CU12 B01-00-069 B en MANUAL

Part #: B01-00-069 Rev: B
Model PCS-521B
Twin Pump Cementing Skid
Operation & Maintenance

Instruction
SJS Limited
Add: Xihuan Rd, Jingzhou dis.Jingzhou city,Hubei Code:434024
Tel:(0716)8428889 Fax:(0716)8016063
E-Mail:sjs@ServaCorp.com Web Site:www.SERVAgroup.com
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PCS-521B Twin Pump Cementing Skid
Operation＆Maintenance Manual B01-00-069_B
Safety
Preface
Chapter Ⅰ Overview ................................................................................................................... - 7 -
1.1 Overall Dimension and Weight ...................................................................................... - 8 -
1.2 Adapter size.................................................................................................................... - 9 -
1.3 Main compositions ......................................................................................................... - 9 -
1.4 Ambient Parameters ....................................................................................................... - 9 -
1.4.1 Temperature................................................................................................................. - 9 -
1.4.2 Humidity ................................................................................................................... - 10 -
1.4.3 Vibration/oscillation .................................................................................................. - 10 -
1.5 Working Performance .................................................................................................. - 10 -
1.5.1 Pressure range ........................................................................................................... - 10 -
1.5.2 Maximum Flow Rate................................................................................................. - 10 -
1.5.3 Slurry density range .................................................................................................. - 10 -
1.5.4 Mixing Capacity........................................................................................................ - 10 -
1.5.5 Slurry density precision............................................................................................. - 10 -
1.5.6 Operating time.......................................................................................................... - 10 -
Chapter Ⅱ Lubrication Instructions........................................................................................... - 11 -
Chapter Ⅲ Operating Instructions ............................................................................................. - 25 -
Chapter Ⅳ Plunger pump power system.................................................................................... - 34 -
4.1 Diesel Engine ............................................................................................................... - 34 -
4.2 Transmission ................................................................................................................ - 34 -
4.3 Transmission Shaft ....................................................................................................... - 35 -
4.4 High Pressure Triplex Pump ........................................................................................ - 35 -
4.4.1 Triplex plunger pump ................................................................................................ - 35 -
Chapter Ⅴ Hydraulic System .................................................................................................... - 38 -
5.1 Hydraulic System Principle.......................................................................................... - 38 -
5.2 Hydraulic System Operation ........................................................................................ - 38 -
5.3 Troubleshooting ........................................................................................................... - 41 -
Chapter Ⅵ Air System ............................................................................................................... - 43 -
6.1 Air System Principle .................................................................................................... - 43 -
6.2 Air System Operation................................................................................................... - 44 -
6.3 Maintenance and Repairs ............................................................................................. - 46 -
Chapter Ⅶ Lubrication System.................................................................................................. - 47 -
7.1 Brief Introduction of Lubrication System .................................................................... - 47 -
7.2 Packing Lubrication System Operation........................................................................ - 50 -
Chapter Ⅷ Fluid Delivery System............................................................................................. - 51 -
8.1. Displacement tank....................................................................................................... - 51 -
8.2. Low Pressure Pipeline................................................................................................. - 51 -
9.1. Slurry mixing system .................................................................................................. - 54 -
9.2 Mixing water pump ...................................................................................................... - 59 -
9.3 Slurry Recirculation Pump ........................................................................................... - 60 -
9.4 Booster pump ............................................................................................................... - 61 -
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9.5 SJS-ACM System ........................................................................................................ - 63 -
Chapter Ⅹ High Pressure Manifold........................................................................................... - 66 -
Chapter Ⅺ Control & Monitoring System................................................................................. - 67 -
11.1． Console................................................................................................................... - 67 -
11.2．Gauges and instrument description ......................................................................... - 68 -
Chapter Ⅻ Brief Introduction of Slurry Mixing Operation Procedure ...................................... - 72 -
12.1 Operation instructions before cementing ................................................................... - 72 -
12.2 Continuous cementing job—manual control.............................................................. - 73 -
12.3 Emergency operation ................................................................................................. - 75 -
12.3.1 Emergency Operation of Water Pump..................................................................... - 75 -
12.3.2 Emergency Operation of Mixing Pump ............................................................. - 76 -
12.3.3 Emergency Operation Instructions.......................................................................... - 77 -
12.3.4 Post job cleaning ..................................................................................................... - 78 -
Chapter ⅰElectrical Circuit System.......................................................................................... - 79 -
13.1 Power Supply Circuit ................................................................................................. - 79 -
13.2 Overpressure Protection Electrical Circuit................................................................. - 79 -
13.3 Instrument and illumination ....................................................................................... - 80 -
13.4 XP5000/GD-A8D Explosion-proof detection system（optional） ........................... - 80 -
13.5 Auto Density Control Circuit ..................................................................................... - 81 -
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Safety
Proper service techniques and repair procedures are necessary
for reliable and safe operation of this equipment as well as safety of
the personnel performing the work. The following list contains some
general precautions the operator should follow when operating this
equipment, to avoid the possibility of personal injury or property
damage:
Make sure the equipment has the certificate to be operated in the dangerous area.
Check components of equipment in advance, ensure all the components are
properly and completely fixed.
If the equipment is in dangerous area, it’s forbidden to start the equipment when the
safety and protection system fails.
The safety protection system of the equipments with the certificate to be operated
in the dangerous area should be inspected to be qualified by authoritative
organization, and the operators must be trained to hold the working license.
The assembling, maintaining, repairing and operating staff should be trained to
hold working license.
The operator should carefully read and fully understand the operation manual
before operating the equipment.
The operator should carefully read and fully understand all the warnings, notice,
prohibition, the labels on equipment before doing operation and maintenance.
Do not remove the cover or guard of any equipment while the equipment is
running.
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It’s forbidden to dip the hands and feet into drive shaft, pump drive or other
mechanical parts while the equipment is running.
The high pressure outlet of equipment can only be connected by high pressure pipe,
it’s forbidden to use low pressure pipe.
Shutdown engine in case of fires, mechanical failure, and natural gas entering into
engine inlet resulting in engine out of control. The emergency shutdown system
can only be tested while stopping this equipment or run at idle speed, do not test
under full load to avoid damage to engine, with resetting inlet valve of the
emergency shutdown system after tested and before starting engine.
Company and person can not modify the equipment components without the
written authorization by SJS. Otherwise, all the results caused by random
amendment will be undertaken by modifier.
Warning—The electrical parts can be damaged from welding

on the unit unless taking the following measures.
z All power switches are off;
z The wires of electrical parts near welding are off;
z The welder blowpipe and ground wire are strictly forbidden to loop in through
electrical element.
Caution—Any welding on control equipment will probably extensively damage
computer, screen, sensor and electrical parts of auto control system.
Abbreviation
Definition of Abbreviation used
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Abbreviation Unit
lb Pound
kg Kilogram
ft Foot
m Meter
in. Inch
min Minute
bbl Barrel
kw Kilowatt
Hp Horsepower
Mpa Mega-pascal
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Preface
This manual covers main structure, specifications, operation and maintenance of Model
PCS-521B Density Auto Control Twin Pump Cementing Skid. Read these instructions
thoroughly and review until you fully understand before proceeding with the work
described in this manual. Failure to follow these instructions will result in personal
injury or damage to the equipment.
1. The cementing skid must be placed or fixed on the stationary and flat
foundation.
2. Only qualified personnel trained or familiarized with engine, transmission and
triplex pumps should install or operate these units.
3. The operator must wear proper personnel protective articles while working or
maintaining this equipment. i.e. coverall, hard cap, steel toe shoes and goggles.
4. Keep hands or feet away from moving parts of mixing tank, drive shafts, engine
to avoid personal injury.
5. If hydraulic system leaks, shutdown this equipment immediately for
troubleshooting.
6. After the completion of cementing operation, immediately wash and clean
mixing pipelines to ensure that pipelines are clean without any sediment. The dry bulk
cement shall be turned upwardly while washing jet mixer. Do not wash the bulk valve
with water.
7. The specific preventative maintenance system shall be established and strictly
follow specific instructions to ensure long-term normal working condition of these
equipment.
8. This manual doesn’t contain operation and maintenance of diesel engine,
transmission and triplex pump, you can attain them from documentation with these
equipment packages.
9. The documentation handover to user with these equipment covers operation and
maintenance manual, parts manuals of engine, transmission manual, ACM- III.1
system manual, 4x3 centrifugal pump manual, 5x6 centrifugal pump manual, TPH400
triplex pump manual, etc.
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Chapter Ⅰ Overview
Model PCS-521B Density Auto Control Cementing Skid is the new
generation cementing equipment based on plenty of proprietary techniques
such as TPH400 model field dedicated triplex pump, high energy
circulation mixing and ACM-Ⅲ.1 auto density control. The skid design is
utilized in offshore platform cementing job, acidizing job, pressure test and
other fluid pumping jobs. Two TPH400 high pressure triplex plunger
pumps are driven by the diesel engine with auto transmission separately.
Model TPH400 triplex plunger pump is a field dedicated single action
plunger pump, which is suitable for pumping various well conditioning
fluids except hypothermal fluid. High energy mixing system is driven by
closed hydraulic system, and its driving force is from two transmissions
PTO. It owns the characteristics of high mixing energy and even slurry
density. The core part of the skid---ACM-Ⅲ.1 model density auto control
mixing system is not only one of the most advanced slurry density control
systems all over the world at present, but also the most successful and the
most popular mixing technique used at offshore and land field.
The equipment design and production will reduce the requirement of
maintenance/repairs under higher environment temperature condition. The
entire equipment arrangement ensures that the operators can clearly and
comprehensively monitor the working condition of all the control switches,
instruments and each system. With the high automation, only 1-2 operators
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can finish the cementing job.
1.1 Overall Dimension and Weight
Gross weight(dry): 24t
Total length: 7,200 mm
Width: 2,590 mm
Height: 3,350mm (operating height with cement metering valve)
3,100mm (shipment height without cement metering valve)
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1.2 Adapter size
Water suction inlet: three 4" pipe steel
One 4" FIG.206，FEMALE
Cement metering valve suction inlet: one 5" hose adapter
High pressure discharge: two 2"FIG.1502, MALE
Drain outlet: four 4" couplings
Engine muffler exhaust assembly: two 5" stainless steel pipe/ 5"
straight steel pipe.
1.3 Main compositions
Two CAT C13 diesel engines, 475HP@2100RPM.
Two ALLISON 4700 OFS transmissions
Two SERVA TPH400 (4.5", 4")Triplex plunger pumps
One set of closed hydraulic system
One 12bbl mixing tank
One 25bbl displacement tank
Two SERVA 6x5 centrifugal pumps (Circulation and booster pump)
One MISSION 4x3 centrifugal pump (water and displacement
pump)
One set of auto density control mixing system(ACM-Ⅲ.1)
1.4 Ambient Parameters
1.4.1 Temperature
Minimum working temperature: -20℃(-4℉)
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Maximum working temperature: 50℃(122℉)
1.4.2 Humidity
Relative humidity: 90%
1.4.3 Vibration/oscillation
Maximum vibration:1g
1.5 Working Performance
1.5.1 Pressure range
Maximum working pressure: 96.5Mpa (14,000psi)
1.5.2 Maximum Flow Rate
Maximum flow rate: 2.7 m³/min(17.2bpm)
1.5.3 Slurry density range
Maximum slurry density range: 1.3--2.5 g/ cm³ (11—20.9lb./gal)
1.5.4 Mixing Capacity
Mixing capacity variation: 0.3--2.3 m³/min (2--14.4bpm)
1.5.5 Slurry density precision
When system is close to stable status, i.e. stable and accuracy
delivery of dry bulk cement, the densitometer reading will display
±0.01~0.02 g/cm3 (±.083~.167lb./gal) under auto control mode.
1.5.6 Operating time
4 hours continuous operation at rated working pressure; 4-6 hours
continuous operation at maximum flow rate.
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Chapter Ⅱ Lubrication Instructions
Lubrication is divided into two parts. The first part introduces the
oiling instructions, and describes the filler and oil amount of the
equipment. The following table lists the recommended oil types, and
different oil type is determined by different working environment. The
foreign countries recommend using Mobil and Shell. It’s acceptable to
use other brands if they can meet the using requirements.

Oil
Components Items Volume(L)
Type
Cooling system
TableⅠ
(fan radiator)
CAT C13
Engine oil TableⅡ 34Lx2
Engine
900L
Fuel Table Ⅲ
91.7L/Hr
Allison
Transmission Engine oil 15W-40 31Lx2
750DR
250L(closed)
Hydraulic oil Table Ⅴ
135L(open)
Air system ISO
0.2L
lubrication oil VG32
Lubricating
Table Ⅴ
grease
TPH400 Pump power end Table Ⅶ 84Lx2
Plunger pump Packing lubrication 15W-40 38L
5X6"
centrifugal Packing lubrication Table Ⅴ
pump
4X3" Packing lubrication Table Ⅴ
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centrifugal
pump
Note: 1. The total capacity of engine cooling system is equivalent to engine
capacity plus external system capacity.
2. Triplex pump power end lubrication only refers to cabinet volume,
doesn’t include the volume of lubrication oil filter.
Table Ⅰ: Caterpillar recommends using 50/50% monoethylene glycol
cooling mixing liquid to reach the optimum performance: (it is applicable
to refer to the following table)

Antifreeze concentration (monoethylene glycol)
Antifreezing temperature Concentration
-15ºC（5ºF) 30% antifreezer and 70% water
-23ºC（-9ºF) 40% antifreezer and 70% water
Table Ⅱ:
Recommend using SAE 15W40, please choose the above CI-4.

Engine Lubrication Oil Viscosity Protection
Engine lubrication oil Ambient Temperature
viscosity Lowest ºC（ºF) Highest ºC（ºF)
SAE 0W20 -40(-40) 10(50)

SAE 5W30 -30(-22) 30(86)
SAE 5W40 -30(-22) 40(104)
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SAE 10W30 -20(-4) 40(104)
SAE 15W40 -15(5) 50(122)
Table Ⅲ:
Diesel Engine Oil Specification
Specifications Fuel type
American NO.1-D,NO.2-D and
ASTM D975
（U.S.) standards NO.4diesel oil
Low sulfur NO.1and

ASTM D396
NO.2diesel oil
ASTM NO.1-GT and NO.2-GT gas turbine
D2880 fuel
Light diesel oil 0#, -10#, -20#
China
(based on working field temperature)
Table Ⅳ:
Recommend using SAE 15W-40 for Allison transmission 750DR

Lowest working temperature
10W -20ºC（-4ºF)
15W-40 -15ºC（5ºF)
SAE 30 0ºC（32ºF)
SAE 40 10ºC（50ºF)
The following table is one part of approved oil listed by Allison
transmission.
Note: 1. Approval number is the criteria of liquid oil that proved to utilize
in Allison transmission. The approval number is marked at liquid oil
containers; users can also require the related documents from oil
- 13 -
suppliers.
2. Please use the oil above CI-4.

