Operation,Maintenance,and Repair

HALLIBURTON

Manual No.277~01833(Rev. B)

Foreword

This manual is intended to provide the cementing equipmentoperator with the basic knowledge to operate the RCM II system. Itincludes troubleshooting, maintenance, and parts information. Italso covers the manual operation of the axial flow mixer for thoseunits that do not have Automatic Density Control (ADC).

This manual should be used with the Trailer or Truck Operator’sManual, the UNIPRO II Operation Manual (P/N 458.00084), and theCompupac system Operation Manual (P/N 458.81369) to providecomplete operating information for the cementing unit.

All information contained in this publication is confidential and proprietary property ofHalliburton Energy Services, a division of Halliburton Company. Any reproduction oruse of these instructions, drawings, or photographs without the express writtenpermission of an officer of Halliburton Energy Services is forbidden.

Copyright 1995, Halliburton Company

All Rights Reserved.

Printed in the United States of America.

Table of Contents

Foreword……………………………………………………………………………………………..iTable of Contents…………………………………………………………………………………...ii

Section 1RCM II System Description

RCM II Mixing………………………………………………………………………………………1-1Introduction…………………………………………………………………………………………1-1Mixing Capabilities…………………………………………………………………………………1-1System Description………………………………………………………………………………...1-1RCM II System Standard Features……………………………………………………………….l-2Component Function Descriptions………………………………………………………………..I-2

Section 2Bulk Equipment Operation

Bulk Equipment Operation with RCM II System (with Constant Pressure Device………….2-1Bulk Equipment Operation with RCM II System (without Constant Pressure Device)..........2-2Bulk Material Manifold and Valve Arrangement………………………………………………...2-4Standard Operating Procedure…………………………………………………………………...2-4Bulk Cement Delivery Procedure to Deliver Cement Directly to the RCM II……………...…2-4Maintenance (Pre-Job)..........................................................................................................2-8

Section 3RCM II Operation

Cement Mixing Procedure……………………………………………………………………….3-1Summary of UNI-PRO II Operating Instructions Including Event Codes…………………..3-3Example of ADC Operating Instructions.............................................................................3-4Post-Job Clean-Up and Inspection……………………………………………………………..3-5

Back-up Control With ADC System…………………………………………………………….3-5 Operating Technique………………………………………………………………………….....3-6

Batch Mixing-Low-Rate (Squeeze) Jobs………………………………………………………3-7Manual Control of RCM II System (without ADC)…………………………………………….3-7Manual Control (non-ADC) Operating Procedures…………………………………………..3-7Cement Delivery Directly to Recirculating Mixer (RCM II)…………………………………..3-7Cement Mixing Procedures…………………………………………………………………….3-8Clean-Up Procedures……………………………………………….......………………………3-9Detailed ADC System Description……………………………………………………………3-10Electronic Subsystem Description……………………………………………………………3-10Cement Valve Position Sensing System…………………………………………………….3-10Water Valve Position Sensing System………………………………………………………3-11Cement Valve Positioning System…………………………………………………………..3-12Water Valve Positioning System…………………………………………………………….3-13Flow Rate Sensing Circuitry…………………………………………………………………3-15Master Water Valve Positioning System…………………………………………………..3.-15Density Sensing System……………………………………………………………………..3-16Summary................................................................................……………………………3-16Hydraulic Subsystem Description..................................................................................3-16

Section 4Maintenance and Troubleshooting

RCM II Inspection and Maintenance Procedures…………………………………………………4-1Cement Throttling Valve Maintenance and Inspection Procedures....................………………4-1Axial Flow Mixer Maintenance and Inspection Procedures.……………………………………...4-2Disassembly..............................................................................………………………………….4-3Re-Assembly................……………………………………………………………………………….4-5412.15018 Mixer Assembly - Cement - RCM II - with Coned Diffuser.………………………….4-7RCM II Troubleshooting Procedures………………………………………………………………..4-9Automatic Density Control Troubleshooting.......................................………………………….4-15ADC System Spare Parts (for 1 Year’s Operation)………………………………………………4-16Hydraulic System Spare Parts.................................……………………………………………..4-l6Axial Flow Mixer Spare………………………………………………………………………………4-l6Parker Hydraulic Actuators (for ADC System)……………………………………………………4-17

