JET Module6_Bulk System

JET Module 6 Bulk System version 1.0

TABLE OF CONTENTS 1 2 2.1 2.2 2.3 2.42.4 3 3.1 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 4 4.1 4.2 4.3 4.4 4.4.1 4.4.2 JET 6 – Bulk System Training Manual

Introduction Principles of operation Purpose of a bulk system Basic bulk system components Principles of pneumatic conveying Principles of vacuum conveying Bulk systems Bulk storage tanks Pressure tank Components of pressure tank Weigh batch blender Additive/cutting bottle Bulk tank construction Gravity discharge bulk tanks Discharge valve Air supply line Aeration device Sight glass Weight indicator Pressurized surge can Vent line Pressure sensor Pneumatic controller Side discharge Air slide/commercial hauler Air compressors Reciprocating compressors Rotary axial compressors Vane-type compressors (blowers) Compressor package Compressor Air filters

TOC pg 5 pg 6 pg 6 pg 7 pg 8 pg 13 pg 14 pg 14 pg 16 pg 16 pg 21 pg 22 pg 22 pg 24 pg 25 pg 25 pg 25 pg 26 pg 26 pg 27 pg 27 pg 27 pg 28 pg 28 pg 29 pg 30 pg 30 pg 32 pg 33 pg 34 pg 34 pg 34 

TABLE OF CONTENTS 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7 4.4.8 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 5 5.1 5.1.1 5.1.2 5.1.3 6 7 7.1 7.2 7.2.1 7.2.2 7.2.3 7.2. 7.2.4 7.3 7.4 8.0 8.1 8.1.1 8.1.2 8.1.3 JET 6 – Bulk System Training Manual

Power unit Air receiver tank Safety relief valve (PRV) Pressure gauge After cooler and dryers Unloader lines Air compressor moisture control After-coolers Water separator Air dryers Refrigeration Absorption Dust collectors Dust collector operation Cloth sock filters Pleated paper cartridges Overpressure protection Bulk system piping Pressure-vacuum systems Principle of operation Non-pressure bulk tanks Vent line Vacuum breaker Pressure relief valve Pressure vacuum compressors Weigh batch blender Additive hopper Bulk equipment operations Operating bulk plant equipment on location STEM 1 Rigging up Transferring bulk material on location

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TABLE OF CONTENTS

8.1.4 8.1.5 8.1.6 9 9.1 9.2 9.3 9.4 9.4.1 9.4.2 9.4.3 9.5 9.6 9.6.1 9.6.2 9.6.3 9.7 9.8 9.9 9.10 10 11 12 13

JET 6 – Bulk System Training Manual

Operating bulk equipment during the job Rigging down At the District Maintenance of bulk equipment Butterfly valve Check valves Ball valves Aeration devices Pipe jets Canvas pads Stainless steel pads Dust collector socks Connections Figure 206 unions Victaulic connections (groove lock) Dresser sleeve Safety relief valve Pressure gauges Weight measuring devices Annual pressure tank inspection Glossary References Check your understanding Answer key pg 76

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INTRODUCTION This module introduces bulk operations. Advanced bulk operations and maintenance of individual equipment pieces are included in the Advanced Bulk Plant JET Module. This module discusses how a bulk system works, describes the system’s major components, reviews the system’s proper operation, and addresses important maintenance issues. In addition, this module also covers the operation of a pneumatic system used in a bulk delivery system. Schlumberger uses bulk systems to store and blend bulk materials used in cementing and fracturing. The system is also used to supply bulk material such as cement and barite to mixing equipment. The success of a job is directly dependent on the proper blending and delivery of materials, which is controlled by proper operation of the bulk equipment.

Learning objectives Upon completion of this module, you will be able to: • explain the principle of pneumatic conveyance in both full pressure and vacuum plants • identify the differences among various types of bulk storage tanks, air compressors, vacuum pumps, dust collectors, piping, and pressure-vacuum systems • describe the operational guidelines for district bulk plants and bulk plant equipment on location

JET 6 – Bulk System Training Manual

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• describe bulk equipment maintenance and troubleshooting procedures.

Safety Warnings Proper supervision is required during hands-on training. Request assistance from your supervisor if you are unfamiliar or uncomfortable with the operation. All personnel who will be involved with bulk equipment must understand the dangers involved with dealing with pressurized tanks. All WS and OFS safety standards must be met. Follow proper procedures before and while working with equipment (JSA, HARC, etc.). It is recommended that all personnel operating bulk plant systems and components should watch the safety video Don’t Tease the Tiger. Use the following guidelines: • When any bulk tank is under pressure, never permit anyone to be on or under the tank for any reason whatsoever. • Under no circumstance may any piping, connections, or unions be connected, disconnected or worked on while the vessel is under pressure. • Never hammer on pressure vessels. • Always monitor pressure gauges. • Never look into the end of a plugged line.



