Chapter

7
Cementing Equipment
HCS Advantage System
The HCS Advantage system maintains the high standards set by its predeces-
sors, the RCM II series, by providing the industry with a high-energy mixer
capable of mixing thixotropic, difficult-to-mix slurries over a wide range of
densities and rates. The HCS Advantage skid (Figure 7.1) is built in six sections
for ease of shipping and handling. Mixing problems caused by high viscosity,
high density, air entrainment, and dust are significantly reduced with the RCM
II system included in the HCS Advantage skid.

The primary feature of the system is the axial flow mixer (Figure 7.2, Page 7-2),
which is used in conjunction with a variety of mixing tanks, including a single
compartment 5-bbl tank and double compartment 8- through 25-bbl tanks. The
mixer uses a high energy water jet, a high slurry circulation rate, and high
horsepower agitators to obtain a thoroughly homogenized slurry.

Figure 7.1—HCS Advantage skid containing the RCM® II.

April 1996 Cementing Equipment 7-1

 The following section briefly explains the operation of the RCM II.

1. Dry bulk cement enters the mixer through the top and is controlled by
either a conventional or low profile throttling valve.
2. A sleeve inside the mixer guides the bulk cement to a region of high
turbulence, where it is intercepted by the mix water and recirculated
slurry.
3. A single mix water jet forces the mix water to intercept the dry cement
just below the sleeve. Mix water flow control is provided by a single
metering valve.
4. A single high capacity recirculation jet, opposite the water jet, directs
recirculated slurry to a point just below the sleeve, generating a region of
high shear.
5. Two flow detectors in the mixer body generate additional turbulence that
serves to thoroughly wet the dry cement and shear the slurry.
6. The energy of the resultant slurry exiting the axial flow mixer is dissi-
pated by a diffuser plate located just below the fluid level in the mixing
tank. The result is vastly reduced air entrainment.
7. In the tank, the slurry is mixed further by high horsepower agitators. To
achieve optimal performance, the number and configuration of the
agitators is matched to the particular mixing tank design.
8. The recirculated slurry passes through a densometer at a high rate so that
the actual density of the slurry in the mix tank is always known.

Bulk Cement
Control Valve
Bulk
Bulk Cement
Inlet
Mixing
Water
R/A
Densometer
H2O

Recirculating
Fluid

Turbine
Agitator

Screen

Recirculating
Slurry to Centrifugal Pump
Displacement
Pumps

Figure 7.2—Axial flow mixer flow schematic.

7-2 High Pressure/High Temperature Cementing April 1996

 9. When the tank is full and at the necessary density, the slurry is ready to
pump downhole. The mixing process can continue on a steady, continual
basis. Normal mixing rates range from 0 to 12 bbl/min.

Advantages
• Thixotropic slurries can be mixed easily over a wide variety of slurry
densities and rates.
• Compared with conventional mixing systems, air entrainment is signifi-
cantly reduced, thus providing more accurate density measurement.
• High recirculation rates provide faster density measurement response.
• The RCM II system can be used with gravity feed bulk systems.
• Cement dust has been reduced significantly or eliminated altogether.
• The system easily mixes slurries up to 22 lb/gal.
• Excellent mixing and slurry weight control make the RCM II ideal for
critical liner, plugback, and squeeze jobs.
• The slurry is mixed using improved wetting efficiency and high energy
mixing.
• Low air entrainment and a high sampling rate ensure better density
control through better density measurement.

Standard Features
• axial flow mixer
• variety of mix tank configurations, up to 25 bbl in two or three compart-
ments
• recirculating centrifugal pump
• mixing water centrifugal pump
• densometer (U-tube or radioactive)
• hydraulically driven agitators
• cement throttling valve

April 1996 Cementing Equipment 7-3

 ADC (Automatic Density Control) System
Cement job success depends on consistent and precise density control of the
slurry as it is being mixed. The Automatic Density Control (ADC) system
(Figure 7.3, Page 7-5), incorporated with a recirculating cement mixing system,
provides accurate control of the cement-to-water ratio and the slurry mixing rate.

The heart of the ADC system is the Unipro II microprocessor connected to a

fast-response digital radioactive densometer mounted in the recirculating loop of
the mixing system. Monitoring the density of the recirculating cement slurry, the
ADC system responds to variations in slurry density by controlling the position
of the cement throttling valve mounted on the mixer. Additionally, the ADC
processor controls the mixing rate by monitoring the mix-water flowmeter and
positioning the mix-water metering valve accordingly. Control is provided by
using electric over hydraulic positioning to operate actuators attached to the
cement throttling and mix-water valves. With the quick response of the Unipro II
controller, the ADC system can limit the slurry density variations to within ±0.2
lb/gal of the required density.

Through the operator interface keypad, the operator can enter the information for
the blends to be mixed, including the density, yield, water requirement, and
mixing rate. The operator then initiates the startup routine, which fills the tub
with the correct amount of water required for the initial mixing of a specific
blend. The operator initiates the density ramp through the interface panel,
bringing the slurry in the mixing tub up to the required density. The operator
then initiates the mixing process, which will begin mixing the lead slurry at the
required density and rate. At any time during the mixing process, the operator
can instantaneously change the mixing rate without affecting the density. Once
the lead slurry is mixed, the operator can command the ADC to upload the data
entered for the tail slurry, and the ADC system begins mixing the slurry at the
density and rate required for the new slurry.

