Part #: A08010620E REV:C
Operation Manual
Serva Corporation
HEMI
High Energy Mixing Injector
for
Recirculating Mixing Systems
SJS Limited
Phone: 940-761-3361 Fax: 940-761-2207
E-Mail: [email protected] Web Site: www.ServaCorp.com
HEMI MIXER Operation Manual
Part#: A08010920E_C
CONTENTS
INTRODUCTION ........................................................................................................................ 3
COMPONENTS DISCUSSION.................................................................................................... 3
FUNDAMENTAL OPERATING PRINCIPLES......................................................................... 5
MIXING OPERATING PROCEDURE ....................................................................................... 7
CAUTIONS & WARNINGS ......................................................................................................... 9
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Introduction to Serva’s High-Energy Mixing System:
Our mixing system was designed for high energy mixing, ease of operation and maintenance.
There are many of this family of similar mixing systems working throughout the world.
The applications have varied from onshore to offshore and dessert heat to cold climates.
The primary components of the mixing system are:
• HEMI High-Energy Mixing Injector
• Cementing metering valve
• Diffuser
Other components which make up the rest of a complete system are:
• Mixing tub
• Recirculating centrifugal pump
• Mix water centrifugal pump
• Agitating system
• Transfer pump (optional for single pump cementers and required for double pump
cementers).
These items are discussed in separate documents.
Components Discussion:
HEMI, High-Energy Mixing Injector
Introduction:
The latest in mixing technology is the result of 15 years of cement mixing evolutionary
development. This latest mixer, the HEMI, incorporates capability of past systems but
moves the technology two steps forward. Like its predecessors, it is a high-energy mixer.
However, its performance is optimal over a wider range of operating conditions. It is
equally as good as a mixer in the recirculating batch mixing mode as it is in continuous
mixing (its predecessors were poor batch mixers). The mixer also allows the use of the
densitometer discharge for mixing. The densitometer output can be connected to the central
jet inlet so that there is no longer a need for returning densitometer discharge to the mixing
tank directly. This will also apply addition backpressure on the densitometer, which will
provide better measurement (reduced effect of any air entrainment). The bulk flow path
is less restrictive and therefore has a larger capacity. Additionally, the water control has
an optional remote control to make installations more flexible. The bulk control has
always been available with remote hydraulic control.
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Description:
The slurry mixer is a recirculating type mixer designed to meet the most demanding mixing
requirements. The mixer design provides easy cleanup and maintenance. The mixer has a
6” suction union thread half on the inlet for attaching the dry bulk cement metering valve.
In the center of the mixing chamber is a high-pressure jet that wets the bulk cement from
the center of the mixing chamber. The recirculated slurry enters the mixing chamber from
an outer annular position surrounding the dry bulk cement. The water jets enter the mixing
chamber from alternating positions with the recirculation jets. The force of the
recirculating jets and the mix water jets is directed inward and the force of the central jet
directed outward creates the energy to wet and mix the dry bulk cement. This provides
maximum wetting efficiency.
The operator can easily adjust the water flow from almost zero to maximum. The valve is
linear, providing equal increases in water flow per increment of displacement. Maximum
water flow is a function of supply pressure. The recirculating mixer design improves mixing
and homogenizing of the new incoming slurry with the slurry already in the mixing tank.
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Bulk Cement Metering Valve
Serva has developed a new cement metering valve that overcomes common problems with
previous technology. Older technology valves worked reasonably well with clean cement
but would develop operation problems when dirty cement was encountered. The new
valve greatly improves the ability to handle dirty cement (rocks, weld rod, sack material
and other foreign debris) without damaging the valve or becoming difficult to turn.
Bearings further enhance ease of operation and life. The body and metering sleeve are
heat treated.
The rotary operated cement-metering valve adjusts the rate of bulk cement flow. It may be
operated manually or hydraulically. In addition, if the hydraulic system failed that is used
to operate the valve, the valve is provided with a means to insert a .75 in. steel bar for
manually turning.
The valve is approximately linear and will provide near equal increases in bulk cement
delivery per increment of rotation. A particularly important feature is the ability to meter
cement at low flow rates without bridging off (the phenomenon where cement stacks against
the opening and therefore prevents further passage of cement).
FUNDAMENTAL OPERATING PRINCIPLES
The high-energy mixer provides excellent mixing, the metering valve provides good
metering of bulk cement, the diffuser eliminates bulk air and the agitator further
homogenizes the slurry. The slurry is continuously delivered to the cement triplex pump
and from there it is pumped downhole.
Its basic operating principle is as follows:
The cement from the bulk cement tank is delivered into the cement metering valve via a
bulk hose. The mixing water along with the recirculating flow power the high-energy mixer
to effectively mix the bulk cement.
The cement bulk flow rate is controlled and adjusted via the proportional cement metering
valve.
The mixed slurry is further homogenized by the tank agitator in the mixing tub.
The slurry densitometer located on the circulating piping system detects the actual slurry
density.
