CSS421

Cement Silo Skid

Operating Manual
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Table of content

Unit overview..................................................................................................................................................3

Specifications ................................................................................................................................................4

QHSE .................................................................................................................................................................5

Personnel safety............................................................................................................................................5

Environmental................................................................................................................................................5

Safety signs ...................................................................................................................................................5

Local regulations...........................................................................................................................................6

Operation and job execution ....................................................................................................................7

Maintenance ...................................................................................................................................................8

Placement.......................................................................................................................................................8

Lifting .............................................................................................................................................................8

Transportation ...............................................................................................................................................8

Inspection.......................................................................................................................................................9

Appendix A. CSS421 Layout drawing ..................................................................................................10

Appendix B. CSS421 GEMS BOM .........................................................................................................11

Appendix C. Hydrostatic test procedure ............................................................................................12

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Unit overview

The CSS421 is a 30m3 cement silo mounted on a skid. It is designed to store dry cement or other bulk solids as
a part of cement storage area of a bulk plant. It is also used to prepare dry cement mixes.
The cement silo is a vertical reservoir consisting of a tank and a skid. The tank is made of a shell, a cone, and
elliptical flat bottoms (Ø2400mm and Ø1200mm). A discharge line, an airpad, and the air supply are placed in
the dished bottom of Ø1200мм. A hatch for maintenance access is welded on the cone, as well, as load/vent
lines. Schlumberger ID tag is riveted on skid beam, accessible in both vertical and horizontal silo position.
Steel ladder with Tank
safety cage

Air manifold with

Top protection
hoses
for harness

Discharge, fill,
load lines
Skid
SLB ID tag
Figure 1:CSS421 horizontal position

8-section airpad with needle

punched fabric

Figure 2: view of airpad inside silo

The design of this unit is controlled by Tyumen Product Center, Well Services Manufacturing. For any issue
pertaining to QHSE or equipment design, please notify this tech center when submitting your HSE/SQ ticket in
QUEST. Getting feedback from our customers will help us gradually improve our design and ensure
specifications that suit your needs.

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Specifications

Vessel part Shell

Operating pressure, MPa (kgs/sm2) 0.207 (2.07)
Design pressure, MPa (kgs/sm2) 0,284 (2,84)
Test hydraulic pressure, MPa (kgs/sm2) 0,355 (3,55)
Environment temperature, ºC - 40
+ 50
Shell design temperature, ºC + 50
Minimal admissible shell temperature, ºC - 40
Working medium Air, cement
Safety grade 3
Working medium characteristics Explosion hazard No
Fire risk No
Capacity, m3 30
Tare weight, kg 7100
Maximum medium weight, kg 39000
Design vessel’s life, years 10

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QHSE

Due to the many hazards in the oilfield industry, all Schlumberger employees must be familiar with the
appropriate safety regulations and precautions described in the Safety Standards for Well Services Operations,
content ID#4055049.
Anyone who feels an operation is unsafe has the right and duty to stop the operation.
When handling chemicals, ensure that you know the applicable contents of the material data safety sheets
(MSDS) regarding required personal protective equipment (PPE) and handling procedures. PPE is important,
but does not in itself prevent accidents; that is the responsibility of the individual—you.
You should also be familiar with the following:
ƒ Schlumberger QHSE Standard S002: QHSE Reporting, InTouch content ID# 3260257
ƒ Schlumberger QHSE Standard S003: Personal Protective Equipment (PPE), InTouch content
ID# 3260259
ƒ Schlumberger QHSE Standard S007: Management System Audit, InTouch content ID#
3260262
ƒ Well Services Safety Standard 4: Facilities and Workshops, InTouch content ID# 3313678
ƒ Well Services Safety Standard 18: Hazcom, InTouch content ID# 3313694
ƒ Well Services Safety Standard 25: Confined Space Entry, InTouch content ID# 3313705
ƒ Well Services Safety Standard 26: Air Tanks and receivers, InTouch content ID# 3313706
ƒ Well Services Safety Standard 27: Inspection and Testing of Pressure Relief Valves and
Gauges, InTouch content ID# 3313707

Personnel safety
Ensure that all relevant procedures and standards are followed at all times. Make certain that PPE is always
worn around the unit. All nonessential personnel should stay away from the unit during operation. If it is
necessary to climb up on the unit, exercise extreme caution.