Company (supplier) Brand (Approval Viscosity
number) rank
MOBIL AUTOMATIC
F-30107 ATF
TRANSMISSION FLUID
MOBIL 1 SYNTHETIC
MOBIL OIL
AUTOMATIC F-30126 ATF
CORPORATION
TRANSMISSION FLUID
MOBIL SHC
AUTOMATIC F-30126 ATF
TRANSMISSION FLUID
MOBIL AUTOMATIC
F-30127 ATF
TRANSMISSION FLUID
SHELL SHELL DONAX TG F-30358 ATF
INTERNATIONAL SHELL DONAX TX F-30388 ATF

PETROLEUM DONAX TG F-30735 ATF
CO. LTD. SHELLHARVELLA T 15W/40 15W-40
SHELL RIMULA X SAE 30 30
SHELLRIMULAXSAE15W-40 15W-40
SHELL RIMULA X SAE 30 30
SHELL RIMULA X 15W-40 15W-40
Table Ⅴ:
Hydraulic oil
68# antiwear hydraulic oil or HM-46#
Summer
antiwear hydraulic oil
Winter (cold area) HV-32# low-freezing hydraulic oil
Winter (frigid area) HS-32# low-freezing hydraulic oil
- 14 -
Table Ⅵ:
Lubricating grease should be used in the following components of
equipment:
Applicable
Oil type
temperature
Drive shaft universal
joint
Pneumatic butterfly
valve
Great wall Runfeng multipurpose
Diesel engine fan -15ºC---120ºC
lubricating grease #3
bearing
Plug valve
4X3,5X6 centrifugal
pump
Table Ⅶ:
Lube selector by outside
tempºF（ºC)
50
to
20
Pour (1 Below
pointºF Above
TPH400 Company Product 0 20(-6.
50(10)
（ºC) to 7)
-6
.7
)
TPH400 Mobilube
Power HD 0(-17.8) X X -
end 85W-140
lubricati Mobil
on extra
hecla
+40(4.4) X - -
super
cylinder
Mobil oil
Mobil
-40(-40) X X X
shc-634
Mobilgear
+20(-6.7) X - -
636
Mobil
+20(-6.7) X - -
gear634
Mobil
0(-17.8) - X -
gear632
Shell
Shell -5(-20.6) X X -
spirax hd
- 15 -
85w/140
Shell
spirax hd -15(-26.1) - - X
80w-90
Alamo oil
-10(-23.3) X X -
525
Alamo oil
Mobil -20(-28.9) X - -
527
TPH400 Alamo oil
-10(-23.3) X X X
Hydraul 529
ic end Torcula
-50(-45.6) - - X
lubricati 32
on Torcula
-20(-28.9) X X -
Shell 100
Torcula
-10(-23.3) X - -
320
SAE 15W40
Note: The oiling procedure should be completed according to the
requirements. Fill in 2/3 oil first, low speed run for 2 minutes so that the
pipeline is filled up with oil, and then fill to the desired scale. Check the
following items after filling.
Lubricating checking points are marked in the following drawing:
- 16 -
- 17 -
Lubrication check list

Lubricating Job
Serial Lubrication
Components Quantity Componen conte Lubricant
No. Frequency
t Number nt
Engine
1 lubrication 2 Each time 1 Check ATF
oil level
Engine fuel
2 Each time 1 Check ATF
level
Transmission
2 lubrication 2 Each time 1 Check ATF
oil level
Drive shaft
3 grease 2 Each time 5 Fill Grease
lubrication
Plunger
pump power
4 end 2 Each time 1 Check ATF
lubrication
oil
Torque rod
5 4 Each time 8 Fill Grease
adapter
Closed
6 hydraulic oil 1 Each time 1 Check ATF
tank level
PTO drive
7 shaft grease 3 Each time 6 Fill Grease
lubrication
Jet mixer
grease
lubricant
point
Cement
metering
valve grease 1 Each time 1 Fill Grease
lubricating
point
Oil/water
9 separator 1 Each time 1 Check ATF
liquid level
Plunger
pump
10 packing 1 Each time 1 Check ATF
lubrication
oil level
1”Cock
valve grease
lubricating
point
2”Cock
valve grease
5 Each time 1 Fill Grease
lubricating
point
- 18 -
4x3
centrifugal
12 pump grease 2 Each time 1 Check Grease
lubricating
point
5x6
centrifugal
13 pump grease 2 Each time 2 Check Grease
lubricating
point
5x6
centrifugal
14 pump grease 2 Each time 2 Check ATF
lubricating
point
Lubrication
oil level scale.
Lubrication
oil filler.
Check left, right engine lubrication oil each time.
Note: Left, right engine oil fillers are symmetrically placed.
Right
lubrication
oil level
scale, oil
filler.
Left
lubrication oil
level scale, oil
filler
- 19 -
Check left, right transmission lubrication oil each time.
Note: Left, right transmission oil fillers are symmetrically placed.
Plunger pump power end

lubrication oil level scale,
oil filler
Check left, right triplex pump lubrication oil each time.
Plunger pump packing

lubrication oil level scale,
oil filler
Check lubrication oil of tank each time.
Fuel level,
oil filler
Fuel level
scale
- 20 -
Hydraulic
oil filler
Hydraulic
oil level
scale.
Check lubrication oil of tank each time.
Grease
filler
Grease
filler
Fill the left, right drive shaft with lubricating grease each time.
Grease
filler
Grease
filler
Fill left, right triplex pump support with lubricating grease each time.
- 21 -
Grease filler
Fill the high pressure manifold with lubricating grease each time
Grease filler Grease filler Breather
Fill the centrifugal pump with lubricating grease each time.
Grease filler Grease filler Grease filler
Fill the jet mixer and cement metering valve with lubricating grease each
time.
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Lubrication
oil filler and
check the oil
level
Drain valve
Grease filler
Fill the lubrication oil filler and drain off water each time.
Please change the filter element according to the fixed time in the
following table:
Serial Job
Components Quantity Interval Part No.
No. content
Engine oil filter Three
1 2 Change X04-04-276
element months
Engine fuel thick Three
2 2 Change X04-04-280
filter element months
Engine fuel thick Three
3 2 Change X04-04-502
Transmission
Three
4 engine oil filter 2 Change X04-04-306
months
element
Hydraulic oil
Three
5 return oil filter 2 Change X04-04-283
months
element
Hydraulic oil
Three
6 suction filter 2 Change X04-00-527
months
element
Hydraulic oil pump Three
7 3 Change X04-00-587
Engine air filter Three
8 2 Change X02-03-012
element months
Plunger pump
Three
9 thick long filter 6 Change X04-09-155
months
element
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Plunger pump thin
Three
10 and short filter 2 Change X04-09-155
months
element
1. Change engine oil 2. Change engine fuel 3.Change engine fuel

filter element thick filter element thick filter element
X04-04-276 timely. X04-04-280 timely. X04-04-502 timely.
4.Change 5. Change hydraulic 6. Change hydraulic oil

transmission oil filter oil return oil filter suction filter
element X00-00-952. X04-04-283. X04-00-527.
7.Change the hydraulic 8.Change the engine air 9. Triplex pump thick filter
oil pump filter element filter element element long X04-09-155, three,
- 24 -
X04-00-587 according X04-04-283 according thin filter element X04-09-155,
to fixed time. to fixed time. one.
Chapter Ⅲ Operating Instructions
The operator should clarify the equipment job this time (pressure
test/pumping preflush/pumping slurry amount and precalculated
engine speed/transmission gear)

1. Check oil level (refer to the attachment)
2. Connecting the pipes (including water, bulk cement and air).
2.1. Connecting the water supply pipe. Sea water
Fresh water
Mixing water
12 11 10
2.2. Connecting the bulk cement suction inlet.
Bulk suction inlet
2.3. Connecting the external air source, and open the air supply valve of air storage tank.
Air supply valve
2.4. Check if the pressure of air source is between 0.6Mpa---0.8Mpa.
Pressure
gauge
2.5. Switch on the power of battery box.
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Power
switch
2.6. Check if the voltage is 24VDC
Voltmeter
3. Switch on the main power, computer, and lamp.

Main power switch
Computer power switch
4. Open the valve to lubricating oil and regulate the pressure to 30psi。See the lubrication
check list (attachment).
5. Check if the left and right engine throttles are at idling position, and left and right
transmissions are at neutral position.
Shift to neutral
Shift to neutral
position.
Throttle idling
position. Throttle idling
position.
6. Start the left, right engine respectively, and keep engine running at idle speed for more
- 26 -
than 5 minutes. See the check list after equipment starts (refer to attachment).
Start the right

engine
Start the left ht

engine
7. Proceed the pressure test on high pressure manifold, start the pump, pump the
preflush fluid, see the attached operation.(please skip if there’s no the above task)
8. Auto Mixing Preparation.
8.1 Increase engine RPM (that to provide recirculation pump and water pump power) to
about 1800 – 2100 rpm.
Rotate CCW to Rotate CCW to

increase engine increase engine
speed. speed.
Observe the left

engine speed.
Observe the
right engine
speed.
8.2 Open valve #1(or #2), #3, #29 and #30. Start water pump. Open control valve to half.
Increase tub level to 1/2 position. Close master water valve (Water pump doesn’t need
- 27 -
to be stopped.)
8.3 Open valve #6, #17, #7, #31. Start recirculation pump, push its control valve to half.
8.4 When mixing tub blender has been covered, push its control valve to half.
8.5 Push cement metering valve and water valve control handle to check if flexible.
8.6 Turn engine to idle.
Clap the throttle Clap the throttle

downwardly, downwardly,
turn left engine turn right engine
to idle. to idle.
9. Engine idle. Enter Computer Setting.
9.1 Switch on computer
Switch on computer
9.2 When the computer is in self-checking, cement metering valve should stop at zero
position itself. Manually open cement metering valve at position 2.
9.3 Enter Info. screen Information screen

pops up 1 minute
later.
Move the cursor

using and to
ENGLISH. Press
to go to main
screen.
9.4 Preset bulk cement density value is 3.15, the operator can modify it if need.
- 28 -
Input value in
CMT ABS DENS
input box.
Press M SCRN key to accept

the setting and back to main
screen.
9.5 Input desired density value and job number.
Press DENS DES key; input the desired density value using the right number keyboard, press
“Enter” button to confirm.
Press Job# key, input the job number using the right number keyboard, press “Enter” button to
confirm.
Press DENS DES

key to input the
desired value.
Press Job# key to

input the desired
number.
9.6 Accept all the settings. Switch cement metering valve and water valve to manual
control mode.
Press “Man/Auto”to
switch to manual
state.
9.7 The preparation of mixing job is finished.
10. Start manual powder -unloading for mixing.
- 29 -
Press Start key.
10.1 Press START key to start job.
10.2 Increase engine RPM (which to provide recirculation pump and water pump
power) to about 1800 – 2100 rpm.
10.3 Adjust mixing tank blender control valve to its maximum.
10.4 Open master butterfly valve of cement metering valve slowly to start
powder-unloading for mixing.
10.5 Observe density and mixing tub level changes on running screen. When the
actual density display is approaching to the desired value (lower than 0.06
g/cm3), start water pump. Open master water valve and adjust water valve
control to make water flow rate at about 300L. At the same time, operator may
adjust cement metering valve open to make slurry density much more
approaching to the desired value.
10.6 Now mixing tub level has reached to 2/3 position. Shift transmission to the
desired gear 3. Start triplex pump, at the same time, start booster pump.
10.7 Keep mixing tub level stable. Observe bulk cement proportional supply value.
Adjust water valve and cement metering valve to maintain slurry density at the
desired value and steady.
10.8 During mixing and pumping, the mixing tub level should be maintained at 2/3
position.
11. Start auto control mixing when the slurry density is close to the desired value.
Shift the cement metering valve to auto control mode.
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switch to manual
mode.
During auto control mixing, the operator should switch control button back to “manual” when
bulk cement supply or water supply is not stable. During mixing job, desired density
value can be modified if needed.
Press DENS DES

key to input the
desired value.
12． Stop auto control mixing.
14.1 When pumping is completed, operate for finish. (See attachment)
14.2 Press STOP key to stop the job.
Press STOP
key
13.Turn to manual control mode and wash the unit. (See attachment)
- 31 -
switch to manual
state.
Observe the density value, lower than 0.01g/cm3 means the unit is cleaned up.
14. Stop engine.
14.1 Idle the engine.
Clap the throttle Clap the throttle

downwardly, turn left downwardly, turn right
engine to idle. engine to idle.
14.2 Push the transmission to neutral position.
Push gearshift handle to Push gearshift handle to

turn the left turn the left
transmission to neutral transmission to neutral
position. position.
14.3 Stop left and right engines.
Turn the right engine

Turn the left
key switch to Stop
engine key switch
position to stop right
to Stop position to
engine.
stop left engine.
15. Close power switch.
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Close the power switch of displacement tank,

illuminator switch, computer power switch and
master power switch in sequence.
Close the battery