Section 5Drawings

278.98014 lnstln - Equip - Std - Mix Module - RCM II-ADC - 8 bbl Alum Tub……………….5-1278.98023 lnstln - Kit - Retrofit - UNI-PRO II and...…………………………………………….5-8278.98018 lnstln - Wiring - ADC - RCM II - 8 bbl - 75TC4........………………………………5-15277.43171 Panel Assembly - Control Stand - UNI-PRO II...................................................5-19278.98022 lnstln - Kit - Retrofit - Hydraulic System……………………………………………5-23458.50019 Basic Assembly - UNI-PRO II – Digital…………………………………………….5-27412.13553 Valve Assembly - 5-in. - Cement Throttling……………………………………….5-29277.01300 Kit - Retrofit- Axial Flow Mixer to 2-Compartment, 8-bbl RCM………………….5-33412.13367 Valve Assembly - 5-in. - Cement Throttling……………………………………….5-41278.98024 Test - ADC-RCM II - Incl/Set-up, Tuning, and Test - Cement Units………...5-43278.10158 lnstln - Calibration - UNI-PRO II – Cementing……………………………………5-49

Section 6Bulletins

Engineering Bulletin: Axial Flow Mixer Update…………………………………………………..6-1Technology Bulletin: New Material Introduced for the RCM II Water Jet……………………..6-4

Section 1RCM II System Description

RCM II Mixing SystemIntroductionThe RCM II System offers a uniquecombination of capabilities that makesaccurate mixing possible over a broad rangeof operating conditions.

Advantages of the RCM II System includethe following:

Mixes the initial lead and final slurry to thedesired density and maintains excellentdensity control throughout the cementingjob.

High specific mixing energy producesideal slurry properties fluid loss, yieldpoint and viscosity.

Possesses 8 or 25 barrel batch mixingcapabilities, depending on the tub size.

Allows ideal slurry characteristics to bemaintained in mixing rates down to onebarrel-per-minute.

The RCM II system is used for mixingslurries where accurate slurry properties arerequired. It operates by mixing dry cement,water and recirculated slurry. Thesecomponents are partially mixed and thendischarged into the first compartment of themixing tub.

In the first compartment, the slurry is blendedby an agitator, recirculated by a centrifugalpump and weighed by a densometer. Anyweight variations are corrected by theAutomatic Density Control (ADC) system.

When the first compartment is full, the slurryflows over a partition into the secondcompartment, which already contains someslurry at the desired weight. The combinedslurries are blended further by the agitator inthe second compartment in order to helpensure a uniform mixture. This slurry then ispumped down-hole.

Mixing Capabilities

The improved mixing provided by the RCMII system results in more uniform slurrieswith densities as high as 22 Ibs/gal that canbe mixed as slowly as 1 bbl/min. The lengthof time required for the slurry to flow throughthe two mixing tubs allows sufficient time fortime-dependent additives in the slurry tobecome effective.

Because of the versatility and excellentslurry control, the RCM II system is ideal forjobs such as liners, plug-backs, squeezejobs or large jobs where slurry properties arecritical.

System DescriptionThe RCM II system consists of an axial flowmixer used on a 2 compartment, 8 or 25barrel mixing tub with high-horsepowerturbine agitators in each compartment andUNI-PRO II with ADC (automatic densitycontrol).

1. The axial flow mixer has increased themixing energy put into HalliburtonServices cement blends. This hasallowed the handling of viscous and hard-to-mix cements at higher rates withreduced dusting when compared with astandard RCM system. Air entrainmenthas also been reduced significantly.Slurry densities of up to 22 Ibs/gal havebeen successfully mixed.

The mixing water rate is controlled by asingle rotary water valve located insidethe mixer. Both the bulk cement throttlevalve and the rotary water valve arecontrolled automatically by the ADCsystem or manually on non-ADCsystems.

2. The ADC system allows operators togive more time to other responsibilities. TheADC automatically operates the RCM IIsystem with much the same logic asmanual operation in controlling the slurrydensity and mix rate.

With good bulk delivery, density can becontrolled with +/- 0.1 lb/gal. It is availablefor both 8-barrel, 2 compartment and 25barrel, 2 compartment tub designs. Theautomatic start-up routine providesaccurate density from the beginning of thejob. The ADC system is started andstopped easily for batch mixing in the RCMII tub.

