JET Manual 06: Bulk Plant Equipment

JET Manual 06
Bulk Plant Equipment

Version 1.1
JET Manual 06 Bulk Plant Equipment
InTouch Content ID# 4127830
Version: 1.1
Release date: July 31, 2006
Owner: Well Services Training & Development, IPC
Schlumberger private
Document Control
Revision History
Rev. Effective Date Description Prepared by
Copyright © 2006 Schlumberger, Unpublished Work. All rights reserved.

This work contains the confidential and proprietary trade secrets of Schlumberger and may not
be copied or stored in an information retrieval system, transferred, used, distributed, translated, or
retransmitted in any form or by any means, electronic or mechanical, in whole or in part, without
the express written permission of the copyright owner.
Trademarks & service marks

“Schlumberger,” the Schlumberger logotype, and other words or symbols used to identify the
products and services described herein are either trademarks, trade names, or service marks of
Schlumberger and its licensors, or are the property of their respective owners. These marks may
not be copied, imitated or used, in whole or in part, without the express prior written permission
of Schlumberger. In addition, covers, page headers, custom graphics, icons, and other design
elements may be service marks, trademarks, and/or trade dress of Schlumberger, and may not
be copied, imitated, or used, in whole or in part, without the express prior written permission of
Schlumberger. A complete list of Schlumberger marks may be viewed at the Schlumberger Oilfield
Services Marks page: http://www.hub.slb.com/index.cfm?id=id32083
An asterisk (*) is used throughout this document to designate a mark of Schlumberger.
Other company, product, and service names are the properties of their respective owners.
Table of Contents
1.0 Introduction 7
1.1 Learning objectives 7
1.2 Safety warnings 7
2.0 Principles of Operation 9
2.1 Purpose of a bulk system 9
2.2 Basic bulk system components 9
2.3 Principles of pneumatic conveying 10
2.4 Principles of vacuum conveying 13
3.0 Bulk Systems 15
3.1 Bulk storage tanks 15
3.2 Pressure tank 16
3.2.1 Pressure tank components 16
3.2.2 Weigh batch blender 21
3.2.3 Additive/cutting bottle 22
3.2.4 Bulk tank construction 22
3.3 Gravity discharge bulk tanks 24
3.3.1 Discharge valve 25
3.3.2 Air supply line 25
3.3.3 Aeration device 25
3.3.4 Sight glass 25
3.3.5 Weight indicator 26
3.4 Pressurized surge can 26
3.4.1 Vent line 27
3.4.2 Pressure sensor 27
3.4.3 Pneumatic controller 27
3.4.4 Side discharge 27
3.5 Air slide/commercial hauler 27
4.0 Air Compressors 29
4.1 Reciprocating compressor 29
4.2 Rotary axial compressor 30
4.3 Vane-type compressors (blowers) 31
4.4 Compressor package 32
4.4.1 High-volume compressor and high‑pressure (controls) compressor 32
JET 06 Bulk Plant Equipment | iii

4.4.2 Air filters 32
4.4.3 Power unit 33
4.4.4 Air receiver tank 33
4.4.5 Safety relief valve (PRV) 33
4.4.6 Pressure gauge 33
4.4.7 After-cooler and dryers 33
4.4.8 Unloader lines 33
4.5 Air compressor moisture control 34
4.5.1 After-coolers 34
4.5.2 Water separator 34
4.5.3 Air dryers 34
4.5.4 Refrigeration 35
4.5.5 Absorption 35
5.0 Dust Collectors 37
5.1 Dust collector operation 38
5.1.1 Cloth sock filters 38
5.1.2 Pleated paper cartridges 38
5.1.3 Overpressure protection 38
6.0 Bulk System Piping 41
7.0 Pressure-Vacuum Systems 43
7.1 Principle of operation 43
7.2 Non-pressure bulk tanks (zero pressure) 43
7.2.1 Vent line 43
7.2.2 Vacuum breaker 44
7.2.3 Pressure relief valve 44
7.2.4 Pressure vacuum compressors 44
7.3 Weigh batch blender 45
7.4 Additive hopper 45
8.0 Bulk Equipment Operations 47
8.1 Operating bulk equipment on location 47
8.1.1 STEM 1 47
8.1.2 Rigging up 47
8.1.3 Transferring bulk material on location 47
8.1.4 Operating bulk equipment during the job 48
8.1.5 Rigging down 54
8.1.6 At the District 55
9.0 Maintenance of Bulk Equipment 55
9.1 Butterfly valves 56
iv | Table of Contents

9.2 Check valves 57
9.3 Ball valves 58
9.4 Aeration devices 59
9.4.1 Pipe jets 59
9.4.2 Canvas pads 59
9.4.3 Stainless steel pads 59
9.5 Dust collector socks 60
9.6 Connections 60
9.6.1 Figure 206 unions 60
9.6.2 Victaulic connections 60
9.6.3 Dresser sleeve 61
9.7 Safety relief valve 61
9.8 Pressure gauges 62
9.9 Weight measuring devices 62
9.10 Annual pressure tank inspection 63
10.0 Glossary 63
11.0 References 65
12.0 Check Your Understanding 67
JET 06 Bulk Plant Equipment |

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vi | Table of Contents

1.0 Introduction
This manual introduces bulk operations. • describe bulk equipment maintenance and
Advanced bulk operations and maintenance of troubleshooting procedures.
individual equipment pieces are included in JET
22 Bulk Plant Operations. 1.2 Safety warnings
This manual discusses how a bulk system Proper supervision is required during
works, describes the system’s major hands-on training. Request assistance
components, reviews the system’s proper from your supervisor if you are unfamiliar or
operation, and addresses important uncomfortable with the operation.
maintenance issues. In addition, this manual
also covers the operation of a pneumatic All personnel who will be involved with bulk
system used in a bulk delivery system. equipment must understand the dangers
involved with dealing with pressurized tanks.
Schlumberger uses bulk systems to store and All Well Services and Oil Field Services safety
blend bulk materials used in cementing and standards must be met.
fracturing. The system is also used to supply
bulk material such as cement and barite to Follow proper procedures before and while
mixing equipment. The success of a job is working with equipment job safety assesment
directly dependent on the proper blending and (JSA), hazard analysis and risk control (HARC)
delivery of materials, which is controlled by etc.
proper operation of the bulk equipment.
It is recommended that all personnel operating
bulk plant systems and components should
1.1 Learning objectives watch the safety video Don’t Tease the Tiger.
Upon completion of this manual, you will be
Use the following guidelines:
able to:
• When any bulk tank is under pressure,
• explain the principle of pneumatic
never permit anyone to be on or under the
conveyance in both full pressure and
tank for any reason whatsoever.
vacuum plants
• Under no circumstance may any piping,
• identify the differences among various
connections, or unions be connected,
types of bulk storage tanks, air
disconnected, or worked on while the
compressors, vacuum pumps, dust
vessel is under pressure.
collectors, piping, and pressure-vacuum
systems • Never hammer on pressure vessels.
• describe the operational guidelines for • Always monitor pressure gauges.
district bulk plants and bulk plant equipment • Never look into the end of a plugged line.
on location

| Introduction
2.0 Principles of Operation
2.1 Purpose of a bulk system Pressure tanks

Cement and
There are many ways to move large quantities pozzolans
of powdered or granular solid materials such
as sand, barite, or cement, including augers, Holding
tanks
conveyor belts and hand-carried sacks. The
preferred method at Schlumberger is pneumatic Dust collector
transport. Air
Compressor
Adds
Pneumatic (operated by air) transport is a Weigh
Blend batch
system that uses compressed air to fluidize blender (WBB)
the dry material and carry it from one place to Additive/
cutting
Air bulk transport (ABT)
another within a bulk system. A bulk system as bottle
defined here includes all associated equipment

Figure 2-2. Bulk System
used to store, blend, and transport bulk
material.
In the vacuum plant the storage tanks are
non‑pressurized vessels. The only pressure
A pneumatic and vacuum bulk system is the
tanks are the WBB, holding tank, and mix
preferred way to move cement and other
tanks. All vacuum storage tanks require a full
materials like sand, bentonite, pozzolan, and
open vent and a 2-in vacuum breaker. These
barite for the following reasons:
components should both be placed on top of
• high transfer rates the tank system.
• low manpower requirements

• less material lost or damaged
2.2 Basic bulk system components
Schlumberger uses pneumatic bulk equipment
• environmentally cleaner.
to store, blend, transport, and deliver bulk
materials to mixing equipment. A basic pressure
bulk system is made up of the following
components:
• air compressors (two: one high-pressure for

bulk plant controls, and one high‑volume
for bulk)
• vacuum pumps in pressure/vacuum
systems bulk tank also called a pressure
tank or P-tank in pressurized bulk plants;
storage tanks are non-pressurized in the
Figure 2-1. Air Compressor
pressure/vacuum system

• piping for air supply, bulk loading, bulk • the length of piping between the tanks, as
discharge, and venting well as elbows and restrictions.
• a dust control device (either sock or filter) • the amount of air and the size and weight
of the particles of material
• measuring and sampling devices (load
cells, gauges, cement samplers, etc.). • the pressure of the holding tank
New plants involve the use of Dilute Phase 1
Few particles of the bulk material are being
• WBB (weigh batch blender)
carried; the air velocity is high.
• double-stacked tank
• truck mix tank.
The WBB and the truck mix tank each have
measuring devices to ensure total product
delivery and service quality to the customer.
Pressure tanks
Cement and
pozzolans
Holding
tanks
Dust collector
Air
Compressor
Adds
Weigh
Blend batch
blender (WBB)
Additive/
Air bulk transport (ABT) cutting
bottle
Figure 2-3. Bulk System Components
2.3 Principles of pneumatic conveying

As compressed air flows through bulk material, Figure 2-4. Piping
it tends to “fluff” or aerate the particles. Once
aerated, the particles are carried by the air as it
moves to a lower pressure area.
The amount of material carried by the air

depends on many factors, including
• the size of the piping between the tanks,

and the cleanliness of the piping (dirty lines
reduce the pipe ID)
10 | Principles of Operation

SPECIFIC
MATERIAL SIZE GRAVITY
ILUMINITE
4.45
D18
SILICA SAND
2.65
D30
SILICA FLOUR
2.65
D66
FLY ASH
2.48
D35
CEMENT 3.16
Figure 2-5. Properties of Particle Materials
Figure 2-7. Surge Can
• the pressure of the receiving tank (e.g.,

surge can).
Ways in which air carries bulk material are
shown in the examples that follow.
Dilute Phase 2
Air velocity high
Figure 2-8. Air Velocity High
Few particles of the bulk material are being

carried; the air velocity is lower than in Dilute
Phase 1.
Unsteady Conveying 1
Lower air velocity
Figure 2-6. Bulk Tank
Figure 2-9. Lower Air Velocity
JET 06 Bulk Plant Equipment | 11

