correctly. When the
centrifugal pump is properly primed, the discharge pressure should be 25 psi or greater. A drop
to 10 psi indicates that the slurry is aerated.
• Verify that the water level in the mixing tub is at least in the center of the agitator blades before
you add dry cement to bring it up to weight.
• Do not allow the mixing water to circulate at a high rate for a prolonged period of time before
you begin cement delivery.
• Rotate the agitators at a speed that achieves good blending but does not churn air into the slurry.
Rotate agitators at a high rate only when dry cement or lumps are present in the tub; the
accelerated rotation helps break up the dry material. As soon as the tub has “leveled out,” slow
the agitator to approximately half-speed.
• Verify that cement delivery is constant and pressure on the tank is 15 to 20 psi (9 to 10 psi on
steady-flow separators). Excessive air sometimes enters the tub from the bulk unit because of
erratic cement delivery or an excessively high compressor setting.
• When the cement blend is brought up to weight, deliver it quickly from 8.33 lb/gal (water) to
12 lb/gal, the critical range on these blends. Some cement slurries tend to create air. Add a
defoaming agent to the slurry to control the aeration level when appropriate. Do not circulate
“air-prone” slurries at a high rate for a prolonged period.

Heavyweight or Thixotropic Slurries

Heavyweight or thixotropic slurries have minimal water content and approach the upper limits of
mixing capabilities. The minimal water-to-cement ratio can cause improper wetting of the cement
entering the mixer, resulting in a poor-quality blend in the mixer. If necessary, begin mixing at a
low rate and increase the mix rate in small increments until the required rate is attained. Improper
wetting of the cement occurs most often if bulk material is added too quickly, especially at the start
of continuous mixing or if density fluctuations are extreme.

Note Engineers design slurries in labs tests with Waring® Blenders. There is little
correspondence between the kinds of materials that can be mixed in a lab blender
and those that can be blended by an RCM® mixer.

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Elite™ Cementing Trailer Manual

At the start of continuous mixing, the operator cannot easily determine exactly where to set the
throttling valve. If the throttling valve is opened too far, the system can become overwhelmed with
excessive cement and air.

Begin mixing at a lower rate. When the proper valve position is determined for the low mixing rate,
increase the mixing rate and the corresponding valve position from the benchmark that has been
established. When using this technique, you may find that the slurry cannot be mixed at the required
rate. When the prescribed rate is approached slowly in increments of approximately 0.5 bbl/min,
small clumps will begin to appear in the mixing tank. These clumps indicate that the upper limit on
the mixing rate has been reached.

Significant density fluctuations, especially on the lower end, result in an overreaction on the
throttling valve position as the valve attempts to recover. This situation can easily lead to too much
cement and air in relation to the volume of water being pumped into the mixer. Make small
adjustments in the throttling-valve position to help ensure that the density does not drift too far from
the setpoint for continuous mixing. Density fluctuations generally occur either at the start of the job
or when poor bulk delivery causes the density level to drop well below the setpoint.

Inability to Maintain Density Setpoint

If the density setpoint cannot be maintained and remains just under the required level, you should
recognize the problem and take appropriate steps to bring the density level under control. The
following factors may be responsible for this situation:

• Outrunning the Bulk Supply. The maximum normal delivery rate from a bulk system will
average 35 to 40 sacks/min. If the delivery is below this level but the density cannot be
maintained, lower the mixing rate to match the delivery from the bulk supply. Achieving the
proper density on slurry going downhole is more vital than maintaining the high mix rate.
• Blocked Cement-Throttling Valve. A rock or other obstruction may be lodged in the 5-in.
master cement valve or in the opening to the mixer.
• Blocked Throat in the Mixer. Cement that has accumulated between the cement-throttling
valve and the water jet in the mixer can cause the mixer cement inlet to become blocked. This
problem is more prevalent when thixotropic slurries and blends with high-gel concentrations
are mixed. Clean the area thoroughly after each job to help prevent buildup. However, if the
bulk delivery is higher than normal or if the slurry level in the tub is allowed to become too
high, splashback will continuously wet the area above the water and recirculation jets.
This splashback can eventually cause buildup in the inlet to the mixer. To avoid splashback, do not
allow the vacuum breakers to become clogged with cement. If the vacuum breakers are clogged, the
resulting vacuum will pull water backward into the cement-throttling valve and can create the

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buildup. If the vacuum breakers are not kept clean and in good operating condition, the water can
eventually migrate down the bulk line.