Environmental
Any chemical spill must be contained, cleaned up, and reported according to local procedures. Dispose of spills
in an environmentally acceptable way and in accordance with local regulations.

Safety signs
Pay attention to the information on all decals, plates, and safety signs when around equipment.

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Local regulations
Specific local laws to be followed:
Only persons having reached 18 years age, learned manual, passed trough job related safety training,
regulatory attestation and safety induction are allowed for servicing of silo. Periodicity and order of inspection
and examination of vessel is to comply with “Rules of design and safe operation of pressure vessels PB 03-
576-03”.

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Operation and job execution

Filling: 1. Close both air lines, to airpad and to discharge
2. Close discharge line;
3. Connect dust collector hose to vent line;
4. Open vent line;
5. Connect fill hose to filling line;
6. Open fill line;
7. Start filling.
End of filling: 1. Close fill line;
2. Open vent line.
Discharge: 1. Close both air lines, to airpad and to discharge;
2. Close fill line;
3. Open vent line;
4. Connect dust collector hose to vent line;
5. Connect discharge hose to discharge line;
6. Open discharge line;
7. Open air line to airpad;
8. Open air line to discharge;
9. Start discharge
End of discharge: 1. Close air line to discharge;
2. Close air line to airpad;
3. Open vent line;
4. Close discharge line.
Storing: 1. Close both air lines, to airpad and to discharge;
2. Connect dust collector hose to vent line;
3. Open vent line;
4. Close fill line;
5. Close discharge line.
If storing time is more than 48 hours, follow next 1. Open vent line.
procedure to prevent cement “caking”: 2. Close both air lines, to airpad and to discharge;
3. Connect dust collector hose to vent line;
4. Close fill line;
5. Close discharge line;
6. Open air line to airpad for 5 minutes;
7. Close air line to airpad

Vent line Fill/load line

PRV

Air line to discharge

Air manifold

Air line to airpad Discharge line

Figure 3: detailed view of air, discharge, vent and fill lines.
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Maintenance

Placement
The silo is to be placed on open or covered area on a monolith reinforced concrete base designed by a
competent 3rd party.
The silo must be mounted in vertical position by an erector truck. Install ladder before mounting and
demounting operations. After the silo is installed, connect all nipples to operation lines. Valves should be
installed on silo’s inlets/outlets. To prevent ingress of cement dust to air line and compressor install check
valves on air line. Make sure that relief valve sealed after calibration with proper reference in valve and silo
passport, and that manometer installed on silo is stamped by certification officer with date of verification.

Lifting
QHSE standard #13 “Mechanical Lifting” must be followed during all lifting operations.
Horizontal silo lifting is to be performed with 4-point slings set of length at least 3000mm, and applicable load
16 tons as a minimum. Use shell mounted shackles to perform horizontal lifting operations.

Figure 4: Scheme of strapping.

Transportation
The silo can be transported without packing by following ways:
- motor transport;
- railway transport;
- water transport,
Local and SLB rules and standards of transportation, technical shipment and strapping for each type of
applicable transport must be followed.

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All methods of transportation must avoid mechanical damaging of unit.

The CSS421 must be transported in horizontal position and be empty.

Inspection
Daily:
- Visual inspection:
o Check shell and piping against leaks, cracks, splits and impacts.
o Look for hoses with loose clamps, clamps tightness.
o Check butterfly valves condition and performance.
- Fasteners, fittings tightness:
o Wing union’s connections to be tightened, if required.
o Impermeability of threaded connections to be checked with soap water.
- Painting:
o Corrosion and paint defects should be addressed in a proper way.