3. The UNI-PRO II data acquisition andcontrol computer displays two pumppressures, two flows, two fluid densities aswell as water flow rate. On ADC units, theADC status also is displayed. A single UNI-PRO II replaces the four existing UNI-PRO Iboxes used on most cementing units.

RCM II System Standard Features12.34:5.

6

Axial flow mixer8- or 25bbl, 2-compartment mixing tubRecirculating slurry centrifugal pumpMixing water centrifugal pumpDensometers - premix (recirculation) anddown holeTwo hydraulic agitatorsCement throttling valveADC (Automatic Density Control)UNI-PRO II for data acquisition/displayand ADC.

NOTE : Some units may be installed with thestandard RCM II system except for manualcontrol (non-ADC). These units operatemuch the same as the ADC units withexception of the mix rate and density control.The operator manually adjusts the mix waterthrottling valve and the cement throttlingvalve to provide the desired cement slurry.The general description of the system, asfollows, will be used to describe the manualcontrol units with the ADC sections beingdisregarded, if not applicable to yourparticular unit.

The standard operating procedures for themanual control units differ considerably fromthe ADC units. A separate section is includedto provide these procedures.

Component Function Descriptions

(Refer to Figures 1-1, 1-2, 1-3, and 1-4for graphical information)

1. The axial flow mixer receives drycement and mixes it with water from thecentrifugal mixing pump and recirculatedslurry from the premix side of the tub. Thedry material is metered through a throttlingvalve on top of the mixer. Water ismetered to the mixer through a meteringvalve located in the axial flow mixer. Theslurry density is controlled by the ADCsystem by opening and closing the bulkcement throttling-valve. The slurry mixingrate is controlled by the ADC system byopening and closing the mixing watervalve. The mixer discharges the water,cement, and recirculated slurry down ontoa diffuser which is submerged inapproximately 2 inches of slurry in thepremix side of the tub. The diffuser allowsentrained air to escape before the slurrymoves to the recirculation pump. Thediffuser is covered by a rubber splashsheath that keeps the slurry fromsplashing out of the tub. Water jets spraydown the inside of the splash sheath tohelp control dusting.2. The 8- or 25-barrel, 2 compartment tubfunctions to divide the slurry into twovolumes - that which has just entered thetub and that which has been through theblending stages and is ready to bepumped down-hole.As slurry enters the pre-mix section fromthe mixer, it is blended by turbineagitators and recirculated and then itflows over the partition into the down-hole section. This is an averaging sectionwhich dampens variations in densityfound in the pre-mix section.Slurry entering the down-hole section iscombined with a volume of slurry whichshould be at or very near the desireddensity. This new slurry is blended by asecond agitator before going to thedown-hole pumps.3. The recirculation centrifugal pumppulls slurry from the bottom of the premixcompartment and pumps it through a 3”radioactive densometer and

3. The recirculation centrifugal pump pulls slurry from thebottom of the premix compartment and pumps it througha 3” radioactive densometer and on to two (2)recirculation jets on the axial flow mixer. The recirculationjets direct the recirculated slurry into the new incomingwater/cement mixture just below the water valve.

4. The mixing water centrifugal pump supplies water tothe axial flow mixer through a strainer and a turbine flowmeter. The water throttling valve has small waterpassages that require the mixing water to be strained bya 3/16” dia. screen. The flow meter is connected to theUNI-PRO II. The water flow rate is displayed on the UNI-PRO II screen when ADC is running. The flow metersignal is also used by the ADC program to hold theproper water rate for a given slurry rate set point.

5. There are two digital radioactive densometers in theRCW II system. A 3” low pressure densometer is used inthe slurry recirculation line to monitor the premix slurrydensity.

Density measurement is an important feature in the pre-mix section which allows the ADC system to make acorrection before the slurry is pumped down-hole. In thismanner, density variations can be corrected, initially, in thepre-mix section and any remaining variation then isdampened in the down-hole section. The result is a moreconsistent down-hole slurry.

The ADC program uses this density signal to adjust thebulk cement throttling valve to maintain the density setpoint. A high-pressure, 2-in. densometer is used in thedischarge line from the HT-400 pump to monitor andrecord the slurry density going down hole.

Both the premix and down-hole densometer readings aredisplayed on the UNI-PRO II screen.

6. There are two hydraulically driven turbine agitators.They provide additional mixing energy to the slurry in thepremix and down-hole compartments.