Few particles of the bulk material are being Steady Dense Flow
carried; the air velocity is high above a dune
A large amount of the bulk material is being
and lower in clear part of the line.
carried; the air velocity is lower than Dense
Plug Flow. The air-bulk material ratio is constant
Unsteady Dense Plug Flow
throughout the line.
High air velocity
Air velocity < Dense plug flow air velocity
Lower air velocity

Figure 2-10. Unsteady Conveying
Figure 2-12. Steady Dense Flow
A large amount of the bulk material is being
carried; the air velocity is lower than Unsteady Schlumberger operates bulk systems using the
Conveying 1. The air-bulk material ratio is not last two types of flow—Unsteady Dense Plug
constant throughout the line. Flow and Steady Dense Flow.
The bulk-to-air ratio is constant in short The bulk-to-air ratio is constant throughout the
sections of the transport line, and there are transport line.
sections of air between these bulk-air slugs.
This type of flow appears as a steady stream of
This type of flow appears as slugs of dense bulk material. The cement delivery rate can be
bulk followed by a blast of air. The delivery controlled at the discharge end of the transport
rate is controlled at the bulk tank located at the line. There must be enough pressure at the
beginning of the transport line. Air may have to bulk tank to overcome all pressure drops in
be added to the system after the cement leaves the transport line. To have this type of flow, the
the tank. The pressure drop required for this theoretical pressure drop required is 1.6 psi for
type of flow is less than that required for Steady each foot of transport line.
Dense Flow.
An example of this type of flow is a MARK III
An example of this flow is a bulk plant on an mixer hooked up directly to a bulk trailer with a
offshore rig hooked up to a surge can through a short (<20-ft or <6.1-m) bulk hose.
long (>20-ft or > 6.1-m) length of piping.
The type of equipment used by Schlumberger
generally causes the transport to be Steady
Air velocity < Unsteady conveying 1 air velocity
Dense Flow if the length of flow is 20 ft or less,
and Unsteady Plug Flow if the length is over
20 ft. The aeration system must be operating
properly to use this rule.
Guidelines for operating Schlumberger bulk

Figure 2-11. Unsteady Dense Plug Flow equipment for both types of flow can be found
in Section 8, Bulk equipment operations.

The components involved are a high-volume
Note: air compressor, a high-pressure air compressor
(for controls), a high-volume vacuum pump, and
A more complete discussion of the
a quality air dryer.
different types of flow regimes for
bulk materials in pneumatic transport
This process and the components involved
can be found in the Cementing
are discussed in depth in Section 7.0,
Materials Handling Manual, InTouch
Pressure‑Vacuum Systems.
Content ID# 384589
2.4 Principles of vacuum conveying

Vacuum conveying consists of the following
process:
• All products stored in non-pressure storage

tanks are protected by both a full open
vent system and a vacuum breaker (these
containers cost less than pressure tanks).
• Products to be blended on transfers are
moved to the WBB by means of vacuum
(differential pressure created between the
atmospheric and the vacuum pump).
• The WBB is then pressurized for both
blending and transfer through the double
stack tank and then to the truck mix tank
and on to the bulk transport.
• Additives are also moved to the WBB
through an additive cone by vacuum.
The pressure vacuum plant has the following
advantages:
• All storage tanks are nonpressured and

considerably less costly.
• When filters are properly maintained, the
plant is more environmentally friendly.
• Additives are added by means of a cone
and vacuum and do not require an additive
tank or another pressure vessel.
• Product transfer takes place at a higher
rate, reducing blend and load time.


3.0 Bulk Systems
This section describes the major components Pressurized tanks

used in Schlumberger pressure and vacuum
These tanks are pressure vessels that meet
bulk systems and explains their principles of
strict requirements. Most countries consider
operation.
1 bar or 15 psi the critical pressure that
designates a tank as a pressure vessel.
3.1 Bulk storage tanks
A bulk tank is both a storage tank and a bulk
feeder, supplying bulk materials to other parts
of the bulk system or discharging them to a
mixing system. This process occurs by way of
either pressure or vacuum, depending on which
type of plant is in place at the district.
Schlumberger uses two types of bulk storage

tanks:
Figure 3-2. ABT Truck
Non-pressurized tanks
These tanks do not meet the requirements
of pressure vessels, and have a maximum
allowable pressure of 1 bar or 15 psi. They may
also be zero pressure containers with a 5-psi
pressure relief valve, a vacuum breaker, and
a fuel open vent system on top of the tanks.
Pressure limits must be clearly marked on each
type of vessel, and necessary pressure relief
valves must be installed.
Figure 3-1. Bulk Storage Tank

Table 3-2. Names of Nonpressurized Tanks
Nonpressured tank
Gravity bins Surge cans
Gravity cans Surge tanks
Air slide Commercial hauler
Storage tanks District storage
3.2 Pressure tank
Vent line Fill line
Figure 3-3. Surge Can
Some of the many names for tanks used as

bulk storage tanks are listed below.
Pressure relief valve
Table 3-1. Names of Pressurized Tanks Manway
Pressure gauge
Names of pressurized tanks
Bulk tanks Bulk trucks Air supply line
Discharge line
P-tanks Silo
Pressurized silos Pressurized tanks
P-cans ABT(Air bulk truck)
Banana bulk truck Field bin Figure 3-4. Pressure Tank
Pressurized tanks are sometimes referred to by 3.2.1 Pressure tank components

their size; e.g.,“1,050s” for 1,050 ft3 or “850s”
for 850 ft3 tanks. One of the more common is a This section describes the functions of the
1,030 (1,030 ft3). pressure tank components.
Non-pressurized tanks are also known by

several names, including the following:
3.2.1.1 Fill line
The fill line is used to convey bulk material from
an outside supply to the inside of the tank. The
fill line is fabricated so that the end of the line
extends into the interior of the tank at its top
such that the bulk material falls down into the
tank as it is filled, and bulk material does not
cover up the entrance into the tank. Care must
be taken not to overfill the tank when supply is
16 | Bulk Systems

being delivered, as this may contaminate other the bottom of the tank. The vent line can
products or spill into the vent system. indicate when the tank is full if bulk material
flows to the dust collector. Extreme care should
be taken to prevent material from entering the
dust collector. A valve is installed in the vent
line so that pressure can be put on the tank
when it is closed.
Figure 3-5. Fill Line and Discharge Line
3.2.1.2 Discharge line

Bulk material is discharged from the tank into Figure 3-6. Vent Line
another tank or mixing system through the
discharge line. The discharge line originates
inside the bulk tank at the bottom, and Note:
penetrates the tank wall to a discharge point Vent line valves should be removed
outside the tank (see Fig. 3-4 Pressure Tank). from tanks used in vacuum systems
to prevent the tanks from collapsing.
Some tanks are constructed with the discharge
line starting as a hole in the middle on the
bottom of the tank, while other tanks have the
discharge line starting as a dip pipe reaching
down to the middle of the bottom of the tank.
A valve is installed on the discharge line near
where the line exits the tank.
3.2.1.3 Vent line

The vent line allows the venting of air and
pressure from inside the tank to the outside.
This is necessary when transferring bulk
materials into the tank (so that the air helping to
convey the material exits the system) or when
bleeding pressure from the tank.
Figure 3-7. Pressure Relief Valve
The vent line is designed to start from the
inside of the top of the tank to a point towards

3.2.1.4 Pressure relief valve relief valve settings is taken from Maintenance
Bulletin 625E, InTouch Content ID# 3998770.
The fill line and vent lines are similar to each
other, but the vent line is identifiable by its Table 3-3. Pressure Relief Valve Settings
pressure relief valve (commonly called a
pop‑off valve) and pressure gauge. Pressure ASME code Pressure relief
vessel tank allowable valve setting
location working pressure (psi)
Inland barges 30 35
Offshore 35 35
tanks
Land bulk 30 35
storage tanks
Truck bulk 30 35
tanks
Portable field 30 35
bins
P-tanks 30 35
Air slide 15 18+15 psi

transports regulator
Pressurized 5 10
surge cans
Figure 3-8. Pressure Relief Valve Close-Up

3.2.1.5 Pressure gauge
The pressure relief valve can also be mounted
For safety reasons and tank operation, every
on the shell of the tank and is designed to
bulk tank must have a working pressure gauge.
relieve tank pressure if it exceeds a preset
The gauge should be installed on the vent in a
pressure. Most of the pressurized bulk
position that will minimize the amount of dust
tanks used by Schlumberger are designed
to which the gauge inlet is exposed during
to operate at 30 psi, and the pressure relief
operation. It is important that the gauge is
valve is designed to open at 35 psi. Refer to
checked and inspected regularly during any
Maintenance Bulletin 625E, InTouch Content
operation.
ID# 3998770.
Some tanks are also equipped with a rupture

Note:
disc. This is an additional safety device
It is critical to Schlumberger
designed to shear if the pressure rises above
that all safety devices be kept in
the designed limit. When the disc ruptures, all
operating condition at all times for
pressure is lost from the tank and the disc must
both safety and legal reasons.
be replaced before the tank can be used again.
Schlumberger uses many pressurized tanks.

The following list of tanks and their pressure
18 | Bulk Systems

3.2.1.6 Air supply line Some tanks are equipped with a small valve
on the vent line to slowly bleed off the pressure
This line supplies the compressed air used to in the tank. This valve should not be used to
carry bulk material out of the tank. The line can pressurize the tank; all air used to pressurize
be mounted anywhere on the outside of the the tank should go through the aeration
tank, but it is connected to the aeration device devices.
on the inside of the tank. A valve is installed
on the air supply line to control the amount of
air entering the tank. The air supply line will 3.2.1.7 Aeration device
normally have a check valve to prevent bulk
Schlumberger uses two types of aeration
material from plugging the air system if the
devices that enable compressed air to fluff/
aeration device fails.
aerate through the cement. These devices
fluidize as much of the contents of the tank
as possible. The aeration device fluidizes bulk
material in the bottom of the tank so that it can
begin to flow out of the discharge.
3.2.1.8 Pipe jets

These are installed in the bottom of the tank
and direct air flow into the tank. The jets are
covered with a membrane to prevent them from
being filled with bulk material. A check valve is
also required on the inlet side (outside the tank)
to prevent backflow of dry material into the air
system.
Figure 3-9. Pressure Gauge Air flow
Vent line Fill line

Membrane
Jet

Manway
Pressure gauge
Figure 3-11. Pipe Jet
Air supply line
Discharge line
Figure 3-10. Air Supply Line