Warning Do not plug a vacuum breaker to prevent dry cement from being deposited
onto the tub.

Dry Cement Entering the Mixing Tub

Occasionally, dry cement material may float on top of the slurry in the tub, eventually causing the
mixer to become clogged. If this condition occurs, the recirculation pump will lose prime and cause
the mixing operation to shut down. You must constantly monitor the density readout on the Unipro
II™ controller and the tub condition. The factors in the following section can contribute to dry
cement entering the mixing tub.

• Erratic Bulk Delivery. If the bulk unit cannot deliver cement to the mixer efficiently because
of poor aeration or low air pressure, you may have difficulty controlling the cement-metering
valve to bring the correct proportion of cement into the tub. When the tub density drops rapidly,
do not open the throttling valve too much. If the throttling valve is opened too much, it is
difficult to lower the setting quickly enough to prevent a large slug of cement from entering the
mixer when good bulk delivery is re-established.
• Inadequate Recirculation Pump Flow. Increase the recirculation pump speed, or add a
defoaming agent to the slurry if it is aerated and is causing the recirculation pump to lose prime.
• Agitators Rotating Too Slowly. Increase the agitator speed if the slurry contains lumps or
small amounts of dry materials.
• Improperly Designed Cement Slurry. Some cement blends do not have the water-to-cement
ratio necessary to achieve their required densities. This improper ratio results in dry cement in
the tub when the bulk flow is not consistent or is increased too rapidly. Check cement blends
thoroughly to help ensure that they can be mixed with good results.
• Air in the Recirculation Pump. In some cases, adding defoamer to the slurry in the premix
side provides a “kick-start” that clears air from the recirculation pump and allows the mixing
process to be resumed.

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Elite™ Cementing Trailer Manual

RCM® Mixing System Troubleshooting Procedures

Table 5.2 lists troubleshooting procedures for the RCM® mixing system.

Table 5.2—RCM® Mixing System Troubleshooting Chart

Problem Causes Remedies

Slow mixing rates Restricted mix-water manifold Clean the unit immediately.

Restricted throttling valve Clean the unit immediately.

Low bulk-cement delivery rate Check the bulk unit thoroughly.

Partially plugged cement delivery Check bulk-unit delivery hose thor-

oughly.

Dirty bulk unit or manifold Check the bulk unit thoroughly.

Low bulk air pressure Check pressure (see the bulk system
manual).

Low mixing pressure 100- to 120-psi normal closed-in pres-

sure. Check centrifugal pump trouble-
shooting procedures. Check for proper
rpm and impeller adjustment.

Low recirculation pump pressure 25- to 35-psi normal closed-in pres-

sure with water. Check centrifugal
pump troubleshooting procedures.
Check for proper rpm, partially
clogged suction, or impeller adjust-
ment.

Dusting Improper bulk delivery pressure Check the bulk pressure (see the
bulk-equipment operator’s manual).

Bulk system being purged by air Check bulk operation (see the
bulk-equipment operator’s manual).

Low or no recirculation pump Check centrifugal-pump troubleshoot-

flow ing procedures. Check pump speed
and pressure. Check for blocked suc-
tion from RCM® mixing system tub.

Low or no mixing pump flow Check centrifugal-pump troubleshoot-

ing procedures. Check pump speed
and pressure.

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Table 5.2—RCM® Mixing System Troubleshooting Chart (Continued)

Problem Causes Remedies

Moisture in bulk Vacuum breaker not operating Check for cement buildup around vac-
equipment or hose properly uum breaker.

Splashback Check mixing jets for restrictions or

wear. Check for excessively high tub
level.

Restriction of cement Check mixer bowl, and remove all

cement buildup.

Throttling valve washup valve Close valve immediately.

open

Excess cement Vacuum breaker not operating Check for cement buildup around vac-
buildup in the throt- properly uum breaker.
tling valve
Throttling-valve washup valve If the valve is open, close it. If the
open or leaking valve is leaking, replace it.

Splashback Check the mixing jet for restrictions or

wear. Tub level may be too high during
mixing.

Restriction of cement buildup in Check the mixer throat, and remove all
mixer throat cement buildup.