7. The bulk cement throttling valve controls the amountof bulk cement being delivered to the axial flow mixer. Itsopening is indicated by the position of the indicatorbonnet located on top of the actuator. It is marked off innumbers 0 through 9 and represents 0% open through90% open valve positions. The cement throttling valveposition is controlled manually or is automaticallycontrolled by the ADC system.

8. The Automatic Density Control (ADC)system monitors and continually adjusts thewater metering valve to maintain the presetslurry mixing rate and the cement throttling valveto maintain the preset slurry density requirement.The slurry density, yield, water requirement andslurry mix rate are programmed into the UNI-PRO II for up to three different blends.

The ADC program then calculates the water flowrate required and the initial water and cementthrottling valve positions. As the mixing processbegins, the cement throttling valve and the waterthrottling valve go to their calculated positions. Ifthe water flow rate is not equal to the calculatedrate, the ADC program adjusts the valve position toget the required water flow. This position will beheld at the calculated position throughout themixing process unless a rate or blend change isinitiated.

If the density is not at the set point, the ADCprogram will adjust the cement throttling valve tothe position required to attain the density set point.This position may change continually during themixing process as changes in bulk delivery occur.

The ADC system does not control the slurrypumping rate of the HT.400 pumps. The operatoris still in total charge of this function. He isresponsible for programming the slurry design datainto the UNI-PRO II and monitoring theperformance during the job. The slurry design datacannot be programmed into the ADC system fromthe COMPUPAC it is done from the UNI-PRO II inthe control stand on the unit.

9. The UNI-PRO II is the data acquisition andcontrol computer used to display two pumppressures, two pump rates, both the recirculationand down hole densities, and ADC systeminformation. Refer to the UNI-PRO II manual (P/N458.50084) to program the UNI-PRO II for aparticular job.

Section 2Bulk Equipment Operation

Bulk Equipment Operation with RCM II SystemWith Constant Pressure Device (Bellofram Valve)

Cement delivery through a typical Steady FlowSeparator found on 660 Ft(3) and 400 Ft(3)units (See Figure 2-1).

1 Close the cement throttling valve and master (butterfly valve) on the mixer.

2

3.

4

5

6

7

8

9

10

11

12.

Close the 10-inch butterfly dump valve on thebottom of the Steady Flow Separator.

Attach a conveyor hose to the 5-inch connectionat the bottom of the separator. It is best to fit avalve between the separator and conveyinghose; this allows the conveying hose to becleaned out while emptying the separator.

Pressurize the pneumatic tank(s) to therecommended 30 to 35 psi prior to unloading.

Open the 4-inch valve between the separator andthe dust collector.

Close the 2-inch vent on the separator.

Close the 5-inch chamber vent valve on the dustcollector.

Adjust the 1-inch valve which supplies air to theseparator aerator to half-open. If a gauge andregulator are supplied on this line, adjust toapproximately 5 psi.

Adjust air regulator to Bellofram Valve to 25 psioutput. This pressure setting maintainsapproximately 9 psi in the separator. Keep inmind, this pressure setting may have to beadjusted during job operation to maintain asteady flow of cement to the mixer. If the bulksystem can provide enough cement to theseparator bin and the separator can provideenough cement to the RCM master valve for thedesired mixing rate, the pressure is correct.

Open the 5-inch valve between the pressurizedpneumatic tank and the separator. Fill theseparator with dry material to a level between thetop two sight glasses.

Close the 5-inch valve between the pneumatictank and the separator.

If material is to be left in the separator for anylength of time (as when waiting to begin mixing orwhen a job is on hold) open the 4-inch valvebetween the separator and the dust collector.

.

This provides aeration of the material. Close the4-inch valve when ready to begin or resumematerial delivery (unloading).

13. When mixing begins or resumes and material isbeing delivered to the RCM, slightly open the 5 inchfill valve from the pneumatic tank enough to maintaina constant a constant level between the sight glasseson the separator. Material discharge rate from theseparator now will be controlled by this 5-inch fillmaster valve and cement throttling valve on therecirculating mixer RCM II) while a constant pressureis maintained in the separator by the Bellofram Valveon the separator vent.

14. If separator is equipped with a 1-inch air bypassvalve, it may be used to supply additional air tomaintain proper pressure in tank or to purge theseparator and vent system during clean up or testing.