power switch.
16. Job ends.
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Chapter Ⅳ Plunger pump power system
The power of unit is mainly supplied by two CAT C13 series engines
and two ALLISON 4700FS transmissions drive the TPH400 triplex
plunger pump to proceed with the work.
This section only briefly describes the technique of engine,
transmission and plunger pump. Please attain the operation and
maintenance of them from documentation with these equipment packages.
4.1 Diesel Engine
Model: CAT C13 diesel engine
Rated horsepower: 354kw(475HP)
Rated rpm: 2100 RPM
Start mode: air start
Cooling method: fan heat exchanger
Shutdown: air cylinder
Others: muffler flex connector, transmission cooler, oil filer, air
filter, etc.
4.2 Transmission
Allison 4700OFS auto transmission with oil filler, oil gauge, torcon
and 1810 series output flange.
Gear ratio:
1 gear: 7.63
2 gear: 3.51
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3 gear: 1.913
4 gear: 1.43
5 gear: 1.00
Torcon locking efficiency: 0.96
Oil pan with oil gauge & oil pipe.
Oil filter (easily disassembled).
Oil cooler
4.3 Transmission Shaft
Heavy-duty transmission shaft, installed between transmission and
triplex pump, is composed of heavy-duty universal joint and 1810 series
flange assembly.
The mounting angle of the heavy-duty transmission shaft accords
with the maximum mounting angle recommended by manufacturer.
The transmission shafts are fitted with metal guard which is
convenient for filling oil and grease.
4.4 High Pressure Triplex Pump
4.4.1 Triplex plunger pump
- 35 -
Model TPH400 triplex plunger pump is the ideal unit in high pressure
oil field working, it has features that each pump is equipped with integral
reducing gearbox, triplex plunger pump design for pumping cement slurry,
sand carrier, skunk oil, acid, slurry and other oil well working fluid.
The technical parameters of triplex plunger pump are as following:
Model TPH-400
Power end
Type horizontal triplex single action line plunger pump
Structure Aligned with engine
Plunger 8" (203.2 mm)
Maximum input torque 7,215 lbf (9782 N.m)
Maximum input
600 BHP
horsepower
Hydraulic end
Maximum pressure
Plunger model Flow rate m3/min(GPM)
PSI/MPa
4" (101.6) 14,000 (96.5) 1.20 (3.2)
4 1/2" (114.3) 11,200 (77.2) 1.52 (4.0)
Reducing gearbox
Gear ratio 8.6:1
Maximum input rotation
2300 RPM
speed
Rated horsepower 600 HP
Input flange Spicer 1800
Notes: the above data calculated according to volumetric coefficient
0.97 and mechanical efficiency 90%.
Regarding the related introduction, operation and regulation
- 36 -
procedure of plunger pump power end and packing lubrication system,
please refer to TPH400 Operation Manual: A08012200C.
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Chapter Ⅴ Hydraulic System
5.1 Hydraulic System Principle
Fig. 5-1 demonstrates the operating principle of hydraulic system.
Table 4-1 lists the main parts of hydraulic system.
Hydraulic system is composed of hydraulic oil tank, three closed
variable plunger pumps, two gear oil pumps, three closed fixed
displacement motors, fan cooler, oil cylinder, control valve and other
hydraulic fittings.
Hydraulic system is divided into two separate systems: closed system
and open system. Closed hydraulic system drives three centrifugal pumps,
and open hydraulic system drives mixing tank, displacement tank agitator,
jet mixer and hydraulic rotary actuator.
5.2 Hydraulic System Operation
In the close-loop hydraulic system, the speed of three centrifugal
pump drive motors (part 18 and 20) can be regulated continuously from
zero to maximum by combination valve (21) fixed in control box. Part 22
is a group of overflow valve which has been setup already, can restrict the
highest revolution of four centrifugal pumps through regulating. The
highest speed of water pump has been set as 2900RPM, the recirculation
pump speed is 2100 RPM, and the booster pump speed is 1900RPM. The
continuous working pressure of closed hydraulic system can reach 21MPa
(3000psi) and the maximum oil pressure will be 35MPa (5000psi). The
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pressure gauge (part 19) on console indicates the working pressure.
In the open hydraulic system, the speed of displacement tank agitator
motor and mixing tank agitator (part 16) are separately controlled by two
throttle valves (part 14) with overflow valve at operating platform, and the
range is from 0 to 300RPM. The designed values of displacement tank and
mixing tank agitation system are respectively 21MPa and 11.5MPa.
The hydraulic rotary actuator (part 13) can be manually controlled by
manual directional control valve (part 11) or automatically controlled by
electromagnetic valve (part 12) through computer system; the oil cylinder
(part 17) which is used for regulating water flow is controlled by manual
directional control valve (part 11). The overflow pressure of hand valve all
are designed as 5MPa, and the working oil pressure can be displayed by
pressure gauge (part 5) on panel.
The dirty oil filter (part 2) will cause the reduction or fluctuation of
flow rate. Observe the oil filter indicator normally, and change the filter
according to experience or after working three months.
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Fig. 5-1 Hydraulic System Schematic Diagram
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Item Quan. Part No. Description
1 1 B01-03-986 Hydraulic system tank assembly
2 1 X04-00-532 Return oil filter
3 1 X04-02-827 Suction oil filter
Model EATON46 variable displacement
4 3 X04-00-508
plunger pump
5 4 X04-00-687 Pressure gauge, 0-1000PSI double scale
Medium pressure filter,10m slippage
6 3 X04-00-533
pump
7 3 X04-00-130 Check valve, 3/8" NPT
Hydraulic pump, CW, displacement tank
8 1 X04-02-320
agitation
Hydraulic pump, CW, mixing tank
9 1 X04-00-887
agitation
10 1 X00-03-489 Hydraulic pump, oil cylinder
11 2 X00-01-617 Hand valve
12 1 X00-03-326 Electromagnetic valve
13 1 X00-00-483 Hydraulic rotary actuator
14 2 X04-00-574 Speed control valve, agitator motor
16 3 X00-01-616 Agitator motor
17 1 X04-00-769 Jet mixer cylinder
18 1 X04-00-507 Hydraulic motor, mixing water pump
20 2 X04-00-509 Hydraulic motor, centrifugal pump
21 1 X04-00-548 Control valve
22 1 X04-04-253 Overflow valve, 4 section
23 1 X04-01-085 Fan motor control valve
24 1 X04-05-261 Fan oil cooler
25 1 X04-00-567 1 1/2" NPT Thermostat, 1 1/2" NPT
26 Belongs to 24 Fan oil cooler motor
Table 5-1 Hydraulic System Main Parts List
5.3 Troubleshooting
Once the hydraulic system works abnormally, operator should check
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Model PCS-521B Twin Pump Cementing Skid
Operation Manual
first based on table 3-2
Trouble Phenomenon Troubleshooting

The system No oil or the oil level is too low. Oiling and check if there is leaking.
doesn’t work. Wrong oil filled into system. Change oil type
Oil filter is blocked. Replace filter element.
The oil way is blocked. Check if the line is pressed, twisted
or blocked.
Pump doesn’t work. Check if the pump transmission is
broken.
The system System contains air. Check if the pump suction inlet
doesn’t work leaks.
steadily. Oil temperature is low. Spare some time for warming up the
system
Oil level is too low. Fill oil
System works Engine speed is too low. Engine speed maintains above
slowly. 1800RP.
Engine oil is too cold Spare some time for warming up the
system
Oil line is blocked. Check if the line is pressed, leaking
or blocked.
Hydraulic oil is Hydraulic oil flows bypass Check the pressure of system and the
too hot. overflow valve. overflow valve
Oil level is low. Fill oil
Bubbles appear. Wrong oil. Change oil type.
Oil level is low or oil is dirty and check if the oil inlet leaks
air leaks.
There is noise Oil level is low, wrong oil or Change oil type or fill oil.
when the pump bubbles in oil
is working. The filter screen of oil inlet is Clean the filter screen.
blocked.
Table 5-2 Constant Faults & Troubleshooting for Hydraulic System
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Chapter Ⅵ Air System
6.1 Air System Principle
Fig. 6-1 Air System Schematic Diagram

Item Quantity Part No. Description
1 1 X04-04-916 Check valve 1/2”
2 1 X04-01-789 Recycle air tank
3 1 X04-01-786 Air dryer (24V), adapter M22X1.5
4 1 X04-01-913 1"NPT ball valve
5 1 X04-00-166 Water drain valve
6 1 X04-02-237 Air tank (70L)
7 2 X04-01-124 Safety valve
8 1 X04-01-487 Pressure regular valve 1/4"
9 1 X04-01-117 Switch 3/8"
10 1 X04-00-647 Oil/water separator and atomizer components
11 26 V06-30-747 Butterfly valve control valve
12 26 V07-67-707 Butterfly valve actuator, 2-6"
Table 6-1 Air System Main Parts List
Air system is composed of air compressor, air tank, dryer, safety valve,
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oil/water separator, various control valves, etc. The air system pressure is
around 0.6－0.8MPa, which supplies power to the devices of engine start,
stop and emergency stop, butterfly valve switch operation, centrifugal
pump and centrifugal pump packing lubrication.
The external air source for engine start should meet the following
requirements: pressure is 0.7MPa and the minimum flow rate is 14.3 LPM.
The compressed air flows into the air tank （part 6）first. The air tank
is to overcome the discrepancy caused by using large volume air in short
time, and separate the water and oil from air by natural cooling. The safety
valve (part 7) installs at outlet, and the setting pressure is 0.8MPa. Besides
the console are the oil／water separator and atomizer components, they are
used to separate the impurity and oil/water from the compressed air, then
atomize the lubrication oil and fill into the airflow, flow with compressed
air into the place that need to be lubricated. The processed compressed air
flows to each control valve so as to operate the corresponding parts.
6.2 Air System Operation
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Fig. 6-2 Oil/water Separator and Atomizer Components
Fig. 6-3 Air Tank
1. Disconnect the pressure relief switch (part. 10) in front of the
oil/water separator (part 9);
2. Check the console to make sure all the control valves reset;
3. Connect the external air source, and open the ball valve of main air
source (part 4)
4. Open the pressure relief switch;
5. Operate the butterfly valve controller of displacement tank (part 12),
and control the switching operation of pneumatic butterfly valve.
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6.3 Maintenance and Repairs
1. The air tank should be drained regularly; open the water ball valve,
especially when work starts and ends. The air tank should be drained
regularly even if it is unused for a long time, otherwise the moisture with
airflow will flow into the pneumatic component which may cause
corrosion. The air tank may be rusted to cause potential safety hazards.
2. Oil/water separator and atomizer components should always be
drained and filled with oil; check regularly if the oil is deteriorated to
ensure the air system components work normally.
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Operation Manual
Chapter Ⅶ Lubrication System
7.1 Brief Introduction of Lubrication System
This section only describes lubrication of plunger pump and
centrifugal pump; please refer to the related technical data for lubricating
other components. The lubrication system of the cementing skid is
composed of triplex pump power end, hydraulic end lubrication and
centrifugal pump packing lubrication.
The power end lubrication of triplex pump mainly consists of oil
pump, overflow valve, suction end screen, filter, pressure gauge,
thermometer, etc. The gear oil pump installs on turbine box and works with
triplex pump. Please see “TPH400 Triplex Pump Operation Manual” for
details of power end lubrication.
The plunger pump hydraulic end lubrication utilizes the lubrication
system of air cap oil type, and supplies continuous cooling lubrication oil
to triplex pump packing system. Main compositions: lubrication oil tank,
pressure relief valve, switch, needle valve, check valve, ball valve and
pipeline. Fig. 5-1 is the structure picture.
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4
2
3
7
Fig. 7-1 Packing Lubrication Oil Tank
9 9
Fig. 7-2 Centrifugal Pump Lubrication Pipeline Fig. 7-3 Triplex Pump Lubrication Pipeline
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1. Packing lubrication oil tank: the each volume of two pressure container
is 38L, and adopts 13# hyperbolic curve extreme pressure oil or SAE
15W-40 engine oil for lubrication.
2. Pressure control valve: lubrication oil pressure regulator, part No. is
X04-00-633, reduces the air source system pressure to the value
required by lubrication packing, it is normally 0.3-0.4MPa (10-60 PSI).
3. Pressure relief switch: 1/4” pressure relief ball valve, part No. is
X04-00-634.
4. Pressure gauge: indicates the lubrication oil tank pressure, part No. is
X04-01-888, the indicated range is around 0-60 psi.
5. Ball valve: switch of lubrication oil system for turning on or off the
lubrication oil in pipeline.
6. Packing lubrication oil control valve: two valves adjust the lubrication
oil amount of plunger pump packing; another two adjust the lubrication
oil amount of centrifugal pump packing.
7. Cover and scale. It can approximately indicate the lubrication oil tank
level. Note: ensure the tank pressure has already been released before
filling oil.
8. Drain valve: drains off the residues at the bottom of tank.
9. Check valve: part No. is X04-00-652, prevent the slurry from flowing
into lubrication pipeline once the packing seal leaks.
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7.2 Packing Lubrication System Operation
The required pressure of lubrication system is 0.3-0.4MPa. Ensure to
switch on air source first (part 3) before starting the plunger pump and
centrifugal pump, regulate and confirm the air system pressure from
pressure control valve (part 2) to air tank (part 1). The lubrication oil
amount should be adjusted when using it at the first time, the steps are as
below: disconnect the oil pipe to plunger pump and centrifugal pump
packing, open the ball valve (part 5) of each pipeline separately, regulate
the needle valve (part 6), observe the flow rate of lubrication oil till it forms
into stable thread and then connect the oil pipe. Thus, it’s only necessary to
open the ball valve but repeating the above steps. After work finishes, turn
off the ball valves of pipeline to avoid making any waste of lubrication oil.
Before each cementing job, the operator should check the lubrication oil
amount and ensure it should be above 1/2 on oil gauge.
Note: open the packing lubrication oil tank for filling oil; turn off
the pressure relief ball valve of air system first to discharge the
pressure from packing lubrication oil tank. When the pressure gauge
indicates “0”, then open the lubrication oil tank slowly. Do not open
lubrication oil tank when it is under pressure.
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Chapter Ⅷ Fluid Delivery System
8.1. Displacement tank
The displacement tank is made from stainless steel and its efficiency
capacity is 25 barrels (4 m3). The tank has two rooms and each room can
hold 12.5 barrels. There is scale installed in the tank and the minimum
measuring unit is 0.5 barrel. The measuring counter is equipped at
external tank and each group has 20. The discharge end of displacement
tank is connected by 6” butterfly valve and 6” pipeline to ensure that the
flow rate of fluid to booster pump and triplex pump will meet the
requirement of system. The backflow releasing lines are used to make the
pressure fluid discharge from triplex pump flow into displacement tank.
The discharge system lines consist of 3” overflow line and 4” discharge
line. Two lines ends are connected and led to appointed place for
discharging fluid from above two rooms. The manifold is designed with
fast clamp connector which is convenient for disassembling and
installing.
8.2. Low Pressure Pipeline
Fig. 8-2 is the low pressure manifold schematic diagram. The low
pressure manifold owns the following characteristics:
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The rated working pressure of suction manifold is 1.2Mpa(175psi);
Water pump can suck in flow from displacement tank or external
water source, and then pump to high energy mixer to supply the
demanded high pressure water for mixing;
Recirculation pump sucks in slurry from the bottom of the mixing
tank. Most slurry is pumped to high energy mixer for twice or
multiple circulations. Meanwhile, the density of rest slurry can be
real time tested by densitometer;
The booster pump can suck in slurry from slurry mixing tank and
pump it to the suction end of triplex pump to guarantee the normal
suction when the density is high so as to improve the capacity
efficiency;
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Operation Manual
The recirculation pump and booster pump can be mutuallu
exchanged under the given conditions by opening or closing the
switching valve between recirculation pump and booster pump;

All the butterfly valves on manifold adopt air control switches and the actuators concentrated on
displacement tank which is convenient for operation. The flow diagram is made to be stainless steel
label and attached to displacement tank with relevant serial number.
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Chapter Ⅸ Auto Mixing System
9.1. Slurry mixing system
The mixing system of the skid is high energy recirculation type,
which is mainly composed of high energy mixer, cement metering valve,
diffusion tank, mixing tank, agitation impeller, recirculation pump,
booster pump, water pump, etc. The high energy for mixing is supplied by
water pump and recirculation pump. The bulk cement is connected to
cement metering valve and the flow rate can be manually operated or
controlled by computer. The flow spurted from high energy mixer not
only build negative pressure for sucking in bulk cement, but also
moisturize the bulk cement to the greatest extent. The recirculation pump
can implement twice or multiple circulations between mixing tank and jet
mixer. The diffusion tank is used to remove the air in preliminary mixing
slurry and clean the dirt from mixing tank. The 12bbl mixing tank allows
some time for slurry thoroughly mixing so that the slurry becomes much
more uniform. The deep tank design can keep the pump head in good
condition to maximally decrease the turbulence effect. The agitation
impeller driven by hydraulic pressure can improve mixing energy to make
the slurry density much more even.
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4
2
7
6
Slurry Mixing Device
8 9 10 11
Fig. 9-2 Regulating Valve
1) Mixing tank: the effective capacity is 12bbl.
2) Agitator: help to make the new and old slurry mix further and
increase the mixing energy.
3) High energy jet mixer is abbreviated as jet mixer, which is used for
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preliminary mixing slurry. The high pressure water produced by
water pump forms a stream in jet mixer. The negative pressure
generated from it will suck in bulk cement from the bulk cement lines
and mix with it thoroughly. The slurry returned from recirculation
pump reinjects into mixer to finish twice or multiple circulations for
new and old slurry. The flow of mixer is regulated by hand valve
through water oil cylinder.
4) Water regulating oil cylinder: the executive body of water flow
regulation is controlled by part 9 hand valve.
5) Bulk cement metering valve: will be specifically described in next
section.
6) Main control valve of circulation pipeline: the valve is used for
cutting off the circulation slurry loop back to jet mixer.
7) Diffusion tank: to eliminate the air in bulk cement, maximally
decrease the air in slurry and remove the dirt from mixing tank in
normal operating condition.
8) Water control hand valve: regulates the water flow to jet mixer, which
is also the part 4 controller of water regulating oil cylinder, the
maximum flow is normally 1.9 m3/min (500gal/min).
Note: in normal condition, adjusting the valve can’t cut off the water
completely.
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9) Bulk cement hand valve: in manual mode, regulates the opening of
cement metering valve to control the amount of bulk cement.
10) Speed regulating valve of mixing agitator: adjusts the speed of
mixing pool agitator and the range is normally around 0-300RPM.
11) Displacement tank agitator speed control valve: regulates the speed
of displacement tank agitator, the range is 0-300RPM.
Water main control valve (unmarked on the picture): 3” butterfly valve
with serial No. B10-07-010, is used to cut off the mixing water
completely, this valve is normally open valve.