Unable to maintain Erratic delivery of bulk cement Check bulk-equipment operator’s and
constant density maintenance manuals.

Erratic mixing pressure Check mixing pump for 100- to 120-psi

normal closed-in pressure.

Losing prime of Slurry bridging off in suction or Check the manifold for obstructions.
recirculation pump discharge of recirculation pump

Closed valve from tub to recircu- Open the valve. See RCM® IIIr system
lation pump operating procedures.

Centrifugal pump stopped turn- Check centrifugal-pump drive system.

ing

Air entrained in volute of recircu- Add slurry-defoaming agent.

lation pump

May 2005 Mixing System Problems and FLECS Operation 5-17

Elite™ Cementing Trailer Manual

Table 5.2—RCM® Mixing System Troubleshooting Chart (Continued)

Problem Causes Remedies

Losing prime of Recirculation pump defective Check rpm of recirculation pump

recirculation pump (1,500 rpm normal) 25 to 35 psi
(continued) closed-in pressure. Check impeller
adjustment or seal leaking allowing air
to be pulled in during operation.

Low recirculation- Centrifugal pump not turning at Check the centrifugal-pump drive sys-
pump pressure proper speed tem (1,500 rpm normal).

Partial plug of cement in suction Check the manifold for obstructions.

Air entrained in slurry Add defoaming agent to slurry.

Gauge or gauge protector not Check, repair, and/or replace as nec-

operating properly essary.

Centrifugal pump seals leaking Check the seals and replace them as
pressure or vacuum necessary.

Low mixing pump Centrifugal pump not turning at Check the centrifugal-pump drive sys-
pressure proper speed tem (2,100 rpm normal).

Restriction in suction side of cen- Check the manifold for obstructions.

trifugal pump

Centrifugal pump seals leaking Check seals and replace them as nec-
essary.

Gauge not operating Replace gauge.

Losing prime on Centrifugal pump stopped Check the centrifugal-pump drive sys-
mixing pump tem. Check for foreign object in volute
of pump. If pump is hydraulically
driven, the system pressure will be at
maximum.

Source of water shutoff or run- Check the water supply.

ning out of water

Insufficient head from the water Check the water supply and elevation
source of in relation to volute of mixing pump.

Suction leaks Check suction manifold and/or centrif-

ugal-pump packing for leaks.

Cement buildup between plug Clean out cement buildup.

valve and throttling valve housing

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 Elite™ Cementing Trailer Manual

Table 5.2—RCM® Mixing System Troubleshooting Chart (Continued)

Problem Causes Remedies

Cement-throttling Inadequate lubrication of plug Lubricate the plug valve.

valve difficult to valve
operate

Lumps in slurry Erratic delivery of bulk cement Check bulk-equipment operator’s

maintenance manuals.

Plugged or eroded mixing jet Clean or replace mixing jet.

Improper agitation Check that agitators are turning and

operating properly.

Inadequate air supply to bulk Check air supply and proper

system bulk-equipment operation.

Bulk cement stops Plugged bulk delivery line or Check the cement-delivery line or
hose hose for restrictions or buildup.

Out of cement Check cement level in bulk tanks.

Plugged discharge valve in bulk Clean or replace.

tank

Inadequate air supply to bulk Check air supply and proper

system bulk-equipment operation.

Dry cement in mix- Cement-throttling valve open too Reduce or close cement-slurry throt-
ing tub wide tling valve. Add water and mix dry
cement.

Losing prime of mixing pump Check the centrifugal-pump system.

No mixing water being added to Check the centrifugal-pump system.

slurry

Low pressure of recirculation Check the recirculation pump for

pump proper rpm and pressure. Check for
cement buildup or blockage on the
recirculation pump tub suction. Speci-
fications are 1,500 rpm minimum and
20- to 35-psi normal closed-in pres-
sure with water.

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Table 5.2—RCM® Mixing System Troubleshooting Chart (Continued)

Problem Causes Remedies

Cavitation of Trying to pump too fast for den- Reduce pumping rate.
HT-400 pump sity of slurry being mixed

Blockage in suction line from Check the tub-suction manifold.

RCM® system to tub-displace-
ment pump(s)

Restriction at tub’s suction valve Check the tub-suction valve. Check

RCM® IIIr system cleanup procedures.