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The water flow meter (optional) mounted on the mix water piping measures the water flow
rate.
Fig. Mixer, Piping and Pump Arrangement Drawing
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MIXING OPERATING PROCEDURE
1. Preliminary
• Check that the inside of the mixer is clean.
• Connect the water supply hose and the bulk cement hose. The rated working
pressure of the bulk cement supply system should be 20 to 30 psi.
• Connect slurry discharge line if not part of unit.
• Check that there is adequate water supply.
• Open the water supply valve.
• Check that the centrifugal pumps are working normally.
2. Operation Procedures (Step by Step)
Start Mixing Process:
◊ Bring on water with the mix water pump and fill all lines. While doing this, set
the water metering valve to 120 to 150 gpm.
◊ Fill the mixing tank to approximately 1/3 full and then close the master water
valve
◊ Prime triplex pumps
◊ Prime recirculation pump
◊ Close the bulk cement master valve
◊ Open the cement metering valve to a position between one and two. After
starting the recirculation pump to full speed and having the bulk delivery system
pressurized to about 25 psi, open the master bulk valve slowly. The color of the
mixing tub should be changing into gray and some dust may be present in the tub.
As soon as the slurry level reaches the agitator, turn on the agitator to the
maximum speed without causing excessive splashing. The idea is to keep the
agitator at its maximum speed to improve mixing and homogenization of the
slurry without causing vortexing or splashing.
◊ If you are not going to immediately start the continuous mixing process, close the
bulk master valve when the density reaches within .2ppg of the desired density.
Continuous Mixing Process – Manual Control
(This process will be started immediately after the tub is full or the density has reached
within .2ppg of the target density.)
◊ Start the continuous mixing process after the “Start Mixing Process” is
completed. Start the mix water pump, open the water metering valve
approximately 20% to obtain 120 to 150 gpm (It should be already in this
position) and open the master water valve. The bulk cement valve should still
be open and therefore cement should be flowing. If it is not open, open it.
◊ Adjusting the tub level: Start pumping down hole when the level reaches
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within about 18” from the top. Adjust pump speed (triplex) to maintain tub
level (about 18” +/- 6”). The tub level can also be adjusted by changing the
mixing rate. When adjusting the rate, note that both the water and cement
flows will require adjusting to maintain a constant density. This is why it is
better to start the mixing process at approximately the required rate and adjust
the tub level by only changing the triplex downhole rate. This will provide a
smoother density chart while manually mixing.
◊ Maintaining density as the bulk unit pressure declines during the delivery of
cement from an individual tank will require opening the bulk metering valve
gradually. Open the valve only one quarter to one half (1/4 to ½) of indicated
increment (i.e. 2.5 to 2.75 or 3.0) and observe the response. If the density is still
falling, open the valve again in small increments.
◊ When changing bulk tanks it will be necessary to reduce the bulk metering valve
position to deliver the correct amount of cement. The new tank will probably
be at a higher pressure (pressurized before the job started) which will deliver too
much cement relative to what is required. The amount the valve position will
need to be reduced will depend on the job rate (the higher the rate, the more the
pressure will decline in a given tank). This is also a function of the ability of the
compressor to keep up. The larger the compressor, the more stable the
pressure and therefore the more stable the bulk cement delivery.
◊ When ending the mixing process, allow the bulk delivery system to “blow down”
while the metering valve is in full position.
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Cautions & Warnings
Before the job:
Read the operation manual carefully before starting the skid.
During the job:
Watch for the possibility of the densitometer becoming plugged.
If during the job, the density reading increases quickly to higher than required values, the
densitometer may be plugged or be partially plugged. This condition can be verified by
looking at the densitometer measurement reading, which has a flow measurement. If the
flow is zero or below 2 BPM, the meter is plugged or partially plugged. To solve the problem,
manually close and then open the recirculation valve (below the mixer). This should clean
the blockage out. A blockage is an inclusion or poorly mixed cement, which may have
several causes. This may be caused by not enough mixing energy due to not operating the
circulating pumps at maximum RPM. Also if the system is operated at rates that are too
high for difficult to mix slurries, the mixing energy may be insufficient. The solution is to
slow the mixing process by 20 to 30%.
After the job:
1. When washing the unit, do not wash the densitometer external transducer with
high-pressure water.
2. Clean the cement metering valve after each job by blowing out with air and physically
emptying dry cement. Do not flush the valve with water.
3. After each cement job it is critical to immediately flush the mixing tub, the piping
system, the densitometer and the slurry centrifugal pumps.
4. Drain the centrifugal pumps, the mixing tank and all equipment that may contain
water after each job, especially during freezing weather.
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Maintenance:
Welding: When welding is required, extreme care must be employed to prevent damage to
electronics.
1) Disconnect starting battery
2) Disconnect any computers and any other electronic equipment
3) Be careful not to allow welding leads to come close to electric cables and wires
associated with electronics including transducer wires.
4) It is best to remove or totally isolate electronics before welding.
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