Note:
Most tanks equipped with a pad‑type
aeration device have an equalization
valve that keeps the pressure the same
on both the top and bottom of the pad.
If the pressure is not equalized, the pad
can rupture.
3.2.1.9 Pads
Pads installed in the bottom of the tank are Offshore silo pads
made of a porous material that allows air flow
into the tank. The pads, which are commonly
made of canvas, are designed to a allow air
to flow into the tank but prevent cement from
flowing into the air system piping.
Land-based pads
Figure 3-12. Pads
3.2.1.10 Manway
Each tank is equipped with a manway that
allows inspection of the inside of the tank. The
manway can be located on the top, bottom or
side of the tank.
If the manway is located on the top of the tank,

a ladder should be permanently mounted on
the outside and inside of the tank. If the tank is
over 12 feet tall, the outside ladder must have a
cage.
20 | Bulk Systems

mix tank. These additions make a total of five
Note: movements:
Always comply with relevant safety
standards for working at heights, 1. WBB
manways, vessel entry, and when
lockout/tagout is applicable. 2. Top of the double stack
3. Bottom of the double stack
4. To the mix tank
5. On to the transport.
Figure 3-13. Manway
Note:
Never modify a tank that is a ASME Figure 3-14. Transfer of Blend in Vacuum System
code vessel. Any modifications to
an ASME tank must be made by a This process is the same in both full-pressure
company certified to do such work. and pressure/vacuum plants, with the exception
that products and additives enter the WBB
under pressure and by way of a vacuum in a
pressure vacuum tank.
3.2.2 Weigh batch blender
A weigh batch blender (WBB), shown in
Fig. 3-14, is a specialized pressure vessel
used to weigh and blend bulk material. A WBB
has steep sides in its cone area and jets as its
aeration device.
Our service quality standard specifies a

minimum of three movements of the bulk blend
to ensure a proper blend. This requires the
addition of the double stack and a truck

The additive bottle, which can be either of the
designs shown here, does not have a fill line;
material is added either through a hatch or a
valve built into the top of the tank.
Figure 3-15. Weigh Batch Blender

Figure 3-16. Additive/Cutting Bottle
In the pressure vacuum plant the WBB is
both a pressure and a vacuum vessel, and is Vacuum/pressure tanks
protected with a pressure relief valve (PRV) and
a vacuum breaker. In a pressure/vacuum plant, the additive bottle
is replaced by an additive cone operating under
Most WBBs are built with three legs. Two are vacuum. Additives are dumped into the hopper
attached to the base with pins or ball-joints and the rate of flow is controlled by a butterfly
so the third leg is free to move. The third leg valve.
is held up by a load cell which transmits a
hydraulic or electronic pressure signal to a
weight scale. Strain gauges attached directly 3.2.4 Bulk tank construction
to the legs can be used instead of the load cell, All of the pressure bulk tanks used by
but they are more costly to install. Schlumberger are designed and built to
the standards of the American Society of
Mechanical Engineers (ASME) Boiler and
3.2.3 Additive/cutting bottle Pressure Vessel Code, Sections I, VIII and IX.
Full pressure plant These standards govern the type of metal, the
welding procedures, and the testing procedures
An additive bottle is a small pressure tank that used during manufacture. In addition, the code
adds sacked material to the WBB and is used requires personnel involved in the welding
in full pressure plants. Cutting bottles are also and inspection to be ASME-approved. The
used to cut and load sacks and/or big bags of ASME code is the accepted standard in most
material such as cement or sand when these countries.
are not delivered in bulk.
22 | Bulk Systems

To construct a tank that qualifies as an ASME
tank, the manufacturer must have a current
certification called a “U” stamp. To make
repairs or modify an existing tank, the shop
doing the work must have a current certification
called an “R” stamp.
Each ASME coded tank has an identification

plate similar to the one shown below, with the
working and test pressures of the tank stamped
on the plate. Information on this plate is
required for the tank to pass safety certification
inspections, and the plate must remain on the
tank throughout its life.
Figure 3-17. Identification Plate

Note:
Any repairs to the tank itself that The records of these containers are registered
require welding or cutting must with the National Board with a serial number;
be done by an ASME coded shop should a plate become unreadable, the district
using a coded welder. records can be sent to the original manufacturer
to produce a new plate.
The plate must be protected throughout the life

An ASME code inspector must approve the of the tank; therefore, measures must be taken
work to be done and must inspect the work to protect these plates during the process of
after it is completed. The inspector prepares a repainting, sand blasting, etc.
report (the partial data sheet), which indicates
his approval of the repairs. The report must be
kept on file for the life of the tank. If repairs are
needed, approval must be obtained from the
local maintenance department before beginning
any repair.
Note:
Pressure bulk tanks that meet all
requirements of the ASME code
are called coded tanks, and bulk
tanks designed for pressures less
than 15 psi are referred to as non-
coded tanks.
Figure 3-18. Bulk Tank

Only pre-approved suppliers are allowed to
manufacture bulk tanks for Schlumberger.

3.3 Gravity discharge bulk tanks
As the name indicates, gravity supplies the
energy to empty gravity silos and surge cans.
Air is used to keep the bulk material fluffed up
and to prevent it from bridging off inside the
tank. Because this tank uses gravity to empty, it
is used only to deliver bulk material to a mixing
unit.
The design of gravity silos and surge cans is

similar, the biggest difference being their size.
A gravity silo is usually 550 ft3 (15.7 m3), while a
surge can is usually 70 ft3 (1.98 m3).
A surge can performs three functions:
• Separates the bulk material transport

system from the bulk material supply
system prior to mixing. This is important for
the Unsteady Plug State. This type of flow
occurs if the Schlumberger mixing unit is
more than 20 ft away from the bulk tank.
• Allows air used to transport the bulk
material to escape. This is important
for the Unsteady Plug State due to the Figure 3-19. Surge Can
large amounts of air that are required for
the distance the bulk material is being
conveyed.
• Provides a buffer when switching from one Fill line
P-tank to another.
Weight indicator
Aeration device jets
Discharge valve
Figure 3-20. Surge Can Components
A gravity silo can perform all the functions of

a surge tank and is large enough to be used
as a storage tank for bulk material systems on
location.
24 | Bulk Systems

Most of the components of gravity discharge surrounding area inside the silo is clean and
tanks perform the same function as a pressure free of cement after every job.
tank; however, a few of the tank components
have different functions, as described below.
3.3.2 Air supply line
• The pressure relief valves (pop-offs) This line supplies air to fluff up the bulk
on surge cans and gravity cans perform material. The air flow maintains a consistent
the same function as those found on flow of bulk material and prevents the line from
pressurized tanks, limiting the maximum bridging off inside the tank.
pressure inside the tank
• The pressure relief valves on surge
cans and gravity silos are set to much
3.3.3 Aeration device
lower pressures than the relief valves on The aeration device enables the compressed
pressurized tanks. Gravity silos should air vent to aerate through the bulk material. This
be equipped with safety relief valves set device is designed to fluidize as much of the
at 3 psi, and the pressure relief valves on contents of the tank as possible and, as with
surge cans should be set at 10 psi. Some pressure tanks, Schlumberger uses two types
tanks are equipped with rupture discs of aeration devices (pads or jets).
instead of or in addition to pressure relief Sight glass
valves.
Sight glass
Figure 3-21. Aeration Device: Jet
3.3.1 Discharge valve

Figure 3-22. Sight Glass
This valve controls the rate at which the bulk
material (usually cement) falls from a gravity
silo or surge can. The valve is relatively large, 3.3.4 Sight glass
usually 8 in (20 cm) or larger, so that high Surge cans are fitted with small windows to
discharge rates can be achieved. allow visual monitoring of cement inside the
tank.
The valve is normally a butterfly valve. It is
important that the valve is well maintained
and in good working condition, and that the

3.3.5 Weight indicator
Note:
Surge cans can be fitted with weight indicators
Gravity silos and surge cans
so that the level of bulk material inside the
(”non‑code tanks”) are not built
tank can be measured. The load cell/indicator
to the rigid standards required
system used on surge cans works in the same
for tanks that will have more than
way as systems found on most WBBs. The load
15 psi of pressure. Nonetheless,
cell and weight indicator have to be calibrated
these tanks must be treated with
to take into account the weight of the tank so
the same respect as pressurized
that the read-out gives bulk material weight
tanks. The amount of force
only.
contained within these tanks is
tremendous, and the film Don’t
A hydraulic load cell holds up one side of the
Tease the Tiger shows dramatically
surge can, while the other side of the surge can
the power of very low pressures
is connected to the frame with pins that allow
exerted on large surfaces.
the surge can to pivot. The force from the tank
is exerted on the surface of a diaphragm in the
load cell.
The weight of the load cell forces the fluid to the

3.4 Pressurized surge can
weight indicator gauge, which reads in weight Vent control
valve
not pressure. The gauge is matched to the load
cell for calibration purposes. Field replacement Vent line
of either the gauge or the load cell must be an Fill line
exact match for proper weight indication. Air supply line

Weight indicator
Jets
Load cell Discharge valve
Load cell
Figure 3-24. Surge Can - Pressurized
Schlumberger also uses a special-designed

surge can called a pressurized surge can.
This tank is a pressure vessel much like the
pressurized tanks described earlier, but it does
not meet the strict standards of ASME code for
Figure 3-23. Surge Can and Load Cell
a pressure vessel and its pressure is limited to
15 psi like a standard surge can. This surge can
is typically used in conjunction with the Slurry
Chief mixer on offshore skid units.
The special features of a pressurized surge can

are described below.
26 | Bulk Systems

3.4.1 Vent line enables bulk material to be discharged a short
distance through this side discharge.
The vent line is equipped with valves: a vent
control valve and a vent bypass valve. If
the bypass valve is left open, the surge can 3.5 Air slide/commercial hauler
performs as a standard surge can. The vent
control valve is automatically opened and
closed to maintain a set pressure inside the
surge can, usually 5 to 7 psi.

Pressure sensor
Figure 3-26. Commercial Hauler
Trucks that transport bulk material are not

certified pressure vessels, and are often
referred to as air slide and commercial haulers.
The differences between these trucks and other
Figure 3-25. Pressure Sensor pressure bulk tanks and trucks are the working
pressure limit and the type of aeration system.
3.4.2 Pressure sensor Unlike a pressurized tank, which operates

at pressures up to 30 psi, air slides and
A pressure transducer is mounted on top of the
commercial haulers have non-coded tanks
surge can. This transducer sends a pneumatic
that operate under 15 psi. These tanks have a
pressure signal to the controller.
pressure regulator set for 15 psi and a pressure
relief valve set for 18 psi. Maintenance Bulletin
3.4.3 Pneumatic controller 743A MUST-DO, InTouch Content ID #4128998,
describes these safety devices.
A pneumatic controller controls the opening and
closing of the vent control valve. The controller
maintains pressure in the surge can at a preset Note:
point. This type of bulk truck delivers
cement at rates of 1,000 to
2,000 lbm/min, which is about
3.4.4 Side discharge
half the rate expected from a
In addition to the discharge valve in the bottom pressure‑type coded bulk tank.
of the surge can, the pressurized surge can
is equipped with a side discharge. The small
amount of pressure kept in the surge can

28 | Bulk Systems

4.0 Air Compressors
Air compressors provide all of the energy drawn into the compressor’s cylinder as the
needed to run a bulk system. Schlumberger piston travels down.
uses several different types of air compressors,
most of which are designed to operate at 30 to
32 psi and deliver 300 to 400 ft3/min of air, or
29 in of mercury at 425 ft3/min.
4.1 Reciprocating compressor