Improper HT-400 pump operation Check the HT-400 pump manual.

Agitators not turn- Control valve in “off” position Turn the control valve to the “on” posi-
ing tion.

Improper function of hydraulic Check hydraulic-system troubleshoot-

system ing and maintenance manuals.

Erratic delivery Improperly maintained bulk Check bulk-equipment maintenance

equipment manual.

Improperly operated bulk equip- Check bulk-equipment operation.

ment

Non-gross aerated bulk equip- Add gross-aeration cartridges to bulk

ment being used tanks, or repair existing cartridges.

Dirty throttling valve Clean the throttling valve (see RCM®

IIIr system maintenance procedures).

Dry cement dis- Erratic delivery of dry cement Check bulk equipment operation.
charging out of
vacuum breaker Vacuum breaker poppet not seat- Check/clean/repair vacuum breaker as
ing properly required.

Air in slurry Improper slurry level in downhole Maintain proper tub level.
side of tub

Improper type of cement used Add defoaming agent.

Air purging of cement Check bulk-equipment operation.

Vacuum leak at circulating pump Replace or regrease seals.

seals

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Table 5.2—RCM® Mixing System Troubleshooting Chart (Continued)

Problem Causes Remedies

Butterfly valves dif- Cement buildup in valves Clean valves thoroughly.

ficult to operate
Improperly lubricated valves Lubricate valves properly.

Faulty valve Repair or replace valve.

Cement buildup in Improper cleanup Check and observe mixer cleanup pro-
mixer cedures.

Partially plugged jet Clean jet thoroughly.

Eroded mixing jet Replace mixing jet immediately.

Improper RCM® system opera- Check RCM® system operating proce-

tion dures.

Low or no mixing or circulating Check centrifugal-pump systems.

pressure

Wild fluctuation in Excessive air entrainment See “Air in slurry” problem above. Cir-
recirculation den- culating pump seals leaking on vac-
sity (± 0.3 lb/gal) uum. Replace or regrease seals.

Faulty densometer Check densometer cable or repair

densometer.

Densometer reads Signal from densometer lost Check cables for good connections.
210 to 220 lb/gal
Power card faulty or other prob- Have densometer repaired.
lems in densometer

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Elite™ Cementing Trailer Manual

Cement Mixing Procedure

Manual Mixing
When the unit has been primed, review the prejob checklist in Section 3, and follow the procedures
outlined in this section. These procedures explain how to mix cement manually.

The operator can independently control the speed of each agitator with the separate needle valves
for each agitator. The premix agitator should be operated at a high speed to impart full mixing
energy into the cement slurry directly after it leaves the mixer. The agitator on the downhole side
of the tub is typically operated at a slower speed to reduce splash that could occur with varying
downhole tub levels.

The RCM® IIIr mixer with rotary-jet water valve combines the following materials:

• Water from the water manifold

• Recirculated slurry from the premix side of the RCM® mixer tub
• Dry cement from the cement-throttling valve
To mix cement manually, perform the following steps:

1. Calibrate the unit densometers. The unit is equipped with a 3-in. (7.62-cm) radioactive den-
someter and a 2-in. (5.08-cm) high-pressure densometer. Calibrate these densometers
“dry” and allow to warm up.
2. Ensure that the master cement valve and master water valve are closed.
3. Set the cement-throttling valve to the 2 or 3 position (20 or 30%).
4. Open the water-metering valve to the one-third position.
5. Set the approximate mixing rate desired.
6. With the tub partition valve in the closed position, open the master water valve, and fill the
premix side of the tub to a level approximately 6 in. above the agitator blades. Then, close
the master water valve.
7. Engage the recirculating pump, and open both the recirculating pump discharge valve and
the tub suction valve. Water will circulate from the premix side of the tub, through the
mixer, and back into the tub.

Important Do not proceed with mixing until the discharge from the recirculating pump is
uniform and not surging. If all air is not out of the system, the pumping may not
be efficient.

8. Before continuing the mixing procedure, empty all water from the downhole side of the
tub. The water from this compartment can be pumped back into the displacement tanks.

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9. Ensure that the densometer is set for the specific gravity of water (8.33).
10. Turn on the agitators.

Important During mixing, keep the cover in place over the premix compartment of the tub
because this side creates the most splashing and dust. Additionally, keep the
downhole side of the tub open, which will allow you to monitor the tub level while
the cement is being mixed.