15. When a pneumatic tank is emptied, close the 5inch valve between the tank and the separator. If asecond tank is to be unloaded, open a similar valveon the (second) tank and continue unloading. Ifcompleting a job, close the 5-inch valve between theseparator and the dust collector to empty theseparator.

16. After material delivery (unloading) is finished,close separator discharge valve and 1-inch air supplyvalve to the separator. In case of malfunction orblockage of the dust collector venting system, the jobmay be continued by:

a. Closing the 4-inch valve between theseparator and dust collector.

b. Maintaining the correct separatorpressure by throttling the 2-inch vent valve atthe top of the separator.

NOTICE: The separator was not designed for haulingsand or cement to or from location. If conditionsmake it necessary to leave material in the separatorwhen a job is completed, be sure to dump thematerial as soon as possible. When dumping leftover material, the separator aerator air supply valvemust be turned on. DO NOT hold leftover materialfor later use.

Bulk Equipment Operation with RCM II SystemWithout Constant Pressure Device (Bellofram Valve)

Cement delivery is accomplished through atypical Steady Flow Separator found on 660Ft(3) and 400 Ft(3) units (See Figure 2-1).

1. Close the cement throttling valve andmaster (butterfly) valve on the mixer.

2. Close the 10-inch butterfly dump valveon the bottom of the steady flowseparator.

3. Attach the 5-inch discharge hose to theconnection on the lower side of theseparator. It is best to fit a valve betweenthe separator and conveying hose; thiswill allow the hose to be cleaned outwithout emptying the separator.

4. Pressurize the pneumatic tank(s) to therecommended 30-35 psi, prior tounloading.

5. Open the 5-inch valve between theseparator and dust collector (see Figure2-1, Loc.16).

6. Adjust the 1-inch valve that suppliesthe air to the separator aerator to halfopen.

7. Open the 5-inch valve between thepressurized pneumatic tank and theseparator. Fill the separator to a levelmidway between the upper two sightglasses.

8. Close the 5-inch fill valve and the 4inch valve between the separator anddust collector.

9. If material is to be left in the separatorfor any length of time (as when waiting tobegin the job), open the 5-inch valvebetween separator and dust collector.This will allow the aerators to work. Closethis valve when ready to begin or resumematerial delivery (unloading).

10. When mixing begins or resumes andmaterial is being delivered to the RCM,open the 5-inch fill valve from thepressurized pneumatic tank enough tokeep a constant level between the top twosight glasses on the separator.11. At the same time, slightly open the 5-inch valve to the dust collector enough tokeep the pressure down in the separator.Too little pressure in the separator willcause a stoppage of material flow to theRCM Too much pressure will cause poor orno delivery of material from the pneumatictank to the separator.

12. When the proper balance is achieved,material will be easily delivered to theseparator and held between the sightglasses while constant delivery is beingachieved to the RCM.

13. If the RCM system master valve isclosed for any reason, shut off the 5-inchvalve on the fill line from the pneumatic tankand close the 5-inch valve between theseparator and dust collector.

14. When the pneumatic tank is emptied,close the 5-inch valve between the tank andseparator. If a second tank is to beunloaded, open a similar valve on the othertank and continue unloading. If completing ajob, close the valve between the separatorand dust collector to empty the separator.

15. After material delivery is finished, closeseparator discharge valve and 1-inch airsupply valve to separator.

NOTICE: The separator was not designed for haulingsand or cement to or from the location. If conditionsmake it necessary to leave material in the separatorwhen a job is completed, be sure to dump the materialas soon as possible. When dumping left-over material,the separator aerator air supply valve must be turned on.DO NOT retain left-over material for use on the next job.

-

-

Bulk Material Manifold and ValveArrangement(see Figure 2-l)

Loc. Description

1. 3-in.Vent manifold2. 3-in. Manifold Valves3. 4-in.Fill Manifold4. 4-in.Fill Manifold Valves5. 5-in.Discharge Manifold6. 5-in.Tank Discharge Valve Operators7. 5-in.Discharge Auxiliary Inlet8. 5-in. Separator Inlet Manifold

Standard Operating ProcedureBulk Cement Delivery Procedure toDeliver Cement Directly to the RCM II

1. Close the cement master controlvalve located at the inlet to the cementthrottling valve.2. Build up air pressure in the bulkequipment to 15-20 psi in each tank tobe unloaded. Gross aerated bulkequipment is strongly recommended foruse with this mixer because it provides amore steady delivery with less dusting.3. Open the bulk unit’s discharge valve(see Figure 2-1, Loc. 6) on only one tankat a time. The bulk equipment operatorshould maintain steady air pressure andshould not operate the butterfly valveagain until the tank is empty. Anexception to this would be if the cementequipment operator shuts off the cementflow to the mixer for more than a minuteor two. This will avoid the possibility ofplugging the delivery hose or the mixerinlet.