Single‑stage-reciprocating compressors are
commonly used in Schlumberger.
Figure 4-2. Intake Stroke
Compression stroke
The air in the cylinder is compressed as the
piston travels up. The intake valve closes and
the exhaust valve opens as the air pressure
inside the cylinder exceeds the pressure in the
discharge piping.
Air compressor
Figure 4-1. Compressor
The basic principles of operation of a

single‑stage reciprocating compressor are
similar to those of a two-cycle engine.
Intake stroke
The air passes through a filter to ensure that
only clean air reaches the cylinder. Air enters
the cylinder through the intake valve, which is
opened by the difference in pressure and is Figure 4-3. Compression Stroke

How pressure is controlled system reaches the set pressure, the pressure
switch turns off the electrical motor turning
Regulator or unloader-type system
the compressor. This system is primarily
The discharge pressure of the air compressor used in the bulk plant for controls such as
is regulated to stay within preset limits. The high‑pressure valve actuation.
unloader valve senses system pressure versus
the desired preset pressure. When the desired A valve in the switch opens to bleed pressure
system pressure is achieved, the unloader off the cylinder so that when the compressor
valve sends air pressure to the pilot unloader; restarts it is not starting under load. The switch
the plunger holds the intake valve open, thus has a differential spring setting, which should
allowing the compressor to keep cool and be set at 20 percent of system pressure, to turn
preventing the compression process. the motor back on when necessary. It gives no
warning prior to starting, so it must display a
The differential pressure of the unloader sign as described in the Well Services Safety
should be set within 15 percent of the set Standard 04: Facilities and Workshops, InTouch
pressure. If the differential pressure is greater Content ID# 3313678.
than 15 percent it indicates an unloader
system malfunction that requires service and
calibration. Unloader assembly
The diagram below illustrates a typical unloader

on reciprocating compressors. Cylinder
assembly
Unloader
pilot valve
Figure 4-5. Intake Stroke
4.2 Rotary axial compressor

The rotary axial flow compressor, commonly
known as a screw compressor, is capable
of producing high volumes of air (100 to
Figure 4-4. Unloader 1000 ft3/ min at 100 to 175 psi).
Another type of system utilizes a pressure Air is pulled into the compressor housing by
switch to allow the electrical motor to turn on the rotation of the screw-type rotors and is
and off as needed to maintain a set pressure. trapped between the lobes of each rotor and
This is the most common type of regulator the housing wall.
for small compressors that must furnish
high pressure (125 to 150 psi), for example As the screws rotate, the air is compressed and
in maintenance shops. The pressure switch moves toward the discharge end of the rotors.
senses tank or system pressure; when the The rotors are tapered to a smaller diameter
30 | Air Compressors

on the discharge end, which creates a smaller 4.3 Vane-type compressors (blowers)
chamber for the air, compressing it before it is
discharged. Vane-type compressors, also called blowers,
are designed to deliver 150 to 400 ft3/min at
Constant speed control regulation allows the pressures up to 35 psi.
compressor to be unloaded at a set pressure
while the electric motor continues to operate As the power source turns the rotor, centrifugal
at a fixed rpm. The basic principle of constant force pushes the vanes outward, sealing the
speed regulation is to throttle an intake valve vanes to the housing. Air is pulled into the area
open or closed, and regulate the ft3/min between the vanes and housing, trapping the
discharge, thereby regulating the psi. air.
Some screw compressors are driven by diesel As the vanes travel along the cam, the volume
engines. When the discharge pressure is at between the rotor and the cam decreases,
or above a set pressure, a variable speed which compresses the air. The cam is designed
regulator closes off a valve in the intake of the so that the maximum volume between vanes
compressor to restrict air to the compressor is at the air intake, and the minimum volume
and regulate discharge volume or ft3/min. between vanes is at the discharge.
Simultaneously, it throttles the engine to idle
position. When it senses a 15 percent drop in A valve on the discharge flow stream is the
the pressure, it throttles the engine back to fast most commonly used control system on a
idle rpm and then opens the valve to the intake. blower-type compressor. When the preset
system pressure is reached, an air actuator
This type of system reduces the need for opens the valve and the compressor discharges
large‑volume storage tanks, but requires a to the atmosphere until the valve closes
larger than average compressor for ft3/min again. A check valve contains the pressure
consumption. downstream of the tee.
Pressure regulation for blowers

The pressure of this type of compressor also
relies on a constant speed control regulator,
as described below. It is critical that air is
constantly passing through the blower.
Figure 4-6. Rotary Axial Compressor
Figure 4-7. Blower

Pressure is regulated in the following way: 4.4.1 High-volume compressor and
high‑pressure (controls) compressor
1. Air from the receiver acts on the
unloader pilot valve. If the pressure is The compressor usually has two or three
above the set pressure (usually 32 psi), cylinders, and is capable of delivering 300 to
the pilot valve opens, allowing air to flow 400 ft3/min at 30 to 40 psi; or it can be a rotary
to the 4-way unloader valve. screw such as the Palatek unit, which can be
used on both a pressure or a vacuum pump.
2. The 4-way valve directs high‑pressure
air to open the control valve, allowing
excess air to be discharged to 4.4.2 Air filters
the atmosphere. This allows the It is important to keep air cleaners clean.
compressor to keep running unloaded. Each compressor generally has one air filter
per cylinder. It is common to see 3-cylinder
3. The unloader valve piston will close compressors with two, or even one, air filter
as the pressure falls below a set point as long as the total ft3/min capabilities of the
(usually 28 psi). This causes the 4-way air filters meet or exceed the needs of the
valve to shift, closing the control valve. compressor.
4. Compressed air is again supplied to the Vacuum pumps require their own filter or the
system. use of the dust collector filter on top of the WBB
in the vacuum mode.
4-way valve
Unloader pilot
valve
Air exhaust
High pressure
air supply
Control valve
Air from the

receiver
Figure 4-8. Pressure Regulator
4.4 Compressor package

Figure 4-9. Compressor Components
A typical compressor package used by
Schlumberger includes many components, as On a reciprocating compressor, if the
described below. differential pressure of the filter is too high, it
will cause a vacuum between the air cleaner
and the cylinder. This usually results in a
vacuum that pulls oil up through the piston
rings and discharges it into the pressurized air.

This oil can be carried all the way to the pads the operator identify potential problems or
in the bulk cement tanks. Because dirt is very restrictions in the system. This may also be a
abrasive, dirty air filters can cause serious lube oil pressure gauge.
damage to the compressor.
Dirty air filters on a vane-type blower can cause 4.4.7 After-cooler and dryers
the vanes to disintegrate. After-coolers remove the heat that air acquires
during compression. The cooling of the air also
removes moisture, which is drained off.
4.4.3 Power unit
A 70-HP diesel engine, an electric motor, or the Dryers, on the other hand, do nothing to cool
engine of a tractor truck drives the compressor. the air, but have passive desiccant cartridges
that remove the moisture from the air. The
moisture is channeled to the bottom of the dryer
4.4.4 Air receiver tank where it is purged from the system by a signal
This tank stores a small volume of air that from the unloader. A typical air dryer operating
can satisfy an increase of the ft3/min output with a 235-CFM screw compressor at 100
needed from the compressor, such as blowing percent humidity can discharge 100 gal of water
lines clean. The tank can also act as a water in a 24-hour period. Desiccant dryers require
trap if the air velocity in the tank is lowered periodic servicing.
sufficiently to allow water droplets to fall out of
the compressed air. The air receiver tank also
helps the length of the cycle time between the
time when the compressor unloads and when it
reloads. This is most often an ASME container.
4.4.5 Safety relief valve (PRV)

This valve is set to open if the pressure of
the compressor exceeds a set limit. All PRVs
should be tested periodically.
The three measures of pressure control in this

process are in this order:
1. Cycle-through pressure regulation

Figure 4-10. Unloader Lines
2. PRV pressure relief valve
3. Rupture disc. 4.4.8 Unloader lines

The pressure regulation system of the
compressor uses these lines to transmit the
4.4.6 Pressure gauge system’s operating pressure to the compressor.
This gauge allows the operator to check the Water in the compressed air system can
operation of the compressor. The location damage the bulk material, make the bulk
of pressure gauges in the system helps material more difficult to move and cause

blockage of the aeration devices (pads and To help separate moisture, air receivers or
jets). The principle methods used to control volume tanks should always be plumbed so that
moisture in air systems are described below. the discharge of the air compressor comes into
Water may also freeze in low temperatures and the tank lower than the air outlet. In areas of
prevent proper valve operation. high humidity, large volume tanks are needed to
capture the moisture to prevent damage to air
controls.
4.5 Air compressor moisture control
Smaller inline water separators, such as those
4.5.1 After-coolers used on air controls, use a centrifuge method
in which air is swirled around the bowl to make
After-coolers cool the hot compressed air
the water fall out. These separators work best
discharged by the compressor to remove
in low-volume applications.
moisture.
Air heats up as it is compressed, and heated air

is able to hold more water as a vapor. Cooling
the air causes the water vapor to condense,
and the condensate can be drained out of the
system. A water-to-air or air-to-air after-cooler
is a device fitted directly to the compressor
discharge that is designed to cool the air and
cause water vapor to condense.
Figure 4-12. Water Separator
4.5.3 Air dryers

Devices used to dry the air are more
complicated than the after-cooler and the water
separator discussed previously. Air dryers
use either the refrigeration or the absorption
method, described below, to reduce the amount
Figure 4-11. After Cooler of water in the air system.
4.5.2 Water separator

A simple way to separate water from air is to
slow down the air and allow water droplets to
settle out and be drained off. A large receiving
tank works this way. The tank also tends to
radiate the heat of the air and this cooling
causes water in the air to condense.

4.5.5 Absorption
Note:
A chemical absorbs water from the compressed
Lubricators are necessary for the
air, then turns into a liquid and is drained away.
proper operation of air control. Air
The chemical is not reusable.
first travels through the air dryer
or water separator to clean the air,
Refrigerant dryers are not usually found on the
then the lubricator adds oil to the
compressors that Schlumberger uses for bulk
air for the components.
systems. Schlumberger uses after-coolers and
Lubrication must be adjusted to air receiver tanks to control the water content of
the proper flow. Too much oil in the compressed air. Most of the new or upgraded
system can be messy and cause plants in North America use refrigeration-type
problems with some components, dryers.
while too little lubrication will result
in some components not getting
any lubrication. A good rule of
thumb is 4 to 6 drops per minute
using SAE10 oil or engine oil
cut with diesel 50/50. Do not
use Marvel Mystery Oil because
it creates a film that causes
components to stick or hang up.
Make certain the air supply is bled
off when filling the lubricator.
Figure 4-13. Air Dryer
4.5.4 Refrigeration
Compressed air is cooled to near freezing, and
most of the water content in the air condenses;
then, the air is reheated.