2 6 7 8
1 5
Fig. 9-3 Cement Metering Valve Components
1) Cement metering valve: is abbreviated as cement valve used for
regulating the delivery value of bulk cement. The valve reliably
measures the bulk delivery capacity even when the delivery capacity
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is low without caking to block the line. The cement valve has feature
of approximate linear. When bulk delivery pressure is 0.17-0.21Mpa
(25-30psi), the valve is on 2-5 position; it is guaranteed to work
normally at common operational mode. Normally the air pressure has
something to do with the bulk pipeline specifications, delivery
distance and cement type. If the pressure of bulk cement delivery
system decreases, for example the bulk supply compressor can’t meet
the system requirements; the cement metering valve should be open
further. If it’s needed to open the cement metering valve to 80%
position, it means the bulk cement tank has already been drained, or
the delivery lines are blocked, or the air compressor pressure is low.
At this time, the mixing rate needs to be reduced. In the process of
mixing, it is avoided to dampen the cement valve or wash it by water.
2) Hydraulic rotary actuator: the serial No. is X00-00-483, which is the
actuator for regulating the opening of cement metering valve. It is
manually operated by hand valve, or automatically controlled by
electromagnetic valve through computer system.
3) Bulk delivery hose adapter: 5″ bulk hose.
4) Bulk main control valve: the serial number is X04-00-122, 5”
butterfly valve, switch of bulk delivery pipe. When job starts, open
the valve slowly so as to reduce the initial pressure shock caused by
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bulk. When the bulk flows steadily, open the valve completely and
utilize the proportional cement valve to control the bulk delivery
capacity.
5) Breather valve: the serial number is X02-00-158. When the vacuum
degree in cement metering valve is too high, the valve will open
automatically to suck in air so as to prevent the water in mixer from
splashing into cement metering valve which will cause condensation.
6) Dial scale: indicates current opening of cement valve with range
0-10.
7) Encoder: the opening position sensor of cement valve, transmit the
acquired signals to computer control system.
8) Needle valve: control the operating sensibility of hydraulic rotary
actuator. If the action of hydraulic rotary actuator is too sensitive,
close the valve properly to reduce the hydraulic oil flow through it.
9.2 Mixing water pump
Mixing water pump MISSION 4X3 specifications:
Suction pipe size: 101.6 (4in.)
Drainage pipe size: 76.2 (3in.)
Flow rate when pressure is 110psi: 1.65 m3/min (10.4bpm)
Maximum pressure:1.19MPa（170PSI）
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Precautions
1. In an extremely hot weather, every other three weeks or over five
hours on pump operation every day, bearing boxes need to be greased,
and grease nipples are at ends of the bearing box.
2.4X3 centrifugal pump adopts mechanical seal, no need to be cooled
by lubrication oil. Only when mechanical seals are failure, backup
sealing system is usually used, i.e. packing seal, screw on the gland.
Notes: it is only a provisional measure; it’s needed to replace the
mechanical seal immediately. When the mechanical seal system is
working normally, if packing seal is too tightened, packing is over heat
resulting in friction. The packing can not work normally any more. Due
to packing seal as temporary seal only, repair or replace mechanical seal
system as soon as possible.
3. It’s forbidden to start the pump in dry condition.
Please refer to Centrifugal Pump Operation Manual with these
equipment packages for detailed technical parameters, operation and
maintenance of mixing water pump.
9.3 Slurry Recirculation Pump
Technical specifications:
Model: MISSION 5X6
Suction port: 152mm (6in.)
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Operation Manual
Discharge port: 127mm (5in.)
Maximum rate at 64psi pressure: 3.7 m3/min (23bpm)
Maximum pressure:0.49MPa（70PSI）
9.4 Booster pump
Technical specification:
Model: MISSION 5X6
Suction port: 152mm (6in.)
Discharge port: 127mm (5in.)
Maximum rate at the pressure of 64psi: 3.7 m3/min (23bpm)
Maximum pressure: 0.49MPa (70psi)
1 2 3 4 4 3 2 1
Fig.9.4 Slurry Recirculation Pump Fig.9.5 Booster Centrifugal Pump
1) Drain valve: it is used to exhaust the residue from pump after job
finishes. The residue remained in pump after job finishes may
damage the pump. Especially in winter, the pump casing will be
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damaged by freezing residue, so this valve can be kept opening
during this period.
2) MISSION 5X6 centrifugal pump: an economic and practical oilfield
dedicated centrifugal pump with simple and easy structure.
3) Packing lubrication pipeline and check valve: be sure to open the
switch of lubricaion oil before job starts; close it after job ends to
avoid the lubrication oil leaking from packing which may cause
contamination and waste.
4) Bearing lubrication: grease nipples are installed at ends of the bearing
stuff. Lubricate the bearing stuff regularly according to working time
and working temperature. In an extremely hot weather, bearing stuff
need to be greased every other three weeks.
Note: the circulation pump and booster pump are generally used as
special pump for fulfilling their functions. However, when one of two
pumps fails, another one can replace it to proceed with the work.
Please refer to the 5X6 Centrifugal Pump Operation Manual with
these equipment packages--A08010410C for detailed technical parameters,
operation and maintenance of circulation and booster pump.
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9.5 SJS-ACM System
This section only introduces the ACM-Ⅲ.1 auto density control
system. Please see《ACM-Ⅲ.1 Operation Manual》for specific operation
procedures.
ACM-Ⅲ.1 auto density control mixing system is the most advanced
computer auto density control system. The system can be real time
adjusted according to the change of designed slurry density, bulk supply
capability, water supply condition, slurry rate, etc so as to ensure the
stability of slurry density.
z Maximum mixing capability: 2.3 m3/min
z Slurry density: 1-2.5g /cm3(21PPG) /cm3
z Slurry density error: ±0.024g/cm3
z Densitometer: 3″Micro Motion non radioactive densitometer
z Flowmeter: 3″ turbulence flowmeter
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Auto Mixing System Principle
Fig. 7-6 ACM System Schematic Diagram
Fig. 7-6 is the auto mixing system schematic and flow diagram. Bulk
will be delivered to high energy mixer through bulk tank and the amount of
delivered bulk is controlled by off-center cement metering valve. Water is
pumped to mixer through jet pump, and the water flow is measured by
flowmeter and manually/automatically controlled by actuator. The core of
control system—SLC microprocessor can respond rapidly and compare
the detected mixing water flow, slurry density with the set slurry density to
control the bulk feeding amount through changing the opening of cement
valve after calculated. The unique "GO-TO" program of system can
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respond the density change rapidly, and automatically adjust the slurry
density error to the set range before it occurs. In the process of operation,
the program can detect three possible changes: slurry rate change, set
density change and bulk delivery amount change caused by irregular
and/or decreasing delivery amount.
In simulation mode, the computer can provide system self-checking
function to test the working state of pipelines, cables, flowmeter, hydraulic
system, information feedback system and microprocessor. The system can
be used to perform manual and auto density control training to operators.
The microprocessor stores the density parameter every one second
which takes as long as 500 hours for data recording. The inputted data
afterwards substitute for previous recorded data. All these data can be
stored in form of ASCII and downloaded via RS-232 computer interface to
connect to operator interface control panel. These data can also be
outputted for painting and analysis.
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Operation Manual
Chapter Ⅹ High Pressure Manifold
Discharge manifold adopts H model arrangement and integral union
joint.
Discharge manifold is equipped with five 2” Fig.1502 integral high
pressure union plug valves.
The manifold is equipped with return pressure relief pipeline which
is controlled by two 2"× 1" 1502 model plug valves. The discharge
port of manifold is connected to displacement tank.
The pressure of manifold is measured by pressure sensor and
pressure gauge with range 0-105MPa
The rated pressure of all pipelines and valve components is
15000PSI (105 MPa).

3 4
2
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Operation Manual
Fig. 10-1 High Pressure Manifold
1. Electronic pressure sensor: the serial number X00-00-546, is used to
measure the slurry pressure from the triplex pump discharge end and
the measured electronic signals are transmitted to computer system.
2. Mechanical pressure sensor: the serial number X00-04-266, is used to
measure the slurry pressure from the triplex pump discharge end and
the pressure is transmitted to Martin Gage on console for indication.
3. Safety valve: the serial number F2A-18-192, the set pressure is
76MPa.
4. Release valve: 2X1” plug valve, the serial number is F1A-11-705. It
can release the pressure from triplex pump to displacement tank.
5. “U” type swivel joint discharge port.
Chapter Ⅺ Control & Monitoring System
11.1． Console
The unit will be controlled and monitored from a control stand fabricated of
stainless steel, with a stainless steel panel labeling in Chinese & English.
Note: the yellow locking device is used to fix the cover of control box in the
process of operation. Press the locking device first before the cover shut down.
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Operation Manual
11.2．Gauges and instrument description
Density transmitter Upper panel
l
Centrifugal pump
control valve Lower panel
Fig. 11-1 Console
Note: there are three pcs of centrifugal pump control valves, part No. is
X04-00-548.
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Operation Manual
5
1
6
2
7
8
3
4 9
10 11 12 13 14 15 16
17 24
18 25
19 26
20 27
21 28
22 29
23 30
31 32 33 34 35 36 37 38 39 40
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Operation Manual
Fig. 11-2 Upper and Lower Control Panel Composition

Serial
Part No. Description Functions
No.
left engine speed, oil
Electronic engines and equipment
1 X04-03-143 pressure and water
applications gauge
temperature
left transmission oil
2 X04-03-711 Thermometer
temperature
left transmission oil
3 X04-00-556 Oil pressure gauge
pressure
hydraulic system oil
temperature
10″PanelView and
5 X04-03-779 PanelView
operation panel
right engine speed, oil
Electronic engines and equipment
6 X04-03-143 pressure and water
applications gauge
temperature
Right transmission oil
7 X04-03-711 Thermometer temperature
8 X04-00-556 Oil pressure gauge Right transmission oil pressure
9 X04-01-321 Voltmeter Electrical system voltage
Water pump hydraulic oil
10 X00-02-625 Pressure gauge
pressure 0-10000PSI
Booster pump hydraulic
pressure 0-10000PSI
Booster pump hydraulic
pressure 0-10000PSI
Indicate working pressure of
mixing agitation, 0-3000PSI
Indicate working pressure of
mixing agitation
Indicate the pressure of
cement actuator, 0-1000PSI
Indicate air pressure of
16 X00-02-627 Barometer
surge tank 0-160PSI
Transmission Manual control gear shift of
17 Shift valve
contains left transmissmission
Discharge pressure of left
18 X00-04-264 M/D Totco
plunger pump
19 V06-43-568 Power switch Computer power switch
20 V06-43-568 Power switch Main power switch
Left plunger pump oil pressure
(w/ alarm indication)
Power switch of left
22 V06-43-568 Power switch
displacement tank
Left plunger pump oil
23 X04-01-844 Thermometer temperature (w/ alarm
indication)
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Operation Manual
Manual control gear shift of
24 Transmision has Shift valve
left transmission
Panel installation download
25 B10-13-065 Download connector
connector
Discharge pressure of right
26 X00-04-264 M/D totco
plunger pump
Light switch 1
28 V06-43-568 Power switch Light switch 2
Right plunger pump oil
pressure (w/ alarm indication)
Right plunger pump oil
pressure (w/ alarm indication)
31 V06-44-697 Switch Left engine E-stop
32 X04-00-561 Start button Left engine start button
33 X04-01-239 Key switch Left engine key switch
Power switch of right
displacement tank
35 X04-02-418 Throttle button Left engine throttle control
36 X04-02-418 Throttle button Right engine throttle control
37 X04-00-561 Start button Horn switch
38 X04-01-239 Key switch Left engine key switch
39 X04-00-561 Start button Left engine start button
40 V06-44-697 Switch Right engine e-stop
Note: 1. The definition for left hand and right hand of twin pump skid: stand on the
operation console, face to the engine, refer to left hand and right hand.
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Operation Manual
Chapter Ⅻ Brief Introduction of Slurry Mixing Operation
Procedure
12.1 Operation instructions before cementing
¾ Check liquid level of each system (radiator, fuel tank, hydraulic
tank, lubrication oil tank) before operation. Turn on the following
switches (valves): ball valve on main air line of air source, power
switch, main power switch of consol and computer power switch.
Please refer to the technical data of each component or the
documentation with the package of《Oil Instruction Manual》while
filling the oil.
¾ Start engine and check the operating condition of each component;
¾ Throttle up to working speed after finishing checking;
¾ Pump about 5bbl water to one side of displacement tank, turn on the
butterfly valve to fill the water pump suction line with liquid. Start
water pump and inject enough water into slurry mixing tank (about
1/4- 1/3). Then start recirculation pump and booster pump
separately, and stop after finishing filling the suction line of
recirculation pump and booster pump. Turn off the valve to pump
booster pipe.
¾ Open the cement valve to about 20% position, start recirculation
pump to full speed, regulate the pressure of bulk cement delivery