Good communication between thecement equipment operator and the bulkequipment operator is extremelyimportant to the success of a goodcementing job. Be sure to switch to a fulltank when a sharp drop in air pressure isnoted. DO NOT wait until delivery fromthe tank is erratic.4. If more than one bulk unit is required,the units should be connected to theRCM II unit through a “Y” manifold withvalves on the two branches. This willallow both bulk units to unload to theRCM II

9. 5-in. Separator Inlet Manifold Valve10. 5-in. Separator Discharge Manifold11. 5-in. Tank Discharge12. 5-in. Tank Discharge Valve13. 5-in. Auxiliary Separator Inlet Manifold14. 5-in. Auxiliary Separator inlet Valve15. 5-in. Auxiliary Separator Inlet Valve Operator16. 5-in. Separator Vent Valve17. 5-in. Separator Vent Valve Operator18. 10-in. Separator Dump Valve19. 10-in. Dump Valve Discharge Boot20. 10-in. Dump Valve Operator21. Dust Collector Vent Dust22. Collector Vent Valve

system (one-at-a-time) without a delay inhook-up or long delivery hoses. If the bulkunits cannot be connected together with a“Y” connection because of tight space orother rig equipment on locationpreventing this arrangement, one unitmay have to be unloaded through thedischarge line of the other unit. Keephoses as short as possible and makecertain sufficient personnel are availableto switch tanks when needed. Thesecond unit should be unloaded at 30-35psi due to the long delivery lines andconnections. Make certain purges areoperational.

FIGURE 2-2

Maintenance (Pre-Job)

1. Check for air leaks by closing allvalves except 1-inch air supply to top of thetank. Pressure tank to 15 psi. At this time the15 psi safety pressure relief valve shouldwork. Hold pressure at 10 psi forapproximately 10 minutes while watching thetwo pressure gauges, one on top and theother at the lower portion of the shell. Ifpressure decreases, check the valve seatsand the disc, replace if necessary.

CAUTION: Relieve all tank pressurebefore removing any part of the separator.

2. Check Bellofram Assembly - checkrubber seal on bellofram to see if loose orworn, if it is loose, reattach with contactcement P/N 70.76816 and if worn, replace.Check the air cylinder at bellofram byremoving relief valve assembly (Figure 2-5)and disconnect air supply. Force the aircylinder to its shortened position. Reconnectto the air supply. This should extend the aircylinder if it is operating properly.

3. Check the air pad by closing allvalves then opening the aerator supply line.If within approximately three minutespressure does not increase in the separator,the pads should be checked for air flowblockage damage and material build up.Clean fabric with wire brush or replaceaerator pads if necessary.

4. Check all air supply lines for leaks,blockage, moisture and properoperation.

5. Check vent system and dust collector(including system past the dust collector)for blockage. Clean the dust collector andvent lines by running air through the entiresystem.

6. Pre-set the adjustable regulator to thebellofram valve for 15 psi output andincrease if necessary to accomplish properdelivery.

7. Pre-set the adjustable regulator to theaerators at 5 psi or 2 to 4 psi less than theseparators operating pressure.

8. Check plumbing between steady flowbin, storage tanks, and the RCM forblockage or damage. These lines must beclear of any foreign material. Disconnectthe hose between the steady flow bin andRCM after every job.

9. Lubricate the vent valve operating arm,located on top of the separator every fewmonths depending upon usage.

10. Drain all water traps and clean the airfilter (supplied by others) in existing systembefore starting bulk system.

11. Check the separator bin and hopperunder the dust collector for collected or leftover material. Remove this material.

12. Clean and check the rubber seal andmating surface on the bellofram pressurecontrol valve located on top of the dustcollector.

13. Remove and clean the sight glass lensand re place if necessary (P/N 935.49543).

Section 3RCM II

Operation

Cement Mixing Procedure.