Annually:
- Airpad inspection. The silo must be emptied out and non-pressurized. Needle punched fabric to be
visually checked against burst and sanding/cementing to prevent low air flow rate. New needle punched fabric
to be installed if required.

Every 8 years:
- Hydraulic test must be done with pressure P=0.475 MPa, duration – 10 minutes. Vessel is to be
equipped with armature. Vessel must be stopped, emptied, hermetically plugged on all lines before hydraulic
test.

Out of turn examination must be done if:

- Vessel wasn’t exploited during 12 month;
- Vessel was demounted and installed on new place;
- Straightening of concavity or convexity was made, or re-construction/repair of vessel was made by
welding/soldering of pressure stressed elements.
- Before vessel shell is coated;
- After damage of the tank shell or its pressure-stressed elements, if repair volume requires such
documentation.
- Out of term examination should include all steps mentioned before.

SLB must control periodicity of inspections, internal examinations, hydraulic tests and technical examinations.

NOTE: Periodical technical examination is to be provided by 3rd party specialist with proper attestation.

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Appendix A. CSS421 Layout drawing

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Appendix B. CSS421 GEMS BOM

Level Name Rev Item # Brief Description U/M Qty

Parent 100269291 AD STORAGE,CEMENT 30M^3(1033FT^3),CSS421 EA
1 100263492 AD 10 TANK, CEMENT STORAGE 30 M^3, CSS421 EA 1
1 100266207 AD 20 SKID, I-BEAM FRAME CSS421 EA 1
1 100266422 AB 30 LADDER, W/SAFETY CAGE,CSS421 EA 1
1 100243713 AD 40 PIPING, AIR CEMENT SILO, CSS421 EA 1
1 100267233 AB 50 PROTECTION, TOP, CSS421 EA 1
1 100267581 AC 60 MANIFOLD,TANK SAFETY,1.5 IN EA 1
1 590669000 AA00 70 DECAL,SCHLUMBERGER 75 INCHES LONG, BLUE EA 2
1 100420532 AA 80 DECAL, VENT LINE, BLUE EA 1
1 100420545 AA 90 DECAL, FILL LINE, BLUE EA 1
1 100191359 AA 100 PLATE,UNIT IDENTIFICATION ESR EQUIPMENT EA 1
SHACKLE, W/SCREW PIN 28MM,OST 5-2312-79,
1 100415671 AA 110 85KN LOAD. EA 8
VALVE,BUTTERFLY 4 IN L/HANDLE W/90 DEG
1 429836000 AB 120 PLATE MODEL 12N,DI BODY & D SC,BUNA-N SEA EA 3
HANDLE,BUTTERFLY VALVE 4-6 IN STANDARD
1 429843000 AB 130 MOD 12N WITH NEW COIL TYPE SPRING, LESS 9 EA 3
1 100254650 AC 140 SUB, UNION 4IN FEMALE, LOW PRESSURE EA 3
1 100254652 AB 150 NUT, UNION 4IN 45MM LG, LOW PRESSURE EA 3
PLUG, UNION 4 IN W/O-RING GROOVE, LOW
1 100254654 AB 160 PRESSURE EA 3
CHAIN,WELDED,WIDTH=5MM,LENGHT=19MM,GOST
1 100244104 AA 170 7070-71. OR EQUAL MM 1350
1 100254647 AB 180 O-RING, 110MM X 5MM EA 3
1 100398562 AA 190 RING, RETAINING B135 GOST 13942-86 EA 3
1 100396155 AB 200 BOLT, HEX, M12, L=105, GOST 7798-70 EA 18
1 100420556 AA 210 SUPPORT, DISCHARGE LINE 114MM OD, CSS421 EA 1
1 100400697 AB 220 WASHER, PLAIN, M12, GOST 11371-78 EA 18
1 100393358 AA 230 NUT, M12, GOST 5915-70 EA 18
1 100245968 AA 240 RIVET,BLIND L=0.675'' 0.376''-0.500''. OR EQUAL EA 4
1 100421310 AA 250 EQUIPMENT, LOOSE, CSS421 RUSSIAN BUILT EA 1