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Operation Manual
system to about 0.17-0.24Mpa (25-35psi) and turn on the main
control butterfly valve of bulk cement delivery system gradually.
Switch on agitator when slurry rises to the height of agitator and
adjust the rotation speed to its maximum. It’s avoided to make
splashing. The function of agitator is to improve quality and
evenness of slurry, meanwhile to avoid turbulence and splashing.
¾ When slurry density reaches the designed value (± 0.2ppg), turn off
main control valve of bulk cement delivery system and cement
valve.
12.2 Continuous cementing job—manual control
¾ Start water pump, turn on main control valve of water, and operate
the manual control valve rod to the set water rate.
¾ Density control: in manual mode, adjust the opening of cement
valve to maintain the density. Turn on the main control valve of
bulk cement lines and adjust the cement valve at very small range
each time and then observe the change of density. Note: while
controlling slurry density, avoid regulating water and cement
together. The recommended method is to maintain the certain water
rate and regulate the bulk cement amount. The cement valve
position is usually among 2-5.
¾ Tub level control: observe the mixing tank level, start pumping
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Operation Manual
slurry to well when tub level is at approximate 0.45m to the top of
tank. Regulate the triplex pump speed and maintain the tub level
0.45±0.15m to the top of tank. Note: regulating the mixing rate can
also control the tub level, but it needs to regulate water rate and
bulk cement delivery amount simultaneously. In manual mode, it’s
difficult to keep slurry density stable. It’s better to implement the
slurry mixing job according to the set pump speed, and maintain the
balance of slurry mixing tank level through regulating the triplex
pump speed.
¾ When bulk cement tank is almost drained off, the decreased bulk
delivery amount causes pressure falling or bulk flow uneven. It
needs to turn on the cement metering valve gradually if want to
keep the stability of slurry density. If the opening exceeds 65%, it’s
necessary to reduce the water rate so as to decrease the slurry
mixing speed.
¾ Change tank: the pressure of newly changed bulk cement tank is
high (under pressure before job starts) while changing tank, the
bulk delivery amount will be the maximum, so please pay attention
to the operation. After changing, turn off the butterfly valve of main
cement line to about 20% opening to reduce the pressure shock
from bulk cement in new tank. Then turn on the butterfly valve
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Operation Manual
gradually within 1 minute so that the operator can have enough time
to readjust the bulk delivery amount.
12.3 Emergency operation
When the centrifugal pump failure occurs at cementing field, the backup or
circumscribed centrifugal pump can be used to proceed with work.
However, when the backup/circumscribed centrifugal pump doesn’t work
sometimes, the triplex pump is considered to be used for pumping water
and slurry.
The above mention is only a probability, it’s not suggested to use triplex
pump for emergency operation, because it's very dangerous and may cause
unpredictable damage to the unit.
12.3.1 Emergency Operation of Water Pump
When the water pump failure occurs, use the triplex pump to pump
water. The triplex pump delivers the water from displacement tank to
water pipeline via 2” hose. Dismantle the mechanical pressure sensor
union from high pressure manifold, and fix the union with threaded
connector, then connect the hose, and connect another end to 2”
coupling beside washpipe of densitometer.
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Operation Manual
Emergency water port
12.3.2 Emergency Operation of Mixing Pump
When the mixing pump failure occurs, use the triplex pump to pump
water. The triplex pump delivers the water from displacement tank to
water pipeline via 2” hose. Dismantle the mechanical pressure sensor
union from high pressure manifold, and fix the 2” union with threaded
connector, then connect the hose, connect another end to 2” ball valve
under pipeline of jet mixer.
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Operation Manual
Emergency slurry mixing

port
12.3.3 Emergency Operation Instructions
Please note the following items before emergency operation:
1．Turn on the jet mixer completely to avoid the pressure of liquid
discharged from triplex pump rising abruptly because of obstruction.
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Operation Manual
It’s better to regulate the centrifugal pump speed first.
2．The engine should go back to idling speed before emergency
operation.
In the process of emergency operation, shift gear and throttle up slowly,
otherwise the pressure may easily increase abruptly. It's suggested to
run the engine at around 1700-1800RPM and the gear at 4 position.
Because the pressure may easily fluctuate when gear is at 5 position.
12.3.4 Post job cleaning
¾ After slurry mixing job finishes, wash mixing tank, mixer and
circulation pipelines immediately in the process of slurry
displacement;
¾ After each cementing job finishes, flush and clean the entire skid
and manifold system thoroughly;
¾ After the engine running a long time, it should run idling for a
while before it stops, till the components of engine cool down
completely;
¾ Drain off the residue in pipeline system and centrifugal pump
volute casing, especially in cold weather.
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Operation Manual
Chapter ⅰElectrical Circuit System
13.1 Power Supply Circuit
The entire electrical system is 24VDC. The battery supplies 28VDC
which is transformed to 24VDC for control system by switching power
supply.
The output power of switching power supply is 300W. The switching
power supply can produce heat while being used; warm packing shell of
power supply is normal, not affecting use. It’s recommended to shut off
the DC power supply immediately after finishing using the unit so as
to avoid the switching power supply in unloaded condition without
output for a long time.
13.2 Overpressure Protection Electrical Circuit
The function of overpressure protection is realized by computer. The
computer acquires the pressure of plunger pump. When pump psressure
exceeds the set pressure limit, computer outputs overpressure protection
signal immediately and drives the relay cutting off the engine throttle
signal so that the engine goes back to idling speed. At the same time, the
overpressure alarm light on panel is on to remind the operator.
When overpressure occurs, press the button “unlock” on PanelView
to reconnect the engine throttle signal, the engine throttle can regulate the
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Operation Manual
speed normally and go back to normal working condition.
13.3 Instrument and illumination
The electrical instruments on operating panel are equipped with
background illumination to guarantee the instrument readings are visible in
dark condition.
13.4 XP5000/GD-A8D Explosion-proof detection system（optional）
XP5000/GD-A8 flammable gas detection system can be used with
diesel engine to continuously detect the hazardous gas concentration of
operation area. When the hazardous gas concentration reaches the alarm
set valve, cut off the engine air inlet source for engine kill so as to ensure
the safety performace of equipment. The equipped equipments of
XP5000/GD-A8 flammable gas detection system can be used in ZONEⅡ
or close to ZONEⅡenvironment.
The working principle of XP5000/GD-A8 flammable gas detection
system:
1. The gas probe detects the hazardous gas concentration of
environment and sends out the sound and light alarm signal when
the gas concentration reaches 10% of lower explosion limit; the
engine kill happens when the hazardous gas concentration reaches
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Operation Manual
25% of lower explosion limit.
2. When the coolant temperature of diesel engine is too high,
automatically stop the diesel power of equipment running.
3. When the diesel engine oil pressure is too low, automatically stop
running the diesel power of equipment.
4. When the diesel engine speed is too high, automatically stop
running the diesel power of equipment.
5. When the flammable gas leaks or predictable danger occurs,
manually stop running the diesel power of equipment running.
Refer to the data with package for detailed manual of system.
13.5 Auto Density Control Circuit
The auto Density control includes: water measuring, cement valve,
water valve position measuring, water valve control, electromagnetic valve
control, density measuring, displacement tank high & low level alarm and
mixing tank level measuring.
¾ Water measuring
The water flow is measured by flowmeter which transmit the water
flow signal to computer.
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Operation Manual
The picture shows the flowmeter.
The flowmeter is turbine type. The
interior turbine is rotated by water
flowing through flowmeter. The turbine
blades revolve cutting the magnetic
field of electromagnetic transducer to
produce electrical pulse signal. The
computer calculates the real time water
flow value by acquiring the pulse signal.
¾ Cement valve position measuring
The current opening of cement valve is transformed to electrical signal and
then transmitted to
computer via valve
position encoder. After
computer receives the
opening signals of cement
valve, the program
real-time calculates the
desired opening of cement valve.
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Operation Manual
¾ Cement valve & Electromegnatic valve control
The electromagnetic valve is an electric control hydraulic valve. It
receives the signals from computer to control hydraulic direction of
two-way actuator which drives cement valve turning so that the computer
can control opening the cement valve.
The above schematic diagram shows the simple control relation and
flow chart of computer, cement valve, electromagnetic valve, two-way
cylinder and cement valve (water valve).
The picture shows the equipped cement electromagnetic valve. The
installation and control principle of water electromagnetic valve is the
same. The proportional electromagnetic valve can realize the function of
fine adjustment and accurate control for valve position.
¾ Density measuring
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Operation Manual
Nonradioactive source densimeter is composed of density transducer
and density transmitter. Density transducer is equipped on recirculation
pipeline, it transmits the real-time detected density signal to density
transmitter (also called secondary instrument). The density transmitter
itself displays not only the real-time density value, but also transforms the
signals of density transducer to standard signals recognized by computer.
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Operation Manual
The left picture shows the transmitter, and the right picture shows the
tranducer.
¾ Displacement tank hi-lo level alarm
Two level switches are equipped in the displacement tank. When tank level
is higher/lower than set height, the level switch outputs signal, two groups
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Operation Manual
of red and orange alarm lamps equipped at two sides of displacement tank
flicker to remind the operator the abnormal tank level.
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Spare Parts List

Item Parts No. Quan. Description
B01-00-610 Tools and spare parts(069)
0001 X04-04-280 1.0000 Filter element (C13, C9)
0002 X04-04-502 1.0000 Flter element（C13）
0003 X04-04-276 1.0000 Engine oil filter,C12,C13
0004 X02-03-012 1.0000 Air filter element,C12,C13
0005 X04-04-306 1.0000 4700 OFS Transmission oil filter element
0006 X02-03-014 1.0000 Lube filte element(X04-00-563 power end)
0007 X04-04-283 2.0000 Return filter element (x04-00-532)
0008 P8T0009450 4.0000 TPH400 packing 4 1/2"
0009 V06-54-820 8.0000 Oil seal 2"IDx2 3/4"ODx1/2"W(imported)
0010 F4P-10-229 2.0000 2" Union seal ring
0011 B01-15-453 1.0000 4"（or3 3/8"）and 4 1/2"TPH400 tool
0012 X04-00-326 1.0000 2.7Kg hammer
0013 X04-00-327 1.0000 600mm pipe wrench
0014 X04-00-290 1.0000 Flat wrench 5.5-32 (ten pieces) ten pcs
0015 X04-00-301 1.0000 Socket screw driver 3/16"-3/8" nine pcs
0016 X04-00-302 1.0000 Wrench for engine filter
0017 P8T0009400 4.0000 Packing assembly,TPH400
0018 X04-01-780 1.0000 25 socket wrench
0019 X04-00-300 1.0000 Metric socket srew wrench 4-14 7pcs
0020 X04-04-331 1.0000 Standard flat wrench 11 pcs
0021 X04-04-335 1.0000 Socket wrench 3/8"-1 1/4" 26pcs 12point
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Rev: A
ACM-Ⅲ.1 Density & Tub Level Auto

Control Mixing System
Parts Manual
SJS Limited
Add : Xihuan Road,Jingzhou City,Hubei,P.R.China Post Code : 434024
Tel : (86)716-8428889 8428114 Fax : (86)716-8016063
http://www.SERVAgroup.com E-mail : sjs@ServaCorp.com
Contents
ACM-3.1 Auto mixing computer assembly ......................................................................... - 2 -

Slurry mixing 10"PLUS PanelView Box (Ethernet communication, 3.1 nameplate) .......... - 5 -
Cable assembly (w/ transducer), C1 (water flow) , 3.5M(11.5FT) ...................................... - 6 -
Valve position connector and wire harness assembly .......................................................... - 7 -
F300 densitometer and 2700 density transmitter electric installation and cable assembly .. - 8 -
Standard 6 pin dual end cable assembly C2 (cement valve position), 5.5M (18FT).......... - 10 -
Standard 6 pin single end cable assembly, C6 (slurry rate), 1M (3.3FT) ........................... - 11 -
Cable assembly (w/ tranducer cover), C7 (Pressure 1#), 3M (10 FT) ............................... - 12 -
Cable assembly (w/ transducer cover), C8 (Pressure 2#), 3M (10FT) ............................... - 13 -
Standard 6 pin single end cable assembly, C10 (overpressure), 1M(3.3FT)...................... - 14 -
Cable assembly (w/ proportional valve plug), C12 (cement proportional valve solenoid A),
3M (10FT).......................................................................................................................... - 15 -
Cable assembly (w/ proportional valve plug), C13 (cement proportional valve B), 3M (10FT)
............................................................................................................................................ - 16 -
Standard 3 pin single end cable assembly, C17 (power), 1M(3.3FT) ................................ - 17 -
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ACM-Ⅲ.1 Density & Tub Level Auto Control Mixing System
Parts Manual
ACM-3.1 Auto mixing computer assembly

Part No. Item Quan. Description
B11-08-035 ACM-3.1 Auto mixing computer assembly
Slurry mixing 10"PLUS PanelView Box (Ethernet
|---B11-08-031 0001 1.0000 communication, 3.1 nameplate)
|---X04-01-648 0002 2.0000 SLC/PANELVIEW Ethernet communication cable
6 wireness dual end cable assembly, C18(PanelView
|---B10-08-251 0003 1.0000 communicatin) ,2M(6.6FT)
2M(6.6FT)3 wireness dual end cable assembly, C16
|---B10-08-786 0004 1.0000 (PanelView power), 2M(6.6FT)
|---X00-03-709 0005 1.0000 Junction box, fiberglass,18"
|---B10-08-128 0006 1.0000 Computer back plate
|---X00-03-702 0007 1.0000 7 slot rack
|---X00-03-704 0008 1.0000 Power supply module
|---X00-04-192 0009 1.0000 5/05CPU module,16K
|---X00-03-705 0010 1.0000 SLC 500 NI4 Analog input module
|---X00-03-733 0011 1.0000 SLC500 OW8 Relay output module
|---X04-00-862 0012 1.0000 Multi-channel high speed counter module
|---X04-00-747 0013 1.0000 Voltage output module
|---X00-02-880 0014 1.0000 MODULE NET, FLASH CARD
|---X04-05-023 0015 1.0000 Ethernet cable, RJ45-RJ45,1M
|---X04-03-186 0016 1.0000 REGULATOR,FIXED VOLTAGE,TYPE 7810
|---X00-03-713 0017 1.0000 Amplifier
|---X00-03-069 0018 0.2500 Din rail, high design
|---X00-03-735 0019 2.0000 End stop
|---X00-03-736 0020 1.0000 End and intermediate plate
|---X00-03-756 0021 4.0000 Fuse terminal block
|---X00-03-797 0022 2.0000 Fuse，10A
|---X00-03-774 0023 2.0000 Fuse,5A
|---X00-03-041 0024 1.0000 Separator plate for 4 hole 2.5mm terminal
|---X04-01-499 0025 14.0000 4 hole 2.5MM connect terminal
|---X04-01-500 0026 8.0000 4 hole 2.5MM connect ground terminal
|---X02-01-314 0027 1.0000 Resistance terminal,2.5MM
|---X00-03-755 0028 1.0000 Resistor,1.5K OHM,1/4W,5%
|---X00-03-900 0029 3.0000 Resistor,250 欧
|---X00-03-745 0030 2.0000 Adjacent type jumper for 4mm terminal
|---X04-01-154 0031 3.0000 Adjacent type jumper for 2.5mm terminal
|---X04-01-501 0032 1.0000 Relay, 24DC,1PDT
|---X04-02-891 0033 2.0000 Relay, 24DC,2PDT
|---X04-01-179 0034 1.0000 Proportional electromagnetic valve control module
|---X00-04-208 0035 1.0000 HEATER,24 VOLT,100 WATTS
|---X04-03-152 0036 1.0000 6 contacts connector
|---X04-03-218 0037 1.0000 6 contacts connector
|---X04-02-114 0038 4.0000 16-18AWG Contacts pin
|---X04-02-137 0039 4.0000 16-18AWG Contact socket
|---X04-02-138 0040 4.0000 16-18AWG Sealing plug contacts
|---X00-03-728 0041 13.0000 6 pin male receptacle
|---X00-05-149 0042 13.0000 Gasket for 6 pin receptacle
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Parts Manual

|---X00-05-150 0044 2.0000 Gasket for 3 pin male receptacle
|---B04-07-238 0045 1.0000 NAMEPLATE,FOR COVER SLC J-BOX
|---B04-07-239 0046 2.0000 NAMEPLATE,FOR RECEPTACLE SLC J-BOX
|---B04-07-208 0047 1.0000 Nameplate "R0" for single phoenix replay
|---B04-07-219 0048 1.0000 Nameplate "R1" for doubles phoenix replay
|---B04-07-220 0049 1.0000 Nameplate "R2" for doubles phoenix replay
|---X00-03-781 0050 12.0000 18-14AWG Fork type terminal
|---X00-03-780 0051 24.0000 22-16AWG Fork type terminal
|---X00-03-772 0052 140.0000 Ferrule with insulating collar, 18 AWG(0.75MM2)
22AWG(0.5MM2) Ferrule with insulating collar, 18
|---X00-03-773 0053 6.0000 AWG(0.75MM2)
|---X00-03-883 0054 6.0000 Ferrule with insulating collar,16 AWG(1.5MM2)
Double cord ferrule with insulating
|---X04-03-466 0055 24.0000 collar,2*18AWG(2*0.75MM2)
|---X04-03-623 0056 0.8000 Standard electrical red wire,16AWG,0.095〞
|---X04-03-625 0057 0.5000 Standard electrical black wire,16AWG, 0.095〞
|---X04-03-800 0058 0.6000 Standard electrical white wire,18AWG, 0.083〞
|---X04-03-617 0059 7.0000 Standard electrical blue wire,18AWG, 0.083〞
|---X04-03-618 0060 7.0000 Standard electrical yellow wire, 0.083〞
|---X04-03-619 0062 6.0000 Standard electrical red wire,18AWG, 0.083〞
|---X04-03-799 0063 7.0000 CABLE,6 WIRENESS,RED JACKET,20AWG*6
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Slurry mixing 10"PLUS PanelView Box (Ethernet communication, 3.1

nameplate)
Slurry mixing 10"PLUS PanelView Box (Ethernet
B11-08-031 communication, 3.1 nameplate)
Panel View Plus1000 (Ethernet, DH+AND DH485
|---X04-03-779 0001 1.0000 COMMUNICATION)
Slurry mixing 10"PLUS display CN/EN nameplate
|---B01-08-576 0002 1.0000 (3.1)
|---B01-08-191 0003 1.0000 PANELVIEW PLUS
|---X00-04-207 0004 1.0000 Heater，24VDC，50W
|---X02-04-801 0009 3.0000 Quick slide type terminal connector
|---X04-03-619 0010 1.0000 Standard electrical red wire,18AWG,0.083〞
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Parts Manual
Cable assembly (w/ transducer), C1 (water flow) , 3.5M(11.5FT)