HALLIBRURTON UNlPRO II

Menu 1= Pressure - UT-400 Menu 5 = Pressure UT-400Menu 2 = Rate (Combined) Menu 6 = Combined Total UT-400 PumpsMenu 3 = Recirculation Pump Density Menu 7 = Downhole Pump DensityMenu 4 = Mix Water Rate Menu 8 = ADC Control Key

Screen and Keyboard of UNI-PRO IIFIGURE 3-1

Note 1: Refer to Print No. 278.10158 insection 5 of this manual and to UNI-PRO IIOperators Manual (P/N 458.50084) for UNI-PRO II calibration instructions.

Note 2: Refer to Print No. 278.98024 insection 5 of this manual for ADC test, set-up, and tuning instructions.

Note 3: Refer to COMPUPAC Operator’sManual P/N

FIGURE 3-2

1. Open the valve on the mixing waterstrainer and drain the strainer.

2. Prime the unit.

3. Switch instrument power “on”.

4. Check the ADC manual/handswitches (Refer to Print No. 277.43171).They should be on “AUTO” position forautomatic operation.

5. Check the master “on/off” hydraulicvalve. It should be in the “on” position(Refer to Print No. 278.98022).

6. Check for cement throttling valveactuator, water metering valve actuator,and master water valve actuatoroperation:- press (ADC IDLE) [menu 8],- (start) [menu 21,- (open all valves) [menu 2]. All threeactuators should open.- press (ADC IDLE) [menu 8],- (stop) [menu 6] All three actuatorsshould close.

7. Close the recirculationmanifold valve.8. Bring the auxiliary engine to 2000 rpmwith both centrifugal pumps engaged. Fluidshould not be entering the tub at this time.

9. Check mixing pump pressure. It shouldbe 100 psi minimum with water.

10. Check recirculation pump pressure. Itshould be 20 psi minimum with water.

11. Idle the auxiliary engine.

12. Open the recirculation manifold valveand allow water to circulate through therecirculation densometer.

13. Autocal the recirculation densometer:

press [menu 3] to select the 3-in.recirculation densometerpress (Autocal) [menu 3]press (water) [menu 3] to Autocal forwater.Wait approximately 10 seconds for theAutocal procedure to run.

14. With water in the down hole densometerAutocal it:press [menu 6] to select the 2-in. down holedensometerpress (Autocal) [menu 3]press (water) [menu 3] to Autocal forwater.Wait approximately 10 seconds for theAutocal procedure to run.

15. Check the preloaded cement blendinformation and change if necessary: press (ADC idle) [menu 8] press (Blends)[menu 4] first stage data press (next stage)[menu 4] for second stage data press (nextstage) [menu 4] for third stage data.

If all stage data is correct:- press [quit].

If changes need to be made:press the [menu] key beside the datathat needs changing, key in thecorrect data and press the [enter]key.If All Is Satisfactory, Proceed:

16. Pump the water level down to the top ofthe sump.

17. Close the tub partition valve.

18. Load the premix side of the tub withthe proper amount of mixing water by:-pressing (ADC idle) [menu 8]-then (start) [menu 2], and -(start water)[menu 3]. The premix side will fill with thepreset amount of water. Be certain thatRecirculation Densometer Menu 4 isreading 8.3 density for water. If not,Autocal the densometer (see 13., above).19. Open the master cement butterfly valveto allow cement to the throttling valve.

20. Turn on the tub agitators. Run the tubagitators at a speed that keeps the slurrymoving. If the agitators rotate too fast, theywill splash slurry out of the tub and willentrain air in the slurry. If the agitators rotatetoo slowly, poor blending will result and tubstagnation will occur.

21. Bring the premix side of the tub up to thedesired

- pressing (ADC idle) [menu 81,- (start) [menu 2],- (start cement) [menu4].Watch the recirculation densometer displayas the density comes up to the set point.

-

22. If the cement throttling valve closes andthe density is still too low, repeat Step 21.

23. To begin mixing:press (ADC idle) [menu 8],(start) [menu 2]press (mix 1) [menu 8] to start the first stage.

24. When both compartments are full (downhole compartment is full when the slurrylevel is 2 inches below the top of the weir)and the density is correct, open the tubsuction valve and start the flow of cementslurry to the HT.400 pumps.The ADC system will adjust the water flow tothe proper rate for the programmed slurry mixrate for that stage. The HT.400 enginethrottles are used to adjust the actual slurrypumping rate to the slurry mix rate.