ADC Features and Benefits

• improved density control
• precise automatic start-up routine
• multiple stage mixing capability
• capability to instantly change the rate without changing the density
• capability to change the density without changing the rate
• simplicity of operation

7-4 High Pressure/High Temperature Cementing April 1996

Figure 7.3—ADC system.

COMPUPAC Data Acquisition and

Analysis
The COMPUPAC is a portable data acquisition system used in Halliburton
cementing, well testing, and stimulation services (Figure 7.4, Page 7-6) . The
new unit combines the features and capabilities of several existing systems such
as the PDR, 73PFO, CT-DAS, and APCS (Automatic Proppant Control system).
COMPUPAC can be used for the following tasks:

• monitor treating parameters

• obtain permanent record of job
• evaluate job performance

COMPUPAC also offers the following features:

• withstands offshore environment

• meets zone requirements
• adapts to a variety of input/output requirements

The heart of the COMPUPAC system is an IBM®-PC compatible computer that

records and processes data from proprietary data acquisition hardware. The
computer has a high-speed microprocessor and a math coprocessor that easily

April 1996 Cementing Equipment 7-5

 Figure 7.4—COMPUPAC system.

allows it to perform complex analysis tasks. Full IBM compatibility means job
data can be provided to customers on IBM-compatible 31/2-in. disks at the
wellsite in a Lotus 123®-compatible ASCII format.

The IBM-PC compatible computer in the system has a large, state-of-the-art,

backlit LCD display for maximum visibility. The compact system also contains
a printer capable of producing high quality data printouts or plots during or after
the job.

The basic COMPUPAC system is capable of monitoring transducer inputs for

the following:

• three pressures
• one temperature
• three flows
• one density

While monitoring the basic transducer inputs, the system simultaneously can
acquire pressure, flow, and density data from multiple remote UNI-PRO units.
Data can be sampled and recorded once per second. The portable system is
housed in a 21.5- by 20.5- by 8.0-in. suitcase and weighs approximately 45 lb,
excluding sensors.

7-6 High Pressure/High Temperature Cementing April 1996

 COMPUPAC w/optional Remote Display Unit Automatic Proppant Control System
(Basic Cementing Pressure, Rate, Density) (APCS) (Fracturing)

A. B. RPM

Electro Hydraulic Valve

UNIPRO

Lan Cable Digital Rate 1 Lan Cable Electro Hydraulic Valve

Densometer
12VDC RPM

Control
Stand

Electro Hydraulic Valve

Digital
12VDC Densometer
2.5 amps 8" 3"
Pressure 2 Pressure 1 Rate 2
Turbine FM Turbine FM

COMPUPAC System (Basic Cementing & COMPUPAC System with Optional Overhead
Stimulation Pressure, Rate, Density, Temperature) Display Unit for Van Mounting (Fracturing & Cementing)

Rate 1

Digital
Temperature Densometer

Rate 2

12VDC Rate 3
2.5 amps

Pressure 3 Pressure 2 Pressure 1

Figure 7.5—COMPUPAC configurations.

A. COMPUPAC with optional remote display unit.
B. Automatic Proppant Control System.

The COMPUPAC was designed to be used with the latest Halliburton transduc-
ers. All power necessary for the transducers is supplied by the base unit. The
COMPUPAC can be powered from a 12 V DC car battery or any available 110
or 220 V AC power source.

In its base configuration, COMPUPAC is well-suited for monitoring typical

stimulation and cementing jobs (Figure 7.5, Page 7-5). Optional hardware and
software allow the COMPUPAC system to be used in a variety of applications:

• job design using programs previously run on a mainframe computer

• DST data collection and reservoir analysis using the popular REZSCAN
software
• closed chamber testing applications
• uses Halliburton’s Automatic Proppant Control system (APCS)
• becomes the recorder unit for Halliburton’s ACQUIRE system

Cementing/Stimulation Applications
Cement and stimulation jobs are handled easily by the COMPUPAC in its base
configuration. Pumping pressure, flow rates, and slurry density are recorded
once per second.

Foamed cementing is simplified with advanced gas calculations, including N2

flow rate in standard units and foam quality. Stimulation services such as

April 1996 Cementing Equipment 7-7

 AQUAFOAM, NIOFRACSM, C-O-TWO fluid, ALCOFOAM, and straight
Nitrogen fracs are fully supported. The more traditional gel, Liquid Gel Concen-
trate (LGC), and acidizing treatments also are supported. Data can be presented
in either English or metric units.