5.0 Dust Collectors
Air outlet
Vibrator
assembly
Air inlet
To the collection tank
Figure 5-2. Interior of Dust Collector
Inlet line of dust collector

An inlet line is hooked to the vent line of the
bulk tank being loaded.
Figure 5-1. Dust Collector
Outlet line of dust collector
Every bulk system must have some sort of dust The outlet line is a large opening that allows
control system, which must be designed to clean air to exit the dust collection system.
meet local air quality regulations.
Filter
Dust collectors are designed as illustrated. The filter, such as a sock or cartridge, prevents
dust from exiting the dust collector.
Dust collector bags are used on locations

where the bulk equipment is not equipped with
a permanent dust collection system.

5.1 Dust collector operation 5.1.2 Pleated paper cartridges
The dust collector system is divided into two Another type of filter is the pleated paper
sections. The upper section contains the filters, filter shown in the illustration below. The dust
while the lower section is open to collect and filters out onto the pleated paper as air flows
hold the dust particles in the collection tank. through the cartridge. A jet of high-pressure
Dirty air enters the system just below the filter. air clears the dust from the filter and causes
Dust is caught by the filter, allowing clean air to the accumulated product to fall into a collection
exit the system. The filter has to be cleaned for tank below the dust collector. The frequency of
the system to continue to work properly. the air blast can be varied, but should be set for
intervals of 4 to 6 seconds. The air jet should
The methods used to clean the filters are be started before the dust collector is used and
described below. continued until after the dust collector is no
longer needed.
5.1.1 Cloth sock filters

Dust is filtered out onto the cloth material as Note:
air flows through. Periodically the socks are It is normal to lose 0.5 to 3.0
shaken off by a vibrator assembly built into the percent of the material being
top of the collector. Continuous shaking of the transferred as dust. The vent
socks causes dust to migrate through the sock, system and dust collection tank
and some dusty air will exit the collector. The must be capable of holding this
shaker should be run 15 to 20 seconds after amount of bulk material.
each load, or 30 to 60 seconds out of each
15 minutes of operation. Each district should
establish regular intervals for running the dust
collector. Air jet
assembly
Air High pressure
Air outlet outlet air supply
Inlet
Vibrator
assembly Air filter
housing
To the collection
tank
Figure 5-4. Pleated Paper Filter

Air inlet
To the collection tank
5.1.3 Overpressure protection
Dust collectors are designed with some type
of overpressure protection to prevent them
Figure 5-3. Dust Sock Filter
from shutting down the entire bulk plant. If
38 | Dust Collectors

overpressured, sock-type filters simply blow
apart or blow off their mounting and allow dirty
air to escape directly into the atmosphere. The
pleated paper cartridge type of dust collectors
are constructed with a bypass mechanism that
opens if the pressure becomes too high.
Both types of filters filters are also used to

protect the vacuum pumps in pressure/vacuum
plants by filtering the air on the inlet side of the
vacuum pumps.

40 | Dust Collectors

6.0 Bulk System Piping
The pipe used for fill lines, discharge lines,

and vent lines in a bulk system is usually 4-in
or 5-in diameter steel. Larger pipe requires
higher volumes of air to transport bulk material,
while smaller pipe requires higher pressures to
overcome friction losses.
To make flow through the lines as smooth as

possible, long radius elbows and Delta Wyes
(shown below) are used instead of standard
elbows and tees. This is often referred to as
3R (triple the radius), the preferred alternative
being 2R (twice the radius).
Figure 6-2. Butterfly Valve
Bulk discharge hose (usually 4-in diameter)

is used to hook up to portable units and
must meet Schlumberger specifications for a
discharge hose. The specifications for blender
discharge hose and bulk discharge hose can
be found in the Treating Equipment Manual,
Version B, InTouch Content ID# 3013931. The
hose must be double-clamped with clamps 90
degrees apart.
Figure 6-1. Delta Wye
Butterfly valves control the flow of materials

in a bulk system. The air supply line may be Figure 6-3. Discharge Hose
equipped with either butterfly valves or ball
valves.

Figure 6-4. Blanking Caps
Blanking caps should be designed as shown,

so that the nut can be loosened and the plug
moved to check for pressure without the risk
of blowing the cap off. Never use one-piece
wet caps on a dry bulk line because it is not
possible to tell if there is pressure on it when
removing the cap.
A rock catcher filters chunks of hard cement or

rocks that may be present in dry bulk material
when it enters or leaves a bulk plant. The rock
catcher has a screen that allows bulk material Figure 6-5. Rock Catcher
to flow through, while catching larger particles.
Rock catchers are intended, for the most part,
to ensure product quality from the supplier and
Warning: are installed on each individual product line
Discharge hoses must not be used from the vendor.
on the discharge side of triplex
or other high-pressure pumps, or The new version of the rock catcher has a
on the suction side of centrifugal replaceable screen.
pumps. Before using the hose,
check it carefully for any signs of
cracking or damage. The pressure
rating of the hose is between
100 and 125 psi; therefore, if a
damaged hose fails under pressure,
it causes damage to equipment and
injury or death to personnel.
42 | Bulk System Piping

7.0 Pressure-Vacuum Systems
Schlumberger uses pressure-vacuum bulk The primary disadvantage is that the

systems at some Districts. A pressure‑vacuum reciprocating compressor has a short life span
system uses the same basic components if it is not maintained correctly.
found in pressure bulk systems, except that the
compressor must be designed for a pressure-
vacuum application and requires an additional 7.2 Non-pressure bulk tanks (zero
filter process for the compressor. pressure)
Non-pressure bulk tanks used in pressure-
7.1 Principle of operation vacuum systems are constructed as shown
where. Most components of the tank perform
The principle of moving material by vacuum the same function as when used on a
is the same as that for a pressure system. Air pressure tank. The components with different
carries the bulk material from areas of high functions are described below. Pressure/
pressure to areas of low pressure. A vacuum vacuum plants require zero pressure tanks for
system creates low pressure in the tank to storage containers. They require a full open
which the product will be transferred while (preferred 5-in) vent on top of the tanks to a
fluffing and jetting the tank from which the vent collection tank. This tank has a single line
product will come. Bulk product is carried faster going to the dust collector, which sits on top of
through this type of system. a dust collection tank. The vent tank is also the
blowdown tank for products being returned to
The compressor is plumbed so that the inlet the plant at the completion of the job.
creates a vacuum while the discharge is
simultaneously expelled to the atmosphere, All storage tanks on the inlet side of the WBB
pressurizing the tank. require a full open vent on top of the tank for
each individual product stored, and a 2-in
The bulk tanks are plumbed in such a way vacuum breaker on the tank.
that the air used to carry the bulk material
out of the tank comes through the tank’s vent All stored products and additives enter the
system, pulled in by the compressor. In most WBB by means of vacuum, and the blending/
new plants, three separate units are used for transfer to the transport unit occurs through the
pressure systems. pressure process.
A pressure-vacuum system has the following

advantages over a straight pressure bulk 7.2.1 Vent line
system: less dust is generated when adding
The vent line allows air to enter the tank, and
additives to the WBB the bulk tanks are easier
does not have a valve. Being a full open vent, it
to clean, the cost of the tanks is lower, and the
does not require a pressure relief valve.
code is not needed.

7.2.2 Vacuum breaker in from the WBB. The compressor has an
additional filter on its suction to prevent pulling
The tank has a vacuum relief system to prevent in dust when acting as a vacuum pump. This
the tank from collapsing if the vent becomes plant may incorporate the use of two separate
plugged. pumps, one for pressure and one for vacuum.
Vacuum breaker The new plants use a Sullivan Palatek

compressor for pressure and a DVT vacuum
pump for vacuum.
In an emergency, the Palatek unit can be used

as both a pressure and a vacuum pump when
the valve arrangement is properly set up to
accommodate both. The emergency occurs
Fill line
when the DVT unit fails.
Manway
Air supply line

Discharge line
Figure 7-1. Non-Pressure Tank
7.2.3 Pressure relief valve

Since these silos are non-pressure tanks,
they must be equipped with a vacuum valve to
prevent collapse.
7.2.4 Pressure vacuum compressors
7.2.4.1 Air compressor

An air compressor used in a pressure-vacuum
system works much like an air compressor in
a pressure system. The key difference is that
the compressor in a pressure-vacuum system
includes flow-selector valves.
Flow-selector valves determine whether the Figure 7-2. Palatek Compressor (above) and DVT Vacuum
compressor pulls air in from the atmosphere Pump (below)
and discharges it to the WBB, or if it pulls air
44 | Pressure-Vacuum Systems

To tanks Most WBBs have eight openings on top of a
5‑in groove lock type. This new type of tank
In the event of failure does not require the use of a vacuum breaker.
change direction of flow
Valve From
weigh batch blender
Palatek compressor
Vacuum pump
Figure 7-3. Air Compressor Components in Pressure Vacuum

Systems
7.3 Weigh batch blender

A weigh batch blender (WBB) used in a
pressure-vacuum system is built to work both
as a vacuum tank and as a pressure tank. In
addition to the features explained earlier, the
WBB has a built-in dust collector located at
the top of the tank. This section filter prevents
the compressor from pulling dust from the tank
when it is being used as a vacuum pump.
The WBB is evacuated through a filter by the Figure 7-4. Weigh Batch Blender
compressor to create the low pressure needed
for the system to blend and move material by
vacuum. The WBB is also used as a pressure 7.4 Additive hopper
tank to blend and move material back out of the
In a pressure/vacuum plant the additive bottle is
tank.
replaced by an additive cone (hopper) operating
under vacuum. Additives are dumped into a
New versions of the WBB have a separate dust
hopper and the rate of flow is controlled by a
collector (metroplex) on top of the tank. This
butterfly valve at the base of the cone.
is a dry filter type with a purge surge cleaning
device incorporated into the dust collector.
The vacuum on the WBB is created by the
vacuum pump and the vacuum on the WBB.
All products, including additives, enter the WBB
Upon completion of the process, the additive
via separate lines. Therefore, if five products
valve is closed and the products are blended
are stored in bulk, you will use five openings on
and then transferred to the bulk transport.
top of the WBB, plus one for dry additives.
One of the advantages of a pressure-vacuum
system is its additive hopper. The hopper relies
on a vacuum to pull the additives into the WBB,

thus eliminating much of the dust created when
adding sacked additives. This process may also
be assisted by jets in the material line between
the additives cone and the WBB.
Material line
to the WBB Upper cleanout jet
Vacuum
vent valve Vent hood
Material Removable product
valve control
screen
Cone base valve
control Cone
Lower and upper

cleanouts
5-in material valve
Lower cleanout jet
Figure 7-5. Additive Hopper
Pressure tanks
Cement and
pozzolans
Holding
tanks
Dust collector
Air
Compressor
Adds
Weigh
Blend batch
blender (WBB)
Additive/
cutting
Air bulk transport (ABT) bottle
Figure 7-6. Pressure/Vacuum Bulk Plant System
46 | Pressure-Vacuum Systems

8.0 Bulk Equipment Operations
8.1 Operating bulk equipment on As the use of air increases, the amount of dust
created while moving the bulk material will
location increase as well.
8.1.1 STEM 1 If portable air lines are rigged up on location,