If the HT.400 engine throttles cannot be usedto control the slurry pump rate, the slurry mixrate will have to be adjusted by the procedurein Step 27.

NOTE: The weir is an effective device to removeentrained air from the slurry only if the down hole sidefluid level is maintained at approximately 2 in. belowthe weir. Adjust the HT-400 pump rate to make smallcorrections in tub fluid level. If the HT 400 pump ratechange is not desired, change the mixing rate as perStep 27.

NOTE: The axial flow mixer body extends about 8inches below the top of the RCM II tub. Effort must betaken to keep the slurry level in the tub lower than thebottom of the mixer body. If the slurry level gets highenough to cover the bottom of the mixer body,excessive splash back will occur inside the mixerthroat and cement build-up will occur. Keep the downhole compartment level 1 to 2 inches below weir. Ifthe slurry level rises above the mixer body, immediateefforts to lower the tub level should be initiated (suchas increasing down hole pump rate momentarily).

25. Adjust the tub agitator speed as required forproper slurry movement but not enough to splashslurry out of the tub.

26. To make a stage change:press [menu 8]

press (change) [menu 3]press (next stage) [menu 4 or 8]- this loads thenext stage data and starts mixing.27. To make a rate change during a stage:press [menu 8]press (change) [menu 3]press (mix rate) [menu 2]press number - example: press “6” for 6 bpm mixratepress [enter]

28. To make a density change during a stage:

29. To stop mixing

press [menu 8]press (change) [menu 3]press (density change) [menu 3]press number - example: press “16.4” for 16.4 ppgdensitypress [enter].

press [menu 8]press (stop) [menu 6] - this closes allauto controlled valves.

30. To begin mixing again:open cement master valvepress (adc idle) [menu 8]press (start) [menu 2]press (mix) [menu 8].

31. After mixing has stopped, open the tub partitionvalve and pump the remaining cement from the tub.Close the down-hole tub suction valve and beginadding fresh water to the mixing tub. This fresh watermust be circulated while pumping the displacementfluid. Once the displacement fluid has been pumpeddown hole, a thorough cleaning of the RCM II cantake place.

Summary of UNI-PRO II OperatingInstructions Including Event Codes1. To zero a pressure channel:press Menu 1press Set Pressurepress 0press Enter

- orpress Menu 5press Set Pressurepress 0press Enter

Do this only with no pressure applied to thetransducer.

2. To get individual rates:presspress 2

3. To get combined rate and combined total:press -press 1

4. To zero a total volume channel:press Menu 6press Zero >

5. Entering event codes:

To enter event:Press event number, enter

NOTE: When mixing is stopped, close the mastercement butterfly valve. This will keep the densityfrom slowly climbing if the cement throttling valve isnot leak-free.

EXAMPLE:

To start job:press 1press Cementpress Enter 1. Start Job 2. End Job 3. Zero Flow Totals 4. Other 5. Prime Pumps 6. Test Lines 7. Pressure Up Well 8. Break Formation 9. Pump Spacer 110. Pump Spacer 211. Clean Lines12. Drop Bottom Plug13. Pump Lead Cement14. Pump Cement15.Pump Tail Cement16. Pump Cap Cement17. Pump Foam Cement18. Start Additive19. Stop Additive20. Start Nitrogen (N) Stop21. Nitrogen (N)22. Drop Top Plug23. Pump Displacement24. Pump Well Fluid25. Displ. Reach. Cement26. Bump Plug27. Shut In Well28.Set Packer29. Release Packer30. Open MSC31. Close MSC32. Drop Plug33.Drop Ball34. Circulate Well35. Reverse Circulate Well36. Clean hole37. Pause38. Resume39. Unknown Event Number

Example of ADC OperatingInstructions

Example: Lead cement 50/50 POZMlX(2%bentonite) at 8 bpm.

Tail cement Class H neat at 6bpm., 16.4 density.

1. Load Cement Information:ADC IdleBlendsWat 5.75 EnterDen 14.15 EnterYld 1.26 EnterRTE 8 Enter<-Next Stage (First)

The display will go to the second blend:

Wat 4.3 EnterDen 16.4 EnterYld 1.06 EnterRTE 6 EnterQuit

2. Get Start-Up Water:ADC IdleStartStrt Water

3. Calibrate densometer to water(water must be