Cable assembly (w/ transducer), C1 (water
B10-13-067 flow) , 3.5M(11.5FT)
|---X00-04-201 0001 1.0000 Cable (20 inch, w/ waterproof adapter)
|---X00-03-729 0002 1.0000 6 pin female plug
|---X04-03-996 0003 1.0000 2 pin female plug for pickup
|---X02-04-591 0004 1.0000 2 pin female plug clamp FOR X04-03-996
|---X04-03-712 0005 1.0000 Cord grip,0.500" RSP-105
|---X04-03-614 0006 3.5000 6 wireness blue jacket w/ braid shield cable, 22AWG,HW
Dual wall tubing heat shrink(adhesive & encapsulant-lined),
|---X02-04-590 0007 0.0650 24/6
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Parts Manual
Valve position connector and wire harness assembly

B10-13-048 Valve position connector and wire harness assembly
|---X26-22-051 0001 1.0000 Adapter 1/2"NPT
|---X00-03-902 0004 1.0000 6 pin receptacle cover
|---X04-03-618 0005 0.1300 Standard electrical yellow cable,18AWG,0.083〞
|---X04-03-615 0006 0.1300 Standard electrical black cable,18AWG,0.083〞
|---X04-03-617 0007 0.1300 Standard electrical blue cable,18AWG,0.083〞
|---X02-04-801 0008 3.0000 Quick slide type terminal connector
|---X00-03-772 0009 8.0000 Ferrule w/ insulating collar,18 AWG(0.75MM2)
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Parts Manual
F300 densitometer and 2700 density transmitter electric installation and

cable assembly

F300 densitometer and 2700 density
transmitter electric installation and cable
B10-13-055 assembly
|---X00-03-752 0001 1.0000 Cord grip
|---X00-03-748 0002 1.0000 90 deg elbow,0.500"(0.312"-0.375")
|---X02-04-584 0003 5.0000 4 wireness black jacket cable,16AWG,HW
|---X04-05-092 0004 2.0000 90 deg elbow,0.500"(0.250"-0.312")
|---X00-03-729 0005 2.0000 6 pin female plug
6 wireness blue jacket w/ braid shield cable,

|---X04-03-614 0006 6.0000 22AWG,HW
Dual wall tubing heat shrink(adhesive &
|---X02-04-590 0007 0.0650 encapsulant-lined),24/6
-8-
REV _A
Parts Manual
-9-
REV _A
Parts Manual
Standard 6 pin dual end cable assembly C2 (cement valve position), 5.5M
(18FT)

Standard 6 pin dual end cable assembly C2 (cement valve
B10-13-066 position), 5.5M (18FT)
|---X00-03-729 0001 2.0000 6 pin female receptacle
|---X04-03-614 0002 5.5000 6 wireness blue jacket braid shield cable,22AWG,HW
|---X02-04-590 0003 0.0650 Heat shrink dual wall tubing (adhesive & encapsulant-lined),24/6
- 10 -
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Parts Manual
Standard 6 pin single end cable assembly, C6 (slurry rate), 1M (3.3FT)

Standard 6 pin single end cable assembly, C6 (slurry
B10-13-056 rate), 1M (3.3FT)
|---X04-03-614 0002 1.0000 6 wireness blue jacket w/ braid shield cable,22AWG,HW
Heat shrink dual wall tubing (adhesive &
|---X02-04-590 0003 0.0300 encapsulant-lined),24/6
- 11 -
REV _A
Parts Manual
Cable assembly (w/ tranducer cover), C7 (Pressure 1#), 3M (10 FT)

Cable assembly (w/ tranducer cover), C7 (Pressure
B10-08-322 1#), 3M (10 FT)
|---X04-03-887 0002 1.0000 6 pin female receptacle cover
|---X04-01-399 0004 1.0000 Pump pressure sensor fix box
|---X04-05-092 0005 1.0000 90 deg elbow, 0.500"(0.250"-0.312")
Heat shrink dual wall tubing(adhesive & encapsulant-lined)
|---X02-04-590 0006 0.0650 24/6
- 12 -
REV _A
Parts Manual
Cable assembly (w/ transducer cover), C8 (Pressure 2#), 3M (10FT)

Cable assembly (w/ transducer cover), C8
B10-13-057 (Pressure 2#), 3M(10FT)
|---X04-03-887 0002 1.0000 子 6 pin female receptacle cover
|---X04-01-399 0004 1.0000 Pump pressure sensor fix box
|---X04-05-092 0005 1.0000 90 deg elbow, 0.500"(0.250"-0.312")
Heat shrink dual wall tubing(adhesive &
|---X02-04-590 0006 0.0650 encapsulant-lined) 24/6
- 13 -
REV _A
Parts Manual
Standard 6 pin single end cable assembly, C10 (overpressure), 1M(3.3FT)

Standard 6 pin single end cable assembly, C10
B10-13-058 (overpressure), 1M(3.3FT)
|---X02-04-590 0003 0.0300 24/6
- 14 -
REV _A
Parts Manual
Cable assembly (w/ proportional valve plug), C12 (cement proportional valve
solenoid A), 3M (10FT)

Cable assembly (w/ proportional valve plug), C12
B10-13-050 (cement proportional valve solenoid A), 3M(10FT)
|---X04-00-034 0002 1.0000 Electromagnetic valve connector,DIN43650

|---X02-04-590 0004 0.0650 Heat shrink dual wall tubing(adhesive & encapsulant-lined) 24/6
|---X00-03-773 0005 2.0000 Ferrule with insulating collar, 22AWG(0.5MM2)
- 15 -
REV _A
Parts Manual
Cable assembly (w/ proportional valve plug), C13 (cement proportional valve
B), 3M (10FT)

Cable assembly (w/ proportional valve plug), C13 (cement
X04-01-630 proportional valve B), 3M(10FT)
|---X04-00-034 0002 1.0000 Electromagnetic valve receptacle, DIN43650
|---X02-04-590 0004 0.0650 24/6
- 16 -
REV _A
Parts Manual
Standard 3 pin single end cable assembly, C17 (power), 1M(3.3FT)

Standard 3 pin single end cable assembly, C17
B10-08-431 (power), 1M(3.3FT)
|---X02-04-584 0002 1.0000 4 pin cable w/ black jacket, 16AWG,HW
- 17 -
REV _A
Parts Manual
- 18 -
Part No.:B01-00-069 Rev: A
Model PCS-521B
Twin Pump Cementing Skid
Parts Manual
SJS Limited
Add : Xihuan Road,Jingzhou City,Hubei,P.R.China Post Code : 434024
Tel : (86)716-8428889 8428114 Fax : (86)716-8016063
http://www.SERVAgroup.com E-mail : sj s@Se rva C or p. co m
-0-
B01-00-069 Rev:A
Parts Manual
Contents
PCS-521B Twin Pump Cementing Skid .............................................................................. - 2 -

Skid Frame Assembly .......................................................................................................... - 4 -
Power System....................................................................................................................... - 6 -
Hydraulic System................................................................................................................. - 8 -
Air System.......................................................................................................................... - 10 -
Lubrication System ............................................................................................................ - 13 -
Operation Platform Assembly ............................................................................................ - 15 -
Low Pressure Manifold Assembly ..................................................................................... - 17 -
Mixing Tank Assembly ...................................................................................................... - 21 -
4X3 Centrifugal Pump Assembly....................................................................................... - 23 -
5X6 Centrifugal Pump Installation Assembly.................................................................... - 25 -
Lubrication System ............................................................................................................ - 27 -
High Pressure Manifold Assembly..................................................................................... - 29 -
Displacement Tank Installation Assembly ......................................................................... - 32 -
TPH400 Pump Installation Assembly ................................................................................ - 34 -
Nameplate Assembly.......................................................................................................... - 36 -
Drive Shaft Installation Assembly ..................................................................................... - 37 -
Spare Parts List .................................................................................................................. - 38 -
-1-
B01-00-069 Rev:A
Parts Manual

B01-00-069 PCS-521B twin pump cementing skid
|---B01-01-330 0001 1.0000 Skid frame assembly
|---B01-02-962 0002 1.0000 Power system
|---B01-03-027 0003 1.0000 Hydraulic system
|---B01-04-140 0004 1.0000 Air system
|---B16-05-050 0005 1.0000 Lubrication system
|---B01-06-502 0006 1.0000 Operation platform assembly
|---B01-07-970 0007 1.0000 Low manifold assembly
|---B01-07-675 0008 1.0000 5X6 centrifugal pump installation assembly
|---B01-09-449 0009 1.0000 Slurry mixing tank assembly (12bbl)
|---B01-07-651 0010 1.0000 4X3 centrifugal pump assembly
|---B01-07-665 0011 1.0000 5X6 centrifugal pump installtion assembly
|---B01-12-141 0012 1.0000 Mixing system
|---B01-13-078 0013 1.0000 High pressure manifold assembly
|---B01-14-244 0014 1.0000 Displacement tank installation assembly
|---B01-15-113 0015 1.0000 TPH400 pump installation assembly
|---B01-99-306 0016 1.0000 Scutcheon assembly
|---B01-17-167 0017 1.0000 Twin pump mixing skid electrical system
|---B01-18-155 0018 1.0000 Drive shaft assembly
|---B01-00-610 0019 1.0000 Spare parts list
|---B11-40-900 0020 1.0000 Ground leak testing device
|---B10-17-599 0021 1.0000 Portable data acquisition unit for cementing net work
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Parts Manual
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B01-00-069 Rev:A
Parts Manual
Skid Frame Assembly

B01-01-330 Skid frame assembly
|---B01-01-595 0001 1.0000 Skid frame welding assembly
|---B01-01-282 0002 1.0000 Lift frame assembly
|---B01-01-158 0003 1.0000 Cover protect for rain and light
-4-
B01-00-069 Rev:A
Parts Manual
B01-01-330 Schematic Diagram
-5-
B01-00-069 Rev:A
Parts Manual
Power System

B01-02-962 Power system (catc13,4700 OFS, air start,air compressor)
|---B01-02-963 0001 1.0000 Left engine (cat c13,4700 OFS air start)
|---B01-02-964 0002 1.0000 Right engine (cat c13,4700 OFS 气启动 air start)
|---B01-02-857 0003 1.0000 Engine and transmission support assembly
|---X26-02-228 0004 2.0000 Plug, Sae O-ring hollow hex plug 7/8"
|---X26-02-227 0005 2.0000 Plug, Sae O-ring hollow hex plug 3/4"
|---B01-02-853 0006 1.0000 Fuel system assembly (900L fuel tank)
|---B01-02-896 0007 1.0000 Fuel tank frame (900L)
|---B01-05-122 0008 2.0000 Cover
|---B01-02-892 0009 1.0000 Air compressor adapter assembly
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B01-00-069 Rev:A
Parts Manual
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Parts Manual
Hydraulic System

B01-03-027 Hydraulic system
|---B01-03-986 0001 1.0000 Hydraulic system tank assembly
|---B01-03-101 0002 1.0000 Hydraulic system & lube hose assembly
|---B01-02-477 0003 1.0000 Cam pump assembly
|---B01-03-116 0004 2.0000 Agitator pump assembly
|---B01-03-919 0005 1.0000 Radiator speed adjusting valve assembly
|---B01-03-123 0006 1.0000 Manual valve assembly
|---B01-03-905 0007 1.0000 Speed adjusting valve assembly
|---B01-03-260 0008 1.0000 Filter assembly
|---B01-20-242 0009 1.0000 Pressure reducing valve assembly
|---B01-20-125 0010 1.0000 Slippage pump pressure panel
|---X26-02-736 0011 2.0000 Adapter 1/4NPTF-7/16"x20 JIC ( 5JN-04/N915 )
Pressure gauge Model:25.911-1000PSI/KPa-1/4"NPT-PMC
|---X04-00-687 0012 3.0000
(w/ bracket),2.5" dial plate
|---X26-02-708 0013 2.0000 Elbow 7/16"-20SAE O-RINGX7/16"-20 JIC M (1JO9-04OG/N915)
|---B01-03-803 0014 1.0000 Cooler assembly
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Parts Manual
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B01-00-069 Rev:A
Parts Manual
Air System