Principles of Operation 2.1 Purpose of a bulk system

2.0.0

Air compressor

There are many ways to move large quantities of powdered or granular solid materials such as sand, barite, or cement, including augers, conveyor belts and hand-carried sacks. The preferred method at Schlumberger is pneumatic transport. Pneumatic (operated by air) transport is a system that uses compressed air to fluidize the dry material and carry it from one place to another within a bulk system. A bulk system as defined here includes all associated equipment used to store, blend, and transport bulk material. A pneumatic and vacuum bulk system is the preferred way to move cement and other materials like sand, bentonite, pozzolan, and barite for the following reasons: • high transfer rates • low manpower requirements • less material lost or damaged

Bulk system Pressure tanks Cement and pozzolans

Holding tanks Dust collector Air Compressor

Blend

Air bulk transport (ABT)

Adds Weigh batch blender (WBB) Additive/ cutting bottle

• environmentally cleaner In the vacuum plant the storage tanks are non-pressurized vessels. The only pressure tanks are the WBB, holding tank, and mix tanks. All vacuum storage tanks require a full open vent and a 2-in vacuum breaker. These components should both be placed on top of the tank system.

JET 6 – Bulk System Training Manual v1.0



BASIC BULK SYSTEM COMPONENTS Schlumberger uses pneumatic bulk equipment to store, blend, transport and deliver bulk materials to mixing equipment. A basic pressure bulk system is made up of the following components: • air compressors (two: one high-pressure for bulk plant controls, and one high-volume for bulk) • vacuum pumps in pressure/vacuum systems • bulk tank also called a pressure tank or P-tank in pressurized bulk plants; storage tanks are non-pressurized in the pressure/ vacuum system

2.2.0

• a dust control device (either sock or filter) • measuring and sampling devices (load cells, gauges, cement samplers, etc.) New plants involve the use of: • WBB (weigh batch blender) • double-stacked tank • truck mix tank The WBB and the truck mix tank each have measuring devices to ensure total product delivery and service quality to the customer.

• piping for air supply, bulk loading, bulk discharge, and venting Bulk system components Pressure tanks

Cement and pozzolans

Holding tanks Dust collector Air Compressor

Blend

Air bulk transport (ABT)

JET 6 – Bulk System Training Manual v1.0

Adds Weigh batch blender (WBB) Additive/ cutting bottle 

Principles of pneumatic conveying As compressed air flows through bulk material, it tends to “fluff” or aerate the particles. Once aerated, the particles are carried by the air as it moves to a lower pressure area. The amount of material carried by the air depends on many factors, including: • the size of the piping between the tanks, and the cleanliness of the piping (dirty lines reduce the pipe ID) • the length of piping between the tanks, as well as elbows and restrictions Dilute Phase 1 Few particles of the bulk material are being carried; the air velocity is high. Piping

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• the amount of air and the size and weight of the particles of material Properties of particle materials

MATERIAL

SIZE

SPECIFIC GRAVITY

ILUMINITE D18

4.45

SILICA SAND D30

2.65

SILICA FLOUR D66

2.65

FLY ASH D35

2.48

CEMENT

3.16

• the pressure of the holding tank Bulk tank



Surge can

• the pressure of the receiving tank (e.g., surge can). Ways in which air carries bulk material are shown in the examples that follow.

JET 6 – Bulk System Training Manual v1.0



Dilute Phase 2 Air velocity high

Air velocity high

Few particles of the bulk material are being carried; the air velocity is lower than in Dilute Phase 1. Unsteady Conveying 1 Lower air velocity

Lower air velocity

Few particles of the bulk material are being carried; the air velocity is high above a dune and lower in clear part of the line. Unsteady Dense Plug Flow Unsteady Conveying

High air velocity

Lower air velocity JET 6 – Bulk System Training Manual v1.0

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A large amount of the bulk material is being carried; the air velocity is lower than Unsteady Conveying 1. The air-bulk material ratio is not constant throughout the line. Unsteady Dense Plug Flow

Air velocity < Unsteady conveying 1 air velocity

Steady Dense Flow A large amount of the bulk material is being carried; the air velocity is lower than Dense Plug Flow. The air-bulk material ratio is constant throughout the line. Steady Dense Flow

Air velocity < Dense plug flow air velocity

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Schlumberger operates bulk systems using the last two types of flow - Unsteady Dense Plug Flow and Steady Dense Flow. Unsteady Dense Plug Flow The bulk-to-air ratio is constant in short sections of the transport line, and there are sections of air between these bulk-air slugs. This type of flow appears as slugs of dense bulk followed by a blast of air. The delivery rate is controlled at the bulk tank located at the beginning of the transport line. Air may have to be added to the system after the cement leaves the tank. The pressure drop required for this type of flow is less than that required for Steady Dense Flow. An example of this flow is a bulk plant on an offshore rig hooked up to a surge can through a long (>20-ft or > 6.1-m) length of piping. Steady Dense Flow The bulk-to-air ratio is constant throughout the transport line. This type of flow appears as a steady stream of bulk material. The cement delivery rate can be controlled at the discharge end of the transport line. There must be enough pressure at the bulk tank to overcome all pressure drops in the transport line. To have this type of flow, the theoretical pressure drop required is 1.6 psi for each foot of transport line. An example of this type of flow is a MARK III mixer hooked up directly to a bulk trailer with a short (