All bulk equipment must be well maintained blow air through them before hooking up to
and be inspected before and after every job. ensure that the lines are clear of water and dirt;
Equipment used to transfer cement from also, be sure they are constructed properly to
the District to location must pass a STEM 1 prevent parting.
inspection before it is dispatched from the
District and as soon as the equipment reaches
location. This ensures that the equipment was 8.1.3 Transferring bulk material on
not damaged in route to the job site. Make location
sure that the equipment is green-tagged and Many jobs performed by Schlumberger require
STEM 1 paperwork is completed on the bulk cement material to be transferred on location.
equipment. Equipment that is not operational It is sometimes better to store bulk material in
should be red-tagged and repaired as soon as portable P-tanks or gravity silos rather than
possible. trying to fit all of the material on location in bulk
trucks.
8.1.2 Rigging up On larger jobs, there are several benefits to
Equipment should be spotted to keep the bulk using large bulk storage tanks instead of relying
discharge lines as short as possible. The longer on bulk trucks to supply the mixing equipment:
the line, the more air is required to transport the
bulk material.
Figure 8-2. Bulk Truck
Figure 8-1. Hook-Up

• Making multiple trips to the location with a dust control system must be available.
the same truck(s) can reduce the
 number of The exit of the dust control system must
bulk trucks required to do the job. be routed so that the chance of exposing
personnel and equipment to dust is
• The number of people required to do the
minimized.
actual job can be reduced. A driver for
each bulk truck is required if all the material • Most locations have rules that require
is brought to location at the time of the job. dust control when transferring cement. An
operational dust control system is required
• Large bulk tanks take up less space than
on every job. The dust control device must
the number of bulk trucks needed to hold
be hooked up before moving cement.
the same volume of material. This is an
important consideration for small locations. Dust collector devices include the CUS-
917 - Dust Collector (Cut Sheet), InTouch
• Fewer hoses, connections, etc. are
Content ID# 3994426; and CUS-900 - Dust
required to hook up the large bulk tanks
Collector (Cut Sheet), InTouch Content
than would be required to hook up the
ID# 3994401.
number of bulk trucks holding the same
volume. • If there are two or more compressors on
location, be sure to connect them together
• Fewer tanks require fewer tank changes.
to provide backup for each other. The use
Switching from an empty tank to a full tank
of disposable dust bags may be required.
causes the flow of cement material to the
mixer to change, which can cause the
slurry density to vary.
Note:
Follow these steps when transferring material
Contents of bulk tanks must be
on location:
clearly marked, documented and be
up-to-date with all parties informed.
• Each bulk truck must have a completed
Costly operational failures have
load sheet. This sheet will list the amount
resulted when there has been
and type of material that is in each tank.
confusion as to contents of bulk
• Each storage tank must pass a STEM 1 tanks.
inspection before being carried to location.
• The FSM or FS/FE assigned to the job has
determined the type of material that will be 8.1.4 Operating bulk equipment during the
loaded into each storage tank on location. job
A sketch of the location showing where
each load is to go must be given to the FS. The operation of bulk equipment plays an
The storage tank should be checked before integral part in the success or failure of a job.
it is loaded to ensure that it has not been The following procedures are guidelines to
damaged on the way to the location. prevent job incidents caused by the improper
operation of bulk equipment.
• Each field storage tank should be clearly
marked with its contents. A field test blend
sample must be taken during the loading. 8.1.4.1 Prejob safety meeting
• The proper equipment to rig up the truck During the prejob safety meeting, the FS/FE
to the storage tank and the storage tank to reviews the location of each cement system
48 | Bulk Equipment Operations

and ensures that the bulk operators know the This is also the maximum rate for dry bulk
sequence to follow while unloading tanks. material passing through the knife-gate/mixing
The FS/FE ensures that the designed pump bowl. This equals a maximum liquid 15.8 ppg
rate does not exceed the capability of the bulk slurry rate of 8.2 bbl/min.
system. A rule of thumb for the maximum bulk
delivery rate from a standard Schlumberger A bulk delivery log should be kept so that the
pressurized bulk tank is 4,000 lbm/min. This delivery rate from a specific bulk system can be
number can be used to calculate the maximum better estimated.
mixing rate for each pump unit.
The bulk operator must know how to operate
the bulk tanks to achieve the best delivery rate
possible. Review the discussion on Steady
Dense Flow and Unsteady Dense Plug Flow in
Section 2, Principles of operation, earlier in this
manual.
Note:
The bulk delivery rate for a bulk
system depends upon the type of
bulk tank, the capacity of the air
compressor, the type of aeration
device, and the type of bulk
Figure 8-3. Prejob Safety Meeting material.
MASS BALANCE
Bulk cement Water Additive Mix Water Slurry

Lead 1,500 sks 285 bbl 75 gal 288 bbl 480 bbl
Tail 500 sks 59 bbl 25 gal 60 bbl 97 bbl
Total 344 bbl 100 gal 348 bbl 477 bbl
Tank Volume Volume Volume Volume

bbl gal bbl bbl
Stage Total Stage Total Stage Total Stage Total
Tank 1
Lead 500 sks 95 95 25 25 96 96 160 160
Tank 2
Lead 500 sks 95 190 25 50 96 192 160 320
Tank 3
Lead 500 sks 95 285 25 75 96 288 160 480
Tank 4 59 344 25 100 60 348 97 577

Tail 500 sks
Figure 8-5. Mass Balance

Set the weight indicator to zero with the tank
empty.
Figure 8-4. Job Execution
The bulk operator, surge can operator and

pump operator must be able to communicate Figure 8-5. Weight Indicator
with each other during the job. Review hand
signals during the prejob safety meeting. If Mark the scale of the weight indicator to show
possible, use radios with headsets to talk during the minimum and maximum weights with which
the job. the surge can will be operated. The tank should
be kept as full as possible without overflowing.
Excessive dust will enter the dust control
8.1.4.2 Surge can operation system if the surge can is too full.
Helpful Hint: The maximum weight to put into a

Note: surge tank can be estimated using the following
The FS/FE should inform the bulk equation:
operator and pump operator how
much slurry each bulk tank will Maximum weight (lbm) = V x W x F x C
make so that both operators can
estimate the volume left in a bulk V = Volume of the surge can (ft3)
tank from the total slurry pumped.
W = Weight of the bulk material (lbm/ft3)
F = Bulk load factor for the bulk material

The vent line from the surge tank should
be connected to a dust control device.
C = 0.5 to 0.75
Before blowing cement into the surge can,
This is a constant that depends on the design
ensure that its valves are in the correct position.
of the surge can.
Open the fill valve, open the air supply lines
and start blowing air through the vent. This will
The minimum level should be set 500 to 700 lbm
ensure that the vent is clear before attempting
under the maximum level.
to load the tank with cement.
It is important to keep the level in the surge
can as constant as possible because the rate

of flow from the surge can is dependent on the 8.1.4.3 Operation of gravity silos
height of material in the can.
If the surge can is not equipped with a weight

indicator, it should be kept approximately
Note:
two‑thirds full. This level can be maintained by A gravity silo is not a pressure
keeping the level of bulk material between the vessel. It is therefore not
first and second sight glass. recommended to connect the vent
line from the gravity silo to a dust
Before the job starts, transfer cement into the control device. If a dust control
surge tank from a bulk tank. It is advantageous device is connected to a gravity
to blow cement from as many tanks as possible silo, there is a risk that it could
to ensure that the bulk lines between the tanks become pressurized if air flow
and the surge can are open. were restricted or if the dust control
device became plugged. This could
Check the level of the bulk material in the surge cause a catastrophic structural
can versus the amount indicated by the weight failure of the gravity silo. Wherever
indicator. possible, therefore, the use of
gravity silos should be limited
Leave the aeration devices in the surge can to specific applications where
going while discharging cement to a jet mixer. pressure vessels cannot be made
This air keeps the material in the surge can available; for example, in a remote
fluidized and prevents the cement from bridging location where all equipment and
off inside the can. materials must be mobilized by
helicopter.
STEP 01 Before blowing cement into the

gravity silo, make sure that its valves are in the
correct position.
STEP 02 Open the air supply lines and start

blowing air through the vent. This will ensure
that the vent and pads are clear before you
attempt to load the tank with cement.
STEP 03 Close off the air supply line and

open the fill line.
STEP 04 Blow air from the bulk tank that

will be used to fill the gravity silo. The jet line
from the bulk tank can be used to supply the
air. This will ensure that the conveying line is
open.

the air supply to a minimum during the cement
Note: job.
Only one type of cement system
can be loaded into the gravity silo. Start the air compressor’s engine; allow
Make sure that you do not exceed the engine to warm up for 5 minutes
the capacity of the tank. before engaging the clutch to power the air
compressor. The air compressor must be run
at the manufacturer’s recommended maximum
speed.
STEP 05 Before the job starts, fluff the
cement in the gravity silo. If a high-volume
compressor is used to supply air to the tank, 8.1.4.5 Bulk tank
fluff the material for 10 minutes. You should fluff Transfer the bulk material from the bulk truck
the material for at least 20 minutes if you are to a storage tank or mixer using the same
using a low-volume blower-type compressor methods described for moving material from a
sometimes found on double pump cementing bulk tank to a WBB in a pressure plant (refer to
units. Section 8.1.3).
Fluffing the bulk material helps it to flow out

of the tank during the job. The more air you
pass through the aeration devices and bulk
material, the more moisture you pass through
the system. Fluffing also tends to cause heavy
additives to settle in the tank. Therefore, avoid
fluffing for long periods of time.
It is important that the interior walls and

discharge valve of the gravity silo are clean and
free of hard cement.
8.1.4.4 Air compressor

Figure 8-6. Job Execution
If there are two or more compressors on
location, make sure that lines are run to
connect them together. This allows a smooth
transition from one compressor to the other if a
problem does arise.
The air compressor supplying air for the bulk

system must be dedicated to the bulk system
and not be used for other purposes during the
job. The rig may provide the bulk air supply.
The same air system may be used to supply
power to run air hoists, needle guns, the driller’s
controls, and so on; therefore, it is important to
request the rig personnel to keep their use of

8.1.4.7 Discharge valve
This valve, in conjunction with the jet air valve,
will determine the rate of bulk delivery.
8.1.4.8 Jet air valve

This valve supplies additional air needed for
the bulk tank to deliver material in the Unsteady
Dense Plug Flow.
8.1.4.9 Bulk tank level

The bulk operator must learn how to estimate
the level in a tank. Tracking the level of the tank
Figure 8-7. Air Compressor allows the bulk operator to anticipate when
the tank will empty. The bulk operator should
The bulk operator has to operate three valves keep the pump operator informed of the level of
(bottle or silo valve, transport discharge valve (if cement in the tank.
bulk truck), and gooseneck valve) to control the
discharge from a bulk tank. A weight indicator is the preferred method of
estimating the amount of material in a tank.
Most bulk tanks are not equipped with weight
8.1.4.6 Air supply valve indicators, so some other method must be
used. A suggested method is to slap the side
This valve is used to maintain the desired
of the tank with an open hand. The vibration of
pressure in the bulk tank. The operator must
the metal as well as the sound of the slap can
monitor the pressure on the tank to keep the
be used to estimate the level of material in the
correct pressure. The desired pressure is 1 to
tank. A new operator must practice to develop
1.5 psi for each foot the tank must discharge
the ability to determine the level of material.
through. A maximum of 30 psi should be put on
most of our tanks.
Warning:
Never hit the tank with a hammer!
8.1.4.10 Wellsite execution requirements

