PCM Operation 101

Schlumberger Private
Kim Hodgson
Sustaining Engineer
Schlumberger
 Rig Up
• Raise handrails
• Lower ladders

Schlumberger Private
• Lower jacks

2 KAH
11/2/2005
 PCM Tanks and Piping

Schlumberger Private
3 KAH
11/2/2005
 Staging Valve Positions

Normal Stage 2

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Stage 1, Stage 3
circulate

4 KAH
11/2/2005
 Staging Summary
Stage From To
• Normal frac tank tank 1

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• Stage 1 tanks 1&2 tank 3
• Stage 2 tanks 1-4 tank 5
• Stage 3 frac tank tank 5

5 KAH
11/2/2005
 Circulate Hydration Tanks
• Run C-pump 2 to circulate
tanks 5 and 6

Schlumberger Private
• Open Gate 2 to circulate
bottom of tank 6
• Go to Stage 2 shutdown,
flows from tank 5 thru tanks
4 and 3
• Crack open V15 fill valve to
circulate tank 1
6 KAH
11/2/2005
 Pressure Out Rear
(Bypass)
• Use 4” discharge hose only
• Close tank 6 fill

Schlumberger Private
• Close discharge valve
• Open bypass valve
• Adds may not run
against pressure

7 KAH
11/2/2005
 Pump Back to Frac Tank
• Use 4” discharge hose on suction manifold
– Violates safety standards to flow back through 8” hose

Schlumberger Private
• Move fluid to rear tanks
• Go to normal fill, but close V15 into tank 1
– Opens C-1 suction to frac tank
• Open V18 between C-pump discharges
• Pump with C-2 backwards through C-1 to tank

8 KAH
11/2/2005
 LSG System Preparation

Schlumberger Private
Open tank
valve Close
circulating
valve

Inject air here

Open to run

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C-pump

Open
Open

10 KAH
11/2/2005
 LSG Run
Recirculate,
Downhole

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Open
Open
Open supply
valve

11 KAH
11/2/2005
 Don’t Do This

Schlumberger Private
Stop Pump

Leave
supply
valve open

12 KAH
11/2/2005
 Reverse LSG Pump

Lever left
to reverse

Schlumberger Private
Adds cannot
reverse

13 KAH
11/2/2005
 Flush LSG System
• Close circulating valve
• Close tank valve

Schlumberger Private
• Open flush tank valve
• Check flush (into bucket) by C-pump 1
• Switch to re-circulate
• Briefly open pump bypass, circulate valve
• Close flush tank valve
• Stop system
14 KAH
11/2/2005
 Check Add Flow Meters
• Prime system in re-circulate
• Stop system, close valves

Schlumberger Private
• Look for steady density and
flow before zero check
• Re-
Re-zero is rarely
necessary!
• If density and flow are not
constant, don’t re-zero

15 KAH
11/2/2005
 Check Sight Glass
• Re-circulate at 4 GPM
• Open sight glass valve

Schlumberger Private
• Close tank valve
• Time one gallon (15 sec)
– Measurement is much less
accurate than flow meter
• Re-open tank valve
• Any error is due to bad zero

16 KAH
11/2/2005
 Fill From Off-Board Additive Tanks
• Put into recirculate
• Close tank valve

Schlumberger Private
• Close sight glass valve
• Connect hose to off-board
tank
• Operate pump slowly until
primed.
Off-board
tank • Avoid over-filling

17 KAH
11/2/2005
 Run From Off-Board Additive Tank
• Use short 2” suction hose to
off-board pump

Schlumberger Private
• Close tank valve and sight
glass valve
• Prime up into discharge
• Operate pump slowly until
primed.
Off-board
tank
18 KAH
11/2/2005
 Switch Additive Tank
Use for
• Connect 2” hose between • Two tanks, one add
suctions
• Spare system for back-up

Schlumberger Private
• Open only tank(s) in use
• Emergency back-up
– Drop non-critical add

19 KAH
11/2/2005
 Empty Add Tanks
• Use external pump, pull from
suction pipe

Schlumberger Private
• Attach hose to 3-way drain
valve
– Run in Down-Hole, pump off
– Also used to change add
injection point

20 KAH
11/2/2005
 Draining Additives
• Close tank valve
• Drain pump suction into bucket
• Drains back through Waukesha pump

Schlumberger Private
– Check valve is at high point
• Drain discharge line from 3-way valve into bucket

21 KAH
11/2/2005
 Normal Hydraulic Pressure
• Charge pressure at idle, cold: 275 – 325 psi
• Charge pressure at idle, warm: 225 – 275 psi

Schlumberger Private
• Charge pressure at full throttle, warm: 260 – 300 psi
– Set at 280 psi
• Additive main pressure: 1500 psi
• Mixer main pressure: 3000 psi
• C-1, C-2 main pressure: 400 – 3500 psi

22 KAH
11/2/2005
 Temperature Extremes
• Hot weather • Cold Weather
– Keep screen shaded – Computer will not start until

Schlumberger Private
– Screen goes black when warm
overheated – Unload hydraulics to start
– Operators should avoid engine
exertion, lie under a tree – Use green anti-freeze in air
lubricator

23 KAH
11/2/2005
 C-Pump 2 Back-up
• Keep tanks full with C-1
• Keep level high

Schlumberger Private
• Open Gate 2 to keep tank 6 full
• Can do stage 1, stage 2, and stage 3 shut-down

24 KAH
11/2/2005
 C-Pump 1 Back-Up
• C-2 takes the place of C-1
• Switch 5 valves

Schlumberger Private
– Close valve on C-1
– Switch two manual suction valves
– Switch two valves on C-2 discharge
• Close tank 6 fill, open V18
• Operate like back-up Open
for C-2 gate 2

• Can still do shutdown stages

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flush – Opens Gate 1 and V13B

26 KAH
11/2/2005
 LSG Back-up

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Regulate
here

Close
circulating
valve

27 KAH
11/2/2005
 Computer Back-Up

Read

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discharge Adjust flow
rate,
calculate
desired
GPM

Read flow
28 KAH
11/2/2005
 Air Valve Back-Up

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Push here

29 KAH
11/2/2005
 Compressed Air Back-up

Attach tractor

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glad-hand
Open
valve

30 KAH
11/2/2005
 Rig Down
• Lower handrails
• Raise ladders

Schlumberger Private
• Raise jacks

31 KAH
11/2/2005
 Fill Hydraulic Oil
• Hydraulic tank has internal walls, but will spill from
section to section

Schlumberger Private
• Always fill through top of near filter
– Oil will flow through filter before entering tank
• Never fill through breather
• Do not climb onto tank

32 KAH
11/2/2005
 Air Filter and Lubricator
• Drain filter regularly, check filter
• Fill lubricator with automatic transmission fluid

Schlumberger Private
• In cold weather use “green” anti-freeze
• NEVER NEVER NEVER use Marvel Mystery oil
– It swells and destroys rubber

33 KAH
11/2/2005