11. Coordinate with the bulk equipment operator to ensure a steady delivery of dry material. Open
the master cement valve, and begin adding cement. The cement will be blended with the water
in the premix side of the tub. The slurry components are circulated through the densometer and
the mixing manifold and sent back into the premix side of the tub.
12. Note the weight buildup indicated on the visual gauge. As the weight builds, the volume builds
in the premix side of the tub. Generally, the slurry reaches the desired weight when it begins to
pour over the partition into the downhole compartment.
13. When the slurry weight is within 0.5 lbm/gal of the desired weight, open the master water valve
and begin adding water.
14. Open the cement-throttling valve past the 2 or 3 position to compensate for the additional water
being added through the water-metering valves.

Important Fresh water and dry cement are now being added to the recirculated slurry.
Continually monitor the slurry density. To change the slurry density, slowly open or
close either the cement-throttling valve or the water-metering valve openings.

15. After the slurry has reached the proper density, and the downhole section of the slurry is above
the agitator paddle, begin flowing the slurry to the HT-400 pumps. In the downhole compart-
ment, maintain a slurry level approximately 2 in. below the top of the weir.

Important If the slurry begins to pour over the partition before reaching the correct density, open
the center partition valve. This valve allows slurry in both sides of the tub to be
circulated through the system. When the tub is full of slurry at the correct density,
close the tub partition valve, open the tub suction valve, and start pumping slurry
downhole.

16. Slowly open or close the water-metering valve and the cement-throttling valve openings to
achieve the desired mixing rate. Maintain the correct slurry density.

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Important Follow these guidelines during the mixing process:

• Maintain a full downhole compartment.
• Continually monitor the slurry density and make corrections to the slurry as
required.
• For densified slurries, control the density with the water-metering valves. For
slurries with high water ratios, control density with the cement-throttling
valve.
• Run the tub agitators continually; they perform most of the slurry blending.

Caution Never use the master water valve or the master cement valve to control the
rate of material being added.

17. After all the cement has been mixed, open the tub partition valve, and pump the remaining
cement from the tub.
18. Close the downhole tub suction valve, and begin adding fresh water to the mixing tub. Con-
tinue circulating fresh water during the entire displacement pumping process.
19. When the displacement fluid has been pumped downhole, begin cleaning the RCM® IIIr
system thoroughly.

Shutdown/Restart Procedures
To stop the pumping operation for manual or FLECS controller mixing, perform the following steps:

1. Close the master cement valve.

2. Close the master water valve.
3. Open the tub partition valve, and continue recirculating the slurry.
To resume pumping for manual or FLECS controller mixing, perform the following steps:

1. Close the tub partition valve.

2. Open the master water valve.
3. Open the master cement valve.

Important When you restart the pumping procedure, the slurry density and mixing rate should
be approximately the same as they were before pumping stopped. Therefore, you
should only make minor adjustments to the cement-throttling valve or the
water-metering valve.

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Cleanup Procedures
After you have completed the mixing job either manually or with the FLECS controller, perform the
following cleanup procedure:

1. Flood the mixing tub with water, and continue circulating it during displacement. If water is not
immediately available, circulate and agitate the slurry during displacement. In either case, open
the valve between the two compartments.
2. Circulate clean water through the mixing pump, the manifolding, all manifolding valves, and the
tub’s suction valve.
3. Close the master cement valve. Wash the cement-throttling valve through the washup connec-
tion, rotating the cement-throttling valve during the washing process.
4. Remove the cement-throttling valve and remove all remaining cement buildup.
5. With the recirculating pump turned off, open the master water valve.
6. Open the water-metering valve.
7. Remove the slurry jet, and check for foreign material or wear. Rotate and/or replace the jet if nec-
essary.
8. Close the master water valve, turn on the recirculating pump, and recirculate clean water through
the pump.

Note If discharge into the premix side of the tub appears normal while you are testing the
mixing manifold, but recirculating discharge is below normal, remove the discharge
line from the recirculating pump to the recirculating slurry jet and check for cement
buildup.

9. Ensure that each air-operated valve on the unit is functioning properly.

10. Open and close each manually operated valve to check for cement buildup.

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5-26 Mixing System Problems and FLECS Operation May 2005