A very important part of the operation is quality
control.
Samples must be collected in the field for

quality control as required by the Cementing
Minimum Service Quality Standards, InTouch
Figure 8-8. Monitor Pressure Gauge

Content ID# 3200513, and in the worst-case protection procedures are followed together
scenario, incident investigation. with those of Schlumberger.
The pressure on the bulk tanks should be bled

off. Do not open the vent valve completely until
the pressure is below 5 psi. A small valve on
the vent system can be used to bleed off the
pressure in the tank to prevent erosion of the
4-in vent valve. Opening the 4-in vent valve
quickly will cause a very high air flow in the
vent lines. This high air flow can damage the
dust control equipment (high air flows can blow
the socks off sock-type dust collectors) and/or
cause any loose hoses in the vent system to be
whipped about wildly.
If any appreciable amount of material is left in

the bulk tank, its volume should be estimated
and the FS/FE notified. The FS/FE will
determine how the excess material is to be
handled. If it is in a bulk truck, the material will
be returned to the District. If it is in a storage
tank, it will have to be blown back into a bulk
truck to be transported back to the District. If
the storage tank will be remaining on location
for future jobs and the same type of cement will
Figure 8-9. Taking a Sample be used, the material can be left in the tank.
In Section 2 of the Cementing Minimum

Service Quality Standards, InTouch Content
ID# 3200513, the amounts of cement, mix water
and additive samples are outlined. Review and
follow these requirements.
Be sure to also follow the policies of your

district regarding the labeling of sample bags
and containers.
8.1.5 Rigging down

After all the cement has been mixed, the bulk
equipment should be rigged down. Be sure that
the location is left as clean as it was on arrival.
Always check with the client and drilling

contractor to ensure that their environmental

Figure 8-10. Rigging Down
8.1.6 At the District

The bulk tanks used on a job should be blown
down into the junk or reclaim tank when they
are returned to the District.
It is very important that these tanks are

maintained and that waste product is removed
periodically to prevent overflow into the vent
system. No contaminants should be left in the
transport to be sure that the unit is ready for the
next job.


9.0 Maintenance of Bulk Equipment
Figure 9-1. Maintaining Bulk Equipment
This section discusses the maintenance

of some basic bulk equipment parts.
Schlumberger depends on STEM inspections
being performed properly. If a problem is found
during a STEM inspection it must be corrected.
This guide leads you through some of the basic
repairs needed on bulk equipment.
When dealing with maintenance issues, always

consult your maintenance personnel.

9.1 Butterfly valves
Screw
Handle
Retainer pin
Washer
O-ring Handle
Upper stem
Release spring
Bolts
Handle release
Lock nuts
Retainer pin
Nuts Body
O-ring
Seat
Retainer pin
Disk
Lower arm
O-ring
Figure 9-2. Butterfly Valve Components
56 | Maintenance of Bulk Equipment

The standard check valve consists of a swing
gate. The valve should swing easily; it relies on
gravity to pull the gate down and close off the
line if air is not being blown through it. If the
check valve becomes plugged, or if it becomes
hung open, it should be removed and cleaned.
If the valve will not seal the swing gate, the seal
should be repaired or the whole valve replaced.
These valves should be disc types and require
no orientation to work properly.
Schlumberger also uses inline-type check

valves on some air supply lines. An inline check
valve relies on a spring to close the disc and is
now the preferred type of valve for this process.
Figure 9-3. Butterfly Valve
Butterfly valves should move easily and seal

against air pressure. The repair of butterfly
valves is covered in JET 1: Treating Equipment,
InTouch Content ID# 4127821. Whenever a
butterfly valve is removed from a bulk tank or
the bulk system, the piping should be inspected
for cement buildup. If buildup is found, it must
be removed at that time.
9.2 Check valves

Check valves are used in the air supply lines
(low-pressure) of bulk tanks as well as in the
discharge lines of air compressors. A check
valve allows flow in only one direction. These
valves help prevent the bulk material from
plugging up the air lines or damaging the air
compressor.
Figure 9-4. Disc-Type Valves

9.3 Ball valves
Low-pressure ball valves are used on the
air supply lines of bulk tanks. A ball valve is
designed as shown in figures 9-6 and 9-7. If the
valve begins to leak, it should be repaired or
replaced.
Nut
Handle
Packing nut
Packing
Washer
Body
Seats
Body end
Stem
Ball
Figure 9-5. Components of the Ball Valve

Figure 9-7. Pipe Jet
Figure 9-6. Ball Valve

If the pad has been in place for a long time, the
nuts may be difficult to remove and the studs
may break. A local welder can replace the
9.4 Aeration devices
studs in the pad holder. Remember to follow
the rules in WSSS 25: Confined Space Entry,
9.4.1 Pipe jets InTouch Content ID# 3313705 concerning tank
The membrane covering the pipe jet should be entry and the performance of hot work before
inspected and replaced if it becomes damaged. making any kind of repairs inside the tank.
Any cement must be removed from inside the
jet so that the inside is free of any buildup. The
preferred mounting is horizontal to prevent 9.4.3 Stainless steel pads
product from entering upon closing the pipe jet. Some bulk tanks are constructed with stainless
steel or porous bronze pads. These pads
perform the same function as the canvas pads.
9.4.2 Canvas pads Be careful when cleaning this pad material with
Any cement buildup on the top of the pad can a wire brush. If the pad is damaged it can be
be removed with a wire brush. If the pad has replaced with canvas.
been damaged it must be removed and the
canvas replaced. The canvas material used is
4-ply cotton belting with interlock weave. The
canvas is cut to fit the pad it is replacing. The
area under the pad must be cleaned of any
cement when a pad is removed.
Figure 9-8. Pad Holder

9.5 Dust collector socks Figure 206 unions should be cleaned and
lubricated each time they are to be hooked up.
The O-ring on the male half and the sealing
surface on the female half of each union should
be cleaned and inspected before they are made
up.
Figure 9-9. Dust Collector Socks
The dust collector socks (bags) can be

damaged or blown off by flowing air at an Figure 9-10. Figure 206 Unions
excessive rate through the socks. This usually
happens when the pressure in a bulk tank is
released too quickly by opening a vent valve
9.6.2 Victaulic connections
too fast, or if the socks become plugged. Victaulic connections are used on bulk piping
to make connections that will not need to be
The socks will also be damaged or blown off if dismantled very often. These connections
a slug of cement is blown into the dust collector. are usually used to make the assembly of the
This will happen if a bulk tank is overfilled. piping easier, and to allow the piping to be
dismantled and inspected.
Maintenance Bulletin 532, InTouch Content
ID# 4128999, contains instructions for installing
and replacing dust collector socks.
9.6 Connections
9.6.1 Figure 206 unions

The main connections used with bulk equipment
are Figure 206 hammer unions. These unions
are designed for low pressure (rated working
pressure of 2,000 psi) and come in various
sizes. The Treating Equipment Manual, Version B,
InTouch Content ID# 3013931, lists the part
numbers for various sizes of unions. The 207
one-piece cap must not be used in cementing
Figure 9-11. Victaulic Connection
applications.

9.6.3 Dresser sleeve Testing of Pressure Relief Valves and Gauges,
InTouch Content ID# 3313707.
Dresser sleeve connections are also used
where a connection will not be dismantled very
often. These sleeves are used less frequently
because of the risk that vibrations will loosen
the sleeves.
Figure 9-12. Dresser Sleeve
Figure 9-14. Safety Relief Valve
The specifications, as well as the proper way

to mount and inspect these valves, can be
found in Maintenance Bulletin 625E MUST DO
- Pressure Vessel, and Relief Valve Inspection
and Test Procedures, InTouch Content ID#
3998770, which includes an inspection as
well as testing and calibration dates and
procedures.
Figure 9-13. Groove Fitting
Some countries have legal requirements
regarding the inspection and testing of
9.7 Safety relief valve relief valves. If local requirements exceed
Maintenance Bulletin 625E they are to be
These valves are commonly called pop-offs. followed. In the absence of local regulations,
It is essential that these pressure relief valves follow Maintenance Bulletin 625E.
function correctly when they are needed. The
valves keep the pressure in our bulk equipment
from exceeding set limits. This protects people
as well as equipment. All pressure relief valves
must comply with WSSS 27: Inspection and

9.8 Pressure gauges
All air compressors and bulk tanks should be
fitted with pressure gauges. Pressure gauges
allow an operator to control the operation of the
equipment safely and efficiently.
As with all mechanical equipment, pressure

gauges must be checked to ensure that they
are working properly. The Maintenance Bulletin
625E MUST DO - Pressure Vessel and Relief
Valve Inspection and Test Procedures, InTouch
Content ID# 3998770 lists part numbers for
the preferred gauges and also describes a
procedure for checking the accuracy of each
gauge.
The counterpart for the pressure gauge, which

is used in the pressure/vacuum system, is
a pressure/vacuum gauge that provides the
pressure and vacuum readings. It will read
30‑in mercury to 60 psi pressure. Figure 9-16. Vacuum/Pressure Gauge
9.9 Weight measuring devices

There are two types of bulk pant weight
measuring devices used in Schlumberger. The
mechanical load cell type, and the electronic
load cell type with digital readouts, which are
used in most new or upgraded plants in North
America today. These systems also have
pointer confirmation with a data link to the front
office.
Mechanical load cell

The load cells used on the WBB and surge
cans are hydraulic and are similar to the gauge
saver diaphragms used on triplex pumps. The
same hand pump used to inflate a gauge saver
diaphragm can be used to inflate a load cell.
For proper maintenance and calibration, refer to

Figure 9-15. Pressure Gauge the product maintenance manual.

supports, which may be cracked due
to fatigue and loose tie-down bolts.
f. Any welding or cutting performed to

be done on the tank must be done
by an ASME code shop with an
“R” stamp and re-inspected by an
ASME code inspector who prepares
a partial Data Report. In countries
outside North America all work
should be performed and inspected
to that country’s ASME equivalent.
Figure 9-17. Mechanical Load Cell
Items b. and c. should not be found on tanks in
permanent installations, but they may be fairly
common on mobile tanks.
2. All pressurized bulk tanks, regardless

of the products they contain, must
be pneumatically pressure tested to
the manufacturer’s working pressure
annually. This test is best performed
with the tanks full, as follows:
Figure 9-18. Digital Readout (left) and Electronic Load Cell
(right) a. Isolate and pressurize the tank to the
manufacturer’s working pressure.
9.10 Annual pressure tank inspection b. Ensure that the pressure relief valve
is functioning by noting the pressure
1. Inspect the exterior of the tank for the at which it relieves.
following:
c. Ensure that there are no leaks at any
a. Rust and pits in weld. connections or hatches. Any leaks
must be repaired before returning
b. Cracks in and near welds. the tank to service.
c. Sharp dents, especially in welded d. Document the results of the pressure

joints. test and retain them at the district.
d. Pay particular attention to cone, 3. The gasket on the manway must be

shell, and head penetrations (pipe removed, cleaned, and greased. The
entries) for cracks and pitting near mating surface must be clean and flat.
welds.
4. If the visual or pressure inspection
e. On the mobile tank pay particular by a Schlumberger inspector reveals
attention to welds at the tank any flaws or poor workmanship, an

ASME code or equal inspector must
be consulted for advice on how to
proceed. The code inspector may run
a magnetic particle and sonic thickness
test to determine the extent of any flaw,
damage, or wear. If the tank requires
repair, an ASME or equal repair facility
must perform the work. Each tank must
have an identifying number (unit/asset
number) which will be used to make a
record of the test for the unit file.
This test is best performed while the tanks are

filled to eliminate the tremendous air volumes
involved.
It is no longer a requirement to hydrostatically

test bulk tanks during the annual inspection.
The only time a hydrostatic test is required is
when a tank is repaired. This test is conducted
by the manufacturing or repair shop involved.