B01-04-140 Air system
Straight adapter 7/8-14UN SAE O-RING MALE/3/8"NPT FEMALE
|---X26-22-290 0001 1.0000
(5ON-10-06/N915)
|---X26-02-053 0002 1.0000 Straight adapter M18x1.5-Z3/8" QBJ5071803
|---X04-00-150 0003 1.0000 Check valve A-L10(bought),M18x1.5 (QI-10)
|---X26-02-738 0004 1.0000 Bushing M18x1.5-3/8"NPTF (外-内)
|---X26-02-652 0005 1.0000 Adapter ,1/2"NPTX3/8"NPT
|---X04-05-885 0006 2.0000 SS ripple metal soft tube, 1/2", L=1600
|---X26-02-537 0007 2.0000 Straight adapter Z1/2"-M22x1.5 QBJ5082204
|---B13-04-307 0008 2.0000 Gasket
|---X04-01-786 0009 1.0000 Air dryer (24V),接口 M22X1.5
|---X26-02-932 0010 1.0000 Adapter ,3/4"NPTX9/16"-18 JIC37
|---X26-01-543 0012 10.0000 Air hose,3/8" 801-6-RLBLK
|---X04-01-789 0013 1.0000 Recycle air tank
|---X26-02-539 0014 2.0000 补芯 Bushing 1/2"NPTM-1/4"NPTF
|---X26-02-718 0015 1.0000 Tee 1X1/4"NPT(male)-2x1/4"NPT(female)
|---X04-01-124 0016 2.0000 Safety valve
|---X26-02-956 0018 2.0000 Straight adapter,2-1/4"NPT (1N-04/N915)
|---X04-01-487 0019 1.0000 Pressure regulator valve 3-1/4"NPT F
|---X26-02-030 0020 1.0000 Plug 1/4" NPT(4N-04/N916)
|---X26-02-807 0021 1.0000 Elbow 1"NPT-1 5/16-12UN (1JN9-16/N915)
|---X04-00-166 0022 1.0000 Water drain valve, Z 1/2"
|---X26-02-722 0023 1.0000 Steel adapter 1/8"NPTMX7/16"-20JIC M
|---X26-02-826 0024 1.0000 Elbow 1NPT(male)x1NPT(female) (5N9-16/N915)
|---X26-02-823 0025 1.0000 Straight adapter 2-1"NPT
|---X04-01-913 0026 1.0000 1"NPT ball valve,Q11F-16P/GB/T 15185-94
|---X26-02-003 0027 1.0000 Straight adapter 1" NPTMx1-5/16"-12 JIC MALE (1JN-16/N915)
|---X04-02-237 0028 1.0000 Air tank (70L)
|---X26-02-460 0030 1.0000 Straight adapter,2-Z1-1/2" QBJ5221212
|---X26-02-804 0031 2.0000 Straight adapter 3/8"NPT-9/16-18UN
|---X04-00-647 0032 1.0000 Air lubricator and filter 3/8〞
|---B16-06-066 0033 1.0000 Air lubricator and filter support
|---B16-06-073 0034 2.0000 U-bolt,M6 L=84
|---X04-01-117 0035 1.0000 Switch Z3/8" NPT
|---X26-02-874 0036 2.0000 Straight adapter 2-3/8"NPT (1N-06/N915)
|---X26-02-344 0037 2.0000 Elbow 2-Z3/8" (7N9-06/N915)
|---X26-02-296 0038 1.0000 Bushing,3/8" NPTM-1/4" NPTF
|---X26-02-412 0040 1.0000 Tee 1/4"NPT,FEMALE
|---X26-02-834 0041 2.0000 Straight adapter 1/4NPT-7/16UN JIC (1JN-04/N915)
|---X26-02-721 0042 1.0000 Elbow 1/4"NPTMX7/16"-20JIC M (1JN9-04/N915)
|---X26-02-769 0043 1.0000 Elbow Z3/8"-7/16JIC
|---X26-02-628 0044 80.0000 90 deg copper elbow 1/4"NPTMX7/16"-20JIC M
- 10 -
B01-00-069 Rev:A
Parts Manual
|---X26-02-639 0045 160.0000 Swivel joint,1/4"

|---X26-02-629 0046 40.0000 Tee,2 X 7/16-20 JIC37 MALE X 1/4"NPTM :(AJJN-04/N915)
|---X26-02-627 0047 100.0000 Straight adapter,1/4"NPTM X 7/16-20 JIC37
|---X26-01-506 0048 300.0000 Air hose,1/4" 801-4-RLBLK
|---X26-02-524 0050 1.0000 Nipple 3/8" NPTx86
|---X26-22-311 0053 1.0000 Straight adapter,9/16"-18JIC 37 XM12X1.5
|---X04-02-760 0055 1.0000 90 deg elbow 2-Z3/8" (male) (1N9-06)
|---X04-01-667 0056 1.0000 3/8"NPT ball valve,Q11F-16P/GB/T 15185-94
|---X26-02-034 0057 1.0000 Plug Z3/8" (4N-06)
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Parts Manual
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B01-00-069 Rev:A
Parts Manual
Lubrication System

B16-05-050 Lubrication system
|---X26-02-956 0001 15.0000 Straight adapter,2-1/4"NPT (1N-04/N915)
|---X04-00-652 0002 8.0000 Check valve,1/4"NPTF
|---X26-02-834 0003 4.0000 Straight adapter 1/4NPT-7/16UN JIC (1JN-04/N915)
|---X04-04-586 0004 2.0000 Pressure gauge, bottom connection 1/4"NPT 0-60PSI Dual PSI/KPa
|---X26-02-947 0005 2.0000 Elbow 2-1/4"NPTM
|---X04-00-635 0007 8.0000 Needle valve,1/4"NPT
|---B01-05-516 0008 2.0000 Welded tank assembly
|---X26-02-412 0009 4.0000 Tee 1/4"NPT,FEMALE
|---X26-22-232 0010 1.0000 Straight adapter 3/4"NPTM-1/4"NPTM (N915/1N-12-04)
|---X26-02-287 0011 2.0000 Tee Z3/8" QBJ806030303
|---X26-02-842 0012 1.0000 Straight adapter 3/4NPT-3/8NPT (1N-06-12/N915)
|---X26-02-296 0013 1.0000 Bushing,3/8" NPTM-1/4" NPTF
|---X26-02-874 0014 3.0000 Straight adapter 2-3/8"NPT (1N-06/N915)
|---X04-02-760 0015 2.0000 90 deg elbow 2-Z3/8"(male) (1N9-06)
|---X04-00-651 0017 2.0000 Needle valve,3/8"
|---X26-02-804 0018 2.0000 Straight adapter 3/8"NPT-9/16-18UN
|---X26-02-803 0019 2.0000 Straight adapter 1/4NPTx9/16-18UN JIC (1JN-06-04/915)
|---X26-02-721 0020 11.0000 Elbow 1/4"NPTMX7/16"-20JIC M (1JN9-04/N915)
|---B13-05-271 0021 2.0000 Welded oil pipe assembly
|---X26-02-631 0022 6.0000 Straight adapter 1/4NPTM X 1/8 NPTM
|---X26-02-740 0023 6.0000 45°elbow connection 1/4"-18NPT X 7/16"-20 JIC
|---X04-00-634 0024 2.0000 Ball valve,1/4"
|---X04-00-633 0025 2.0000 Pressure regulating valve,1/4"NPTF
|---X26-02-744 0026 2.0000 Straight adapter 1/4"NPTF-7/16"-20F ( 7NJ-04-S/N915)
|---X26-02-650 0027 2.0000 Straight adapter,2-1/4"NPT,L=100
|---V06-38-881 0028 3.0000 Plug 1/4"NPT
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Parts Manual
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B01-00-069 Rev:A
Parts Manual
Operation Platform Assembly

B01-06-502 Operation platform assembly
|---B01-06-503 0001 1.0000 Welded platform assembly
|---B01-06-207 0002 1.0000 Support assembly
|---B01-06-208 0003 2.0000 Support assembly L=594
|---B01-06-216 0004 2.0000 Support assembly L=810
|---B10-06-245 0005 1.0000 Steel plate
|---B01-06-217 0006 1.0000 Support assembly
|---B01-06-756 0007 1.0000 Welded ladder assembly
|---B01-06-876 0008 1.0000 Ldder bracket
|---X04-05-449 0009 3.0000 FRP grating Size V-101.6x38.1x38/3660x1220
|---B10-06-195 0010 8.0000 Clips
|---X20-08-841 0011 8.0000 Bolt,M8X50,GB5782-86-1Cr18Ni9
|---X20-22-901 0012 8.0000 Hex nut, M8 GB6184-86
|---X20-27-553 0013 4.0000 Washer 12 GB96-85 100HV
|---X20-08-551 0014 4.0000 Bolt M12X25 GB5783-86
|---B01-06-504 0015 1.0000 Reposition fence
|---B01-06-492 0016 1.0000 Platform
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Parts Manual
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Parts Manual
Low Pressure Manifold Assembly

B01-07-970 Low pressure manifold assembly
|---B01-07-978 0001 1.0000 Water C-pump pipe assembly
|---B01-07-979 0002 1.0000 Displacement tank pipe assembly
|---B10-07-062 0003 1.0000 Water, recirculate, booster C-pump suction pipe assembly
|---B10-07-108 0004 1.0000 Water, recirculate, booster C-pump discharge pipe assembly
|---B01-07-487 0005 1.0000 Emergency pipe assembly
|---B13-02-912 0006 1.0000 Bracket
|---V06-24-240 0007 8.0000 4" flange (butterfly valve)
|---B01-07-996 0008 3.0000 Steel groove pipe 6" L=80
|---B11-07-013 0009 5.0000 Elbow 90E(S)-150-Sch40-20 GB12459
|---B10-09-152 0011 2.0000 Reducer R(E)-125x100-SCH40-20# GB12459
|---B01-07-992 0013 1.0000 Steel groove pipe 2 1/2" L=80
|---B10-03-016 0015 5.0000 Elbow 90E(S)-80-Sch40-20 GB12459
|---B11-07-028 0016 1.0000 Reducer R(C)-80x65-Sch40-20-GB12459
|---B01-14-254 0018 2.0000 2＂ support (height 95)
|---X26-02-191 0019 2.0000 U-bolt,M12 L=109 (2")
|---B01-03-424 0022 1.0000 Half coupling 2"NPT
|---F32-29-886 0023 6.0000 4" butterfly valve
|---X00-01-574 0024 1.0000 2 1/2" coupling, pipe OD 2.875"
|---X04-01-265 0025 1.0000 Relief valve
|---B01-27-531 0026 2.0000 Pressure gauge welding assembly
|---X26-02-852 0027 2.0000 Straight adapter 1 1/2NPT-2 1/2x12UN JIC
|---X26-02-579 0028 4.0000 90 deg elbow 2-7/16"X20JIC (2J9-04/N915)
|---X26-02-578 0029 8.0000 90 deg elbow 2-9/16"X18JIC (N915/2J9-06)
|---X26-22-805 0030 2.0000 90 deg elbow 2-2-1/2"X12JIC
|---X26-02-577 0031 4.0000 90 deg elbow 2-1-1/16"X12JIC (2J9-12/N915)
|---JC02140070 0501 2.0000 Steel pipe OD 140x7／20# GB699-88 GB8163-87
|---JC02089050 0504 5.0000 Steel pipe OD 89x5/20# GB699-88 GB8163-87
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Parts Manual
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B01-00-069 Rev:A
Parts Manual
- 20 -
B01-00-069 Rev:A
Parts Manual
Mixing Tank Assembly

B01-09-449 Mixing tank assembly (12bbl)
|---B01-09-454 0001 1.0000 Mixing tank welding assembly
|---B01-09-154 0002 3.0000 Pin shaft
|---X04-02-010 0003 3.0000 Pin cotter 5X45 GB91-86 (外购)
|---X20-08-565 0004 4.0000 Bolt M10x40 GB5782-86
|---X20-27-610 0005 4.0000 Washer 10 GB93-87
|---B01-09-226 0006 1.0000 Filter assembly
|---B11-40-507 0007 1.0000 Mixing tank agitator
|---X00-01-616 0008 1.0000 Agitator motor
|---X26-02-845 0009 2.0000 Straight adapter,7/8"-14 SAE O-RINGX1-1/16"-12JIC (1JO-12-10/N915)
|---X04-05-301 0010 1.0000 Electrical air trump, model: DQL222(Y-102)，SIZE:S=190mm，L＝255mm
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Parts Manual
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B01-00-069 Rev:A
Parts Manual
4X3 Centrifugal Pump Assembly

B01-07-651 4X3 centrifugal pump assembly
4x3x13centrifugal pump #19206-70-30&#19205-01-30&#20618-12-1
|---X04-00-410 0001 1.0000
w/ motor adapter and bushing
|---X04-00-535 0002 1.0000 Coupling
|---X04-00-538 0003 1.0000 Bushing
|---X04-00-537 0004 1.0000 Bushing adapter
|---X04-00-507 0005 1.0000 EATON 33 motor
|---X26-02-919 0006 2.0000 5151HK SAE flange kit (code 61),1"
|---X20-08-561 0007 4.0000 Bolt M16x50 GB5782-86
|---X20-22-016 0008 4.0000 Nut M16 GB6170-86
|---X20-27-627 0009 4.0000 Washer 16 GB97.1-85
|---X20-27-616 0010 4.0000 Washer 16 GB93-87
|---X20-04-051 0011 4.0000 1. stud, 1/2"-13UNC×3 1/2".
|---V06-68-472 0012 4.0000 Washer 1/2"
|---X26-02-937 0013 1.0000 Elbow,1-1/16"-12X1-1/16"-12 JIC37(1JO9-12OG/N915)
|---X26-02-833 0014 1.0000 Straight adapter 7/16-20UN-O-RING 7/16-20UN JIC
|---X26-02-874 0015 1.0000 Straigt adapter 2-3/8"NPT (1N-06/N915)
|---V06-45-482 0017 4.0000 Hex nut 1/2"-13NC
|---A08011550E 0018 1.0000 4x3" installation, operation and maintenance instruction
|---X26-02-652 0019 1.0000 Adapter,1/2"NPTX3/8"NPT
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Parts Manual
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Parts Manual
5X6 Centrifugal Pump Installation Assembly

B01-07-665 5X6 centrifugal pump installation assembly
|---P06-00-106 0001 1.0000 5X6 centrifugal pump
|---X20-08-555 0002 6.0000 Bolt M16x45 GB5783-86
|---X20-28-516 0003 8.0000 Washer 16 GB93-87
|---X20-27-627 0004 8.0000 Washer 16 GB97.1-85
|---X04-00-509 0005 1.0000 Motor,EATON 46
|---X26-02-833 0006 1.0000 Straight adapter 7/16-20UN-O-RING 7/16-20UN JIC
|---X26-02-919 0007 2.0000 5151HK SAE flange kit (code 61),1"
|---X26-02-937 0008 1.0000 Elbow,1-1/16"-12X1-1/16"-12 JIC37(1JO9-12OG/N915)
|---X20-08-633 0009 2.0000 Bolt M16x75 GB5782-86
|---B01-07-667 0010 1.0000 5X6 centrifugal pump support (2)
|---B01-07-666 0012 1.0000 5X6centrifugal pump support(1)
|---X26-02-875 0013 1.0000 Straight adapter 2-3/4"NPT (1N-12 /N915)
|---X04-00-681 0014 1.0000 3/4" NPT ball valve,Q11F-16P/GB/T 15185-94
|---X20-08-783 0015 2.0000 Bolt,1/2"-13UNX3.5" LONG
|---X20-08-781 0016 2.0000 Bolt,1/2"-13UNX1 1/4"LONG，6 级
|---V06-67-756 0017 3.0000 Stud 1/2"x2 1/2"
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Parts Manual
- 26 -
B01-00-069 Rev:A
Parts Manual
Lubrication System