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Appendix C. Hydrostatic test procedure

1. Location
Workshop area for low pressure tests.

2. Test equipment
- Pumping unit 6 bar;
- Pressure gauge (manometer) 0-6 bar;
- PRV set to 3.6 bar;
- Hose with Weco male 4” union Fig.206 on one end, connection to pump on other one;
- Ball valve G1½”, 6 bar;
- Fitting G1½” (threaded pipe);
- Three plugs with G2” thread, male;
- Plug with G1” thread, male.

3. Tank preparation
In preparation for the hydrostatic tests, the following procedure must be used:
3.1 Stop the compressor. Use Lock out/Tag out procedures on the air compressor during
the test.
3.2 Completely release all air pressure from the tank. Vent line must always be hard pipe
and placed in a direction away from any personnel in the area.
3.3 Disconnect all air and operation lines from the tank. Plug the dished head and the
discharge line jet with G2” plugs. Plug the vent and the fill lines with Weco female unions
Fig.206.
3.4 Inspect the outside surface of the tanks for corrosion or damage. Any minor damage
must be fixed. Tank replacement must be considered in case of senior damage.
3.5 Remove the safety manifold from the vent line. Plug the hole on vent line with G1”
plug.
3.6 Remove the square head plug from the top of tank and install G½” fitting with a ball
valve G1½”. It is important that this valve be placed so that all the air is removed. (Make
sure the working pressure rating of the valve is higher than the test pressure.)
3.7 Install the tank in vertical position.
3.8 Remove the pads (airpad belting assembly) from inside of tank. Ensure compliance
with “Confined space entry” standard during this procedure.
3.9 The tank can be tested at a test bay or wash bay. At the test location, install warning
signs marked: “WARNING - KEEP CLEAR. HIGH-PRESSURE TEST.”
3.10 The working pressure can be applied with a water pump. The pump assembly must
have a calibrated pressure gauge (manometer) that can show readings in units of 0.145
psi (0.01 bar). PRV for water must be installed on the pump discharge line and set to open
at 52.2 psi (3.6 bar).

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3.11 If a hydraulic pump is not used (for example, air pump in the test bay), a regular PRV
must be installed on the discharge pump line and set to open at 52.2 psi (3.6 bar). Before
starting the test, this opening pressure must be checked by applying pressure to the valve.

4. Test procedure
It is recommended to follow this test procedure. Location can adopt these procedures, but must
make sure that the tank is tested correctly and safely.
4.1 Connect the test pump discharge to the tank discharge line with a hose with Weco
male union.
4.2 All other connections on the tank must be plugged except the pump discharge line and
the vent connection (on top of tank).
4.3 Open the vent valve and fill the tank with water on approximate 1/3 of volume.
4.4 Turn off the pump and close vent connection on top of the tank.
4.5 Check tightness, leaks on all connections, tighten as required.
4.6 Open the vent connection on top, fill the tank.
4.4 When the tank is full and the vent valve is open, pump additional water with the test
pump so that all the air is removed from the tank.
4.5 Close the vent valve and slowly increase the pressure in the tank to 51.5 psi (3.55 bar).
4.6 Stop the pump and hold pressure in the tank while you check for leaks.
4.7 After the tank holds pressure for 10 minutes, release the pressure and drain the tank.
The tank can be returned to service after drying and re-installation of airpad. Mark the test
information on the tank.

5. Recording the tank test

5.1 The hydrostatic test must be recorded in the maintenance files. The record must show
the test date, the test pressure and person performing the test.
5.2 The following information must be marked on the body of the tank in a visible position:
TEST DATE:
TEST PRESSURE: _____ psi (kpa)
This mark must be painted with black letters approximately 1 inch high.

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