10.0 Glossary
Blow-down refers to the operation used to

clean out a bulk tank transport of any remaining
bulk material. The process used to clean out
residual bulk material is the same as that used
to empty a full bulk tank. The bulk tank truck
must first be pressured up, then the discharge
valve opened; the pressure in the tank will
fall quickly as the tank empties. This process
should be repeated until little or no bulk material
is discharged when the discharge valve is
opened.
Junk tank or reclaim tank: A bulk waste tank at

the district must be set up to receive unused
bulk material left in bulk tanks. The collection
tank of the dust collector is used as a junk
tank at many districts. This bulk tank must be
separated from the rest of the bulk system
to reduce the possibility of contaminating
other bulk materials with the returned cement
systems.
In a pressure/vacuum plant the use of the

weigh batch blender (WBB) is required to
remove waste product from the waste collection
tank. Product is drawn into the WBB by means
of vacuum and then transferred directly to
the bulk transport for waste removal through
an isolated valve primarily intended for this
purpose. This valve remains locked at all other
times.

64 | Glossary
11.0 References
All Schlumberger employees must be familiar WSSS 26: Air Tanks and Receivers, InTouch
with appropriate safety regulations and Content ID# 3313706
precautions because of the many hazards
involved in the oilfield industry. Be sure that WSSS 27: Inspection and Testing of Pressure
you know the relevant contents of the material Relief Valves and Gauges, InTouch Content
safety data sheet (MSDS) regarding required ID# 3313707
personal protective equipment (PPE) and
handling procedures when handling chemicals. WSSS 28: Pressure Management Operations,
November, 2003, InTouch Content ID# 3313708
CMSQS Cementing Minimum Service Quality
Standards WSSS 30: Pumping Combustible and
Flammable Fluids, InTouch Content ID# 3313709
JET Manuals
QHSE S001: Journey Management and
JET Reference Page, InTouch Content
Driving, InTouch Content ID# 3051691
ID# 4178854
QHSE S002: QHSE Reporting, InTouch
Well Services Safety Standards
Content ID# 3260257
WSSS 4: Facilities and Workshops, InTouch
Content ID# 3313678 QHSE S003: Personal Protective Equipment,
WSSS 5: Pressure Pumping and Location
Safety, InTouch Content ID# 3313681 QHSE S004: Emergency Response, InTouch
Content ID# 3253244
WSSS 11: Pumping Nitrogen, InTouch Content
ID# 3313684 QHSE S013: Mechanical Lifting, InTouch
Content ID# 3260276
WSSS 15: Lockout/Tagout, InTouch Content
ID# 3313691
WSSS 17: Storage and Handling of Oxidizers,

WSSS 18: HAZCOM, InTouch Content

ID# 3313694
WSSS 22: Coiled Tubing Operations, InTouch

Content ID# 3313710
WSSS 25: Confined Space Entry, InTouch

Content ID # 3313705

66 | References
12.0 Check Your Understanding
1. As compressed air flows though bulk 5. On most Schlumberger pressure tanks,

material, it tends to compact the particles. the pressure relief valves are designed to
A. true relieve at what pressure?
B. false A. 35 psi
B. 30 psi
2. The amount of material carried by air C. 20 psi
depends on which of the following factors? D. 15 psi
A. atmospheric pressure
B. amount of compressed air 6. The porous media used as aeration
C. geographical location devices in pressure tanks are commonly
made of high-density plastic.
D. pressure inside the holding tank
A. true
E. size of piping between tanks
B. false
F. pressure inside the receiving tank
7. Which aspects of coded pressure vessel

3. When conveying bulk material using construction does the ASME govern?
unsteady dense plug flow, the delivery Select all the correct answers.
rate is controlled at the discharge end of
the transport line. A. who owns the tank
A. true B. type of metal used for construction
B. false C. welding procedures
D. testing procedures
4. Which of the following is true about the fill E. use of approved welders and inspectors
line on a pressure tank?
A. The opening of the line will be at the
bottom of the tank.
B. The opening of the line will be at the top
of the tank.
C. The line is often constructed as a dip
tube.
D. The line must be positioned in a
specific place on the outside of the
tank.
JET 06- Bulk Plant Equipment | 67

8. Match each pressure vessel component 11. Which of the following components on a
with its description. reciprocating compressor is responsible
component for maintaining the desired pressure?
___ A.discharge line A. pop-off
___ B. pop-off B. after-cooler
___ C. rupture disk C. bleeder valve
___ D. pipe jets D. unloader
___ E. vacuum breaker
12. How is the ft3/min discharge of a rotary
axial compressor regulated?
Description
A. by varying the rpm at which the
1. an additional safety device compressor turns
2. primary pressure relief safety device B. by throttling the intake valve
3. starts as a hole in the middle-bottom of C. by throttling the exhaust valve
the tank
D. by an adjustable relief valve
4. enables compressed air to aerate
through cement
5. pressure system and additional safety 13. Match each type of compressor with its
device principle of operation.
Type
9. Which of the following statements are A. reciprocating
true for both surge cans and gravity silos? B. rotary axial
Select three correct answers. C. vane type
A. They separate bulk material transport
from bulk material supply metering.
Principle of operation
B. They allow air used to transport bulk
1. Air is forced into a smaller diameter on
material to escape.
the discharge end.
C. They provide a buffer when switching
2. It acts like a blower.
from one P-tank to another.
3. It works like a two-cycle engine.
D. They can be used as storage tanks for
bulk material on location.
E. They are considered code tanks. 14. Which of the following is risked by
having a dirty air filter on a reciprocating
compressor?
10. The pressurized surge cans used by
A. Dirt could cause vanes to disintegrate.
Schlumberger are equipped with a side
discharge. B. The four-way valve could be clogged.
A. true C. Oil could be carried to the pads in the
bulk cement tank.
B. false
D. The after-coolers could overheat.
68 | Check Your Understanding

15. Match each moisture removal device with 20. A pressure vacuum system has the
its principle of operation. following two advantages:
Device A. Less dust is generated.
A. after-cooler B. Cleaning is easier than for bulk tanks.
B. dryer C. Costs are lower.
C. water separator D. No code is needed.
D. inline water separator
21. All storage tanks on the inlet side of the
Principle of operation WBB require a full _________ vent on
top of the tank for each individual product
1. desiccant cartridge being stored, and a 2-in _________ on the
2. centrifugal force tank.
3. condensation through thermal change A. open
4. slows air down B. closed
C. valve
16. What is the rule-of-thumb amount of D. vacuum breaker
lubricant that a lubricator should add to
compressed air?
22. The vacuum pressure plants use
A. 14 to 16 drops per minute _________ pumps:
B. 10 to 12 drops per minute A. 1
C. 4 to 6 drops per minute B. 2
D. 1 to 2 drops per minute C. 3
17. National regulations are the most
important regulations in the design of
Schlumberger dust control devices. 23. The WBB is also used as a _________ to
blend and move material.
A. true
A. container
B. false
B. P-tank
C. hopper
18. Pleated paper cartridge dust collectors
are built with a bypass mechanism that D. sand belt
provides overpressure protection.
A. true
B. false
19. The use of the additive hopper eliminates

the use of _________.
A. additive bottle
B. compressor
C. WBB
JET 06- Bulk Plant Equipment | 69

70 | Check Your Understanding

JET Manual 06: Bulk Plant Equipment

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JET 06 Bulk Plant Equipment | iii

iv | Table of Contents

JET 06 Bulk Plant Equipment | 

vi | Table of Contents

JET 06 Bulk Plant Equipment | 

2.1 Purpose of a bulk system Pressure tanks

defined here includes all associated equipment

• low manpower requirements

• air compressors (two: one high-pressure for

JET 06 Bulk Plant Equipment | 

Figure 2-3. Bulk System Components

2.3 Principles of pneumatic conveying

The amount of material carried by the air

• the size of the piping between the tanks,

10 | Principles of Operation

Figure 2-7. Surge Can

• the pressure of the receiving tank (e.g.,

Figure 2-8. Air Velocity High

Few particles of the bulk material are being

Figure 2-6. Bulk Tank

Figure 2-9. Lower Air Velocity

JET 06 Bulk Plant Equipment | 11

Lower air velocity

Guidelines for operating Schlumberger bulk

12 | Principles of Operation

2.4 Principles of vacuum conveying

• All products stored in non-pressure storage

• All storage tanks are nonpressured and

JET 06 Bulk Plant Equipment | 13

14 | Principles of Operation

This section describes the major components Pressurized tanks

Schlumberger uses two types of bulk storage

Figure 3-2. ABT Truck

Figure 3-1. Bulk Storage Tank

JET 06 Bulk Plant Equipment | 15

3.2 Pressure tank

Vent line Fill line

Figure 3-3. Surge Can

Some of the many names for tanks used as

Pressurized tanks are sometimes referred to by 3.2.1 Pressure tank components

Non-pressurized tanks are also known by

16 | Bulk Systems

Figure 3-5. Fill Line and Discharge Line

3.2.1.2 Discharge line

3.2.1.3 Vent line

JET 06 Bulk Plant Equipment | 17

Air slide 15 18+15 psi

Figure 3-8. Pressure Relief Valve Close-Up

Some tanks are also equipped with a rupture

Schlumberger uses many pressurized tanks.

18 | Bulk Systems

3.2.1.8 Pipe jets

Figure 3-9. Pressure Gauge Air flow

Vent line Fill line

Pressure relief valve

Figure 3-10. Air Supply Line

JET 06 Bulk Plant Equipment | 19

If the manway is located on the top of the tank,

JET 06 Bulk Plant Equipment |

JET 06 Bulk Plant Equipment |

JET 06 Bulk Plant Equipment |