B01-12-141 Mixing system
|---B10-11-050 0001 1.0000 Diffuser (left), inlet 6" , top removable
|---X00-01-963 0002 1.0000 Coupling 6" Victaulic STYLE11,OD=168.3
|---B10-12-430 0003 1.0000 HEMI jet mixer
|---X00-00-483 0004 1.0000 Double action actuator
|---B01-09-561 0005 1.0000 Cement metering valve
|---X26-02-803 0006 4.0000 Straight adapter 1/4NPTx9/16-18UN JIC (1JN-06-04/915)
|---V06-30-524 0007 2.0000 1/4" needle valve
|---X20-08-534 0008 8.0000 Bolt M8X25 GB5782-86
|---X20-27-608 0009 8.0000 Washer 8 GB93-87
|---X04-01-659 0010 1.0000 Dry cement encoder assembly
|---B10-11-019 0011 1.0000 8" elbow
|---B11-03-088 0012 1.0000 Bracket and arm (w/o actuator)
|---X04-03-051 0013 1.0000 Actuator
|---B01-03-971 0014 1.0000 Electrical valve control cementing valve assembly
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B01-00-069 Rev:A
Parts Manual
- 28 -
B01-00-069 Rev:A
Parts Manual
High Pressure Manifold Assembly

B01-13-078 High pressure manifold assembly
|---B01-13-137 0001 2.0000 High pressure nipple, 2" 1502FM,L=200
|---F3L-11-592 0002 5.0000 Tee,2" FIG 1502,FxMxF,w/ nut
|---X04-04-927 0003 2.0000 Diaphragm
|---X00-00-545 0004 2.0000 Pressure transducer
|---V06-29-976 0005 1.0000 Control level L=508
|---F1A-11-705 0006 4.0000 Plug valve 1" ,105MPa,2" FIG1502 FXM
|---V06-29-977 0007 1.0000 Control level L=914
|---V06-37-694 0008 3.0000 2" retainer segment
|---V06-37-695 0009 3.0000 2" external retainer ring
|---V06-37-680 0010 7.0000 Union nut,2"FIG1502
|---F4P-10-229 0011 15.0000 2" union seal ring
|---F2P-14-562 0012 2.0000 Tee,2" FIG 1502,MxFxM(w/ nut)
|---B01-13-138 0013 1.0000 High pressure nipple 2" 1502FM,L=360
|---F3L-13-234 0014 1.0000 90 deg elbow 2"FxM,FIG1502, w/ nut and segment
|---V06-37-685 0015 1.0000 Male sub union,2" FIG1502, w/ nut
|---B01-13-139 0016 1.0000 Bleed pipe 2",diameter 60,L=700
|---B01-13-411 0017 1.0000 Steel pipe assembly I
|---B01-13-413 0018 1.0000 Steel pipe assembly II
|---B10-07-191 0019 2.0000 3" pneumatic butterfly valve assembly
|---B10-03-016 0022 2.0000 Elbow 90E(S)-80-Sch40-20 GB12459
|---B01-13-143 0023 1.0000 Steel pipe,3",L=1000
|---X04-00-572 0024 1.0000 Coupling 2"
|---X26-02-192 0025 2.0000 U-bolt,M12 L=138 (3")
|---X20-27-521 0026 4.0000 Washer 12 GB95-85 100HV
|---X20-22-004 0027 4.0000 Nut M12 GB41-86
|---X20-27-612 0028 4.0000 Washer 12 GB93-87
|---X00-01-573 0029 2.0000 3" coupling,OD=89
|---V06-29-975 0030 1.0000 Handle
|---V06-24-253 0033 2.0000 Flange 3"(butterfly valve)
|---X05-91-331 0034 1.0000 Changeover, 2" FIG 1502 M/M(w/ nut),L=200
|---F1A-11-687 0036 5.0000 Plug valve 2" FIG1502 FXM SP150WU-2X2
|---F2A-18-192 0037 2.0000 Relief valve 2" FIG. 1502
|---B01-13-106 0038 2.0000 Release pipe, diameter 60,L=1075
|---B01-13-412 0039 1.0000 Steel pipe assembly II
|---B01-13-414 0040 2.0000 Steel pipe
|---F2A-17-289 0041 2.0000 Swivel joint,2",80,MXF,15,000PSI,1502
|---F3P-10-101 0042 2.0000 Changeover 3"(male)x2"(male) FIG1502,L=7", w/ nut
- 29 -
B01-00-069 Rev:A
Parts Manual
|---V06-37-685 0043 1.0000 Male sub union,2" FIG1502, w/ nut

|---X04-01-265 0044 1.0000 Relief valve
|---B10-03-081 0045 1.0000 2"NPT half coupling
|---B01-13-253 0046 0.0000 Nipple
|---X26-02-875 0047 1.0000 Straight adapter2-3/4"NPT (1N-12 /N915)
|---X04-00-681 0048 1.0000 3/4" NPT ball valve,Q11F-16P/GB/T 15185-94
|---X05-91-445 0049 1.0000 2" high pressure straight tube (w/ nut) L=500 FIG 1502 integral
|---X05-91-004 0050 1.0000 2" high pressure straight integral (w/ nut),105MPa,FIG1502 MF L=1200
|---F3L-13-234 0051 2.0000 90 deg elbow 2"FxM,FIG1502, w/ nut and segment
|---B01-16-232 0052 1.0000 Male union
|---B01-13-109 0053 1.0000 Steel piep 60x6/20,L=60
|---X05-91-163 0054 2.0000 Y type tee,2",FIG.1502,FxFxM,(w/ nut)
|---B01-13-185 0055 6.0000 U bolt M12 L=128 (2")
|---B01-13-423 0056 1.0000 Steel plate
|---B01-13-425 0057 1.0000 Steel plate
|---B01-13-424 0058 1.0000 Bracket
|---X26-02-564 0059 1.0000 Half coupling, 3/4"NPT
|---JM02060060 0502 0.5100 Rectangular steel, 60x60x6/20# GB699-88
|---JD01001200 0503 0.0200 Steel plate S=12/Q235 GB700-88 GB709-88
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B01-00-069 Rev:A
Parts Manual
- 31 -
B01-00-069 Rev:A
Parts Manual
Displacement Tank Installation Assembly

B01-14-244 Displacement tank assembly
|---B01-14-834 0001 1.0000 Displacement tank welding assembly 4 m3
|---B01-14-610 0002 2.0000 Counter
|---B01-09-154 0003 3.0000 Pin shaft
|---X04-02-010 0004 3.0000 Pin cotter 5X45 GB91-86 (外购)
|---B01-09-155 0005 3.0000 Support seat
|---B01-07-841 0007 1.0000 Steel pipe assembly
|---B01-09-102 0008 2.0000 Mixing tank agitator assembly
|---X04-00-954 0009 26.0000 4 way, 3 position air valve
|---X20-08-608 0010 116.0000 Screw M6X20 GB65-85-1Cr18Ni9Ti
|---X20-22-088 0011 116.0000 Hex nut M6 GB6170-86-1Cr18Ni9Ti
|---B01-09-352 0012 3.0000 Gasket
|---B01-09-020 0013 1.0000 Filter net
- 32 -
B01-00-069 Rev:A
Parts Manual
- 33 -
B01-00-069 Rev:A
Parts Manual
TPH400 Pump Installation Assembly

B01-15-113 TPH400 pump installation assembly
|---P40-00-400 0001 1.0000 TPH400 pump, ratio8.6/1, hydraulic end (4"), left drive
|---P40-00-441 0002 1.0000 TPH400 pump, ratio 8.6/1, hydraulic end (4 1/2"), right drive
|---B01-15-472 0004 2.0000 Oil pan (TPH400)
|---B01-01-960 0005 2.0000 Frame
|---B01-01-961 0006 2.0000 Pin
|---B01-01-963 0008 4.0000 Pin
|---B01-01-958 0009 4.0000 Torque rod assembly, chain case
|---B01-15-003 0010 16.0000 Pin cotter 5x35 GB91-86
|---B10-01-030 0011 8.0000 Thimble
|---B01-07-826 0012 4.0000 Support
|---B01-07-832 0013 0.0000 Steel plate
|---B01-15-489 0014 2.0000 Adapter assembly
|---B01-05-103 0015 1.0000 TPH400 power end lubrication system (double pump)
- 34 -
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Parts Manual
- 35 -
B01-00-069 Rev:A
Parts Manual
Nameplate Assembly

B01-99-306 Nameplate assembly (069)
|---B01-99-081 0001 1.0000 Low manifold flow diagram
|---B10-00-532 0002 1.0000 Identity plate
|---B01-99-051 0003 1.0000 Number plate
|---B01-99-283 0007 2.0000 Nameplate (EN), safety and warning,“caution, mechanical injury”
|---B01-99-284 0008 2.0000 Nameplate (EN), safety and warning,“slip caution”(EN)
|---B01-99-285 0009 3.0000 Nameplate(EN), safety and warning, “Scald caution”(EN)
|---B01-99-286 0010 1.0000 Nameplate (EN), safety and warning,“Caution, danger”
|---B01-99-287 0011 2.0000 Nameplate (EN), safety and warning,“High pressure area, no nearing”
|---B01-99-301 0012 1.0000 Nameplate (engine)
|---B01-99-302 0013 1.0000 Nameplate (radiator)
|---B01-99-303 0014 1.0000 Nameplate (fuel tank)
|---B01-99-304 0015 1.0000 Nameplate(lubrication system)
|---B01-99-305 0016 1.0000 Nameplate (hydraulic tank)
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B01-00-069 Rev:A
Parts Manual
Drive Shaft Installation Assembly

B01-18-155 Drive shaft installation assembly
|---X04-00-936 0001 2.0000 Drive shaft, L=86- 5/8"
|---X20-04-025 0002 48.0000 Drive shaft bolt, 7/16"-20X1-5/8"
|---X20-22-086 0003 48.0000 Drive shaft nut, 7/16"-20
|---X20-28-521 0004 48.0000 Lock washer, 7/16"
|---B01-18-156 0005 1.0000 Left guard assembly
|---B01-18-157 0006 1.0000 Right guard assembly
|---B01-18-040 0007 2.0000 Cover
|---B01-02-707 0008 1.0000 Protector bracket
|---B01-02-757 0013 1.0000 Drive shaft protector(left)
|---B01-02-758 0014 1.0000 Drive shaft protector(right)
- 37 -
B01-00-069 Rev:A
Parts Manual
Spare Parts List

B01-00-610 Spare parts list (069)
|---X04-04-280 0001 1.0000 Filter element (C13, C9)
|---X04-04-502 0002 1.0000 Filter element ( C13)
|---X04-04-276 0003 1.0000 Engine oil filter,C12,C13
|---X02-03-012 0004 1.0000 Air filter element for CAT3406,C12,C13
|---X04-04-306 0005 1.0000 Filter element for 4700 OFS
|---X02-03-014 0006 1.0000 Filte element (X04-00-563 power end)
|---X04-04-283 0007 2.0000 Filter return element (x04-00-532)
|---P8T0009450 0008 4.0000 TPH400 packing 4 1/2"
|---V06-54-820 0009 8.0000 Seal 2"IDx2 3/4"ODx1/2"W(进口)
|---F4P-10-229 0010 2.0000 2" union seal ring
|---B01-15-453 0011 1.0000 4" ( or 3 3/8") and 4 1/2"TPH400 for double cementing pump
|---X04-00-326 0012 1.0000 2.7Kg hammer
|---X04-00-327 0013 1.0000 600mm pipe wrench
|---X04-00-290 0014 1.0000 Flat wrench 5.5-32 ten pieces
|---X04-00-301 0015 1.0000 Socket screw driver 3/16"-3/8"
|---X04-00-302 0016 1.0000 Wrench for engine filter
|---P8T0009400 0017 4.0000 Packing assembly,TPH400 pump 4"
|---X04-01-780 0018 1.0000 25 sizes each set wrench
|---X04-00-300 0019 1.0000 Metric socket screw driver 4-14
|---X04-04-331 0020 1.0000 Standard flat wrench 11pcs
|---X04-04-335 0021 1.0000 Drive socket 3/8"-1 1/4" 26pcs 12point
- 38 -

CU12 B01-00-069 B en MANUAL

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Part #: B01-00-069 Rev: B

Operation & Maintenance

Proper service techniques and repair procedures are necessary

for reliable and safe operation of this equipment as well as safety of

general precautions the operator should follow when operating this

equipment, to avoid the possibility of personal injury or property

Check components of equipment in advance, ensure all the components are

properly and completely fixed.

safety and protection system fails.

in the dangerous area should be inspected to be qualified by authoritative

before operating the equipment.

prohibition, the labels on equipment before doing operation and maintenance.

it’s forbidden to use low pressure pipe.

emergency shutdown system after tested and before starting engine.

written authorization by SJS. Otherwise, all the results caused by random

amendment will be undertaken by modifier.

Warning—The electrical parts can be damaged from welding

z All power switches are off;

z The wires of electrical parts near welding are off;

Caution—Any welding on control equipment will probably extensively damage

computer, screen, sensor and electrical parts of auto control system.

Model PCS-521B Density Auto Control Cementing Skid is the new

generation cementing equipment based on plenty of proprietary techniques

such as TPH400 model field dedicated triplex pump, high energy

Model TPH400 triplex plunger pump is a field dedicated single action

plunger pump, which is suitable for pumping various well conditioning

fluids except hypothermal fluid. High energy mixing system is driven by

most popular mixing technique used at offshore and land field.

The equipment design and production will reduce the requirement of

maintenance/repairs under higher environment temperature condition. The

comprehensively monitor the working condition of all the control switches,

can finish the cementing job.

1.1 Overall Dimension and Weight

 Gross weight(dry): 24t

 Total length: 7,200 mm

 Height: 3,350mm (operating height with cement metering valve)

3,100mm (shipment height without cement metering valve)

 Water suction inlet: three 4" pipe steel

One 4" FIG.206，FEMALE

 Cement metering valve suction inlet: one 5" hose adapter

 High pressure discharge: two 2"FIG.1502, MALE

 Drain outlet: four 4" couplings

straight steel pipe.

1.3 Main compositions

 Two CAT C13 diesel engines, 475HP@2100RPM.

 Two ALLISON 4700 OFS transmissions

 Two SERVA TPH400 (4.5", 4")Triplex plunger pumps

 One set of closed hydraulic system

 One 12bbl mixing tank

 One 25bbl displacement tank

 Two SERVA 6x5 centrifugal pumps (Circulation and booster pump)

 One MISSION 4x3 centrifugal pump (water and displacement

 One set of auto density control mixing system(ACM-Ⅲ.1)

1.4 Ambient Parameters

Minimum working temperature: -20℃(-4℉)

Maximum working temperature: 50℃(122℉)

Relative humidity: 90%

1.5 Working Performance

1.5.1 Pressure range

Maximum working pressure: 96.5Mpa (14,000psi)

1.5.2 Maximum Flow Rate

Maximum flow rate: 2.7 m³/min(17.2bpm)

1.5.3 Slurry density range

Gross weight(dry): 24t

Total length: 7,200 mm

Height: 3,350mm (operating height with cement metering valve)

Water suction inlet: three 4" pipe steel

Cement metering valve suction inlet: one 5" hose adapter

High pressure discharge: two 2"FIG.1502, MALE

Drain outlet: four 4" couplings

Two CAT C13 diesel engines, 475HP@2100RPM.

Two ALLISON 4700 OFS transmissions

Two SERVA TPH400 (4.5", 4")Triplex plunger pumps

One set of closed hydraulic system

One 12bbl mixing tank

One 25bbl displacement tank

Two SERVA 6x5 centrifugal pumps (Circulation and booster pump)

One MISSION 4x3 centrifugal pump (water and displacement

One set of auto density control mixing system(ACM-Ⅲ.1)