Features
• portable suitcase-size system
• IBM®-PC compatible computer
• customer disks in Lotus 123®-compatible ASCII format for all pumping
services
• unit can be powered from commonly available 12 V DC or 110 or 220 V
AC sources
• samples eight transducers directly while recording and processing data
from multiple remote UNI-PRO’s
• flexible, software-controlled transducer configuration
• approximately 50 measured and computed job parameters for cement-
ing/stimulation services:
• tubing, casing, annulus, N2, and CO2 pressures
• N2 and CO 2 rates and volumes in standard units
• foam quality at surface
• slurry, return, foam, N2, and CO2 densities
• surface foam rate and volume
• one-second update and recording rate
• full-featured playback capability
• English and metric units available in any combination
• external communications capability for data transfer following a job
• self-contained printer/plotter
• event and stage notations for pumping operations
• comprehensive job summary and title pages
• REZSCAN software support
• popular stimulation and cementing design programs support
• Automatic Proppant Control System (APCS) support
• CT-DAS support

7-8 High Pressure/High Temperature Cementing April 1996

COMPUPAC Specifications
Inputs
• three flows (frequency)
• three pressures (4 to 20 ma)
• one temperature (4 to 20 ma)
• one radioactive densometer

Display
• 10-in. diagonal backlit LCD
• 8.5-in. wide printout from a graphic printer

Communications
• LAN communications port
• RS232C Serial port

Computer
• 20 MHz, 80386 microprocessor
• 4 MByte RAM memory
• MS-DOS Version 5.0
• 120 MByte hard disk and 1.44 MByte 3.5-in. floppy disk

Power
• 10 to 14 V DC
• 110 or 220 V AC

Temperature
• Operating: 0 to 35°C
• Storage: -18 to 65°C

Physical
• L: 21.5 in.
• W: 20.5 in.
• H: 8.0 in.
• Wt: 45 lb

April 1996 Cementing Equipment 7-9

 Liquid Additive Systems
Halliburton Services offers a wide selection of liquid cement additives to help
ensure economical and successful oilwell cement jobs for our customers. To
provide efficient, reliable, handling, metering, and mixing of these liquid cement
additives, Halliburton offers a liquid additive proportioning system for the
Halliburton family of cement pumping skids that provides the following fea-
tures.

• precise metering of cement additive concentrations

• maintained additive quality by preventing additive contamination
• simple adjustment and calibration
• maintained product quality by preventing exposure to moisture
• trouble-free transfer of bulk cement blend
• minimized losses of bulk cement

Continuous Metering System (CMS)

The Continuous Metering System (CMS) consists of either three or four positive
displacement pumps that are capable of delivering any of Halliburton’s liquid
additives into the mixing water and to the cement mixer. Variable speed control
of liquid additive pumps is possible, and liquid additives are injected continu-
ously into the mixing water through the suction piping of the mixing pump.
Additives are not introduced through the displacement tank. The rate of injection
for each liquid additive depends on the rate of water through the mixing pump.
Injecting the liquid additives through the suction piping of the mixing pump
continuously yields optimum distribution of the liquid additives. As the mixing
rate increases, the rate of liquid additive injection also will increase. As the
mixing rate decreases, the rate of liquid additive injection also will decrease. The
mixing pump impeller blends the liquid additives with water before the mix
water is delivered to the cement mixer.

The Continuous Metering System (CMS) is controlled by the Unipro II during

the cement job. All setpoints for each additive are loaded into the Unipro II
before the job, and the operator monitors setpoints during the job. Data acquisi-
tion can be recorded and charted using a printer or COMPUPAC either during or
after the job is completed.

Four-pump systems include three hydraulically operated Hal Tank container

agitators as standard equipment, and three-pump systems include two hydrauli-
cally operated Hal Tank container agitators as standard equipment. The hydraulic
system is connected directly to either a 40-, 50-, or 60-hp electric motor, and all
components are mounted within a protective frame that is designed to accept the
mounting of either a 345-, 375-, or 549-gal Hal Tank container.

7-10 High Pressure/High Temperature Cementing April 1996

Electronic Liquid Additive Proportioning
(ELAP) System
Halliburton’s Electronic Liquid Additive Proportioning (ELAP ) system is
designed to meter liquid additives into the cementing skid displacement tank.
The ELAP system consists of a positive displacement, gear-type chemical pump
driven by a 5-hp explosion-proof electric motor. The pump’s components have
been selected for their resistance to corrosion from cement liquid additives.

The electronic control system for the ELAP system is controlled by the Unipro
II. The amount of fluid to be dumped in each side of the displacement tank is
loaded into the Unipro II before the job. A this time, the operator directs which
side of the displacement tank that the fluid is pumped to during the job. After
the correct side of the displacement tank is selected and the correct volume of
additive is loaded into the Unipro II, the operator pushes the start button to
begin dispensing additives. The liquid additive pump will pump until the
required volume of additive is obtained. The pump will then shut off automati-
cally.

Up to four liquid additive pumps can be operated from one controller. Liquid
additive quantities can be changed easily by the operator during the job.

Additive Transport Tank

Additive transport tanks are available to transport additives from the shore base
to the rig. These tanks are required when the additive storage tanks are perma-
nently mounted. The tanks comply with all appropriate regulations for marine
transport of a liquid cargo. Lifting devices and protective structures are standard.

April 1996 Cementing Equipment 7-11

7-12 High Pressure/High Temperature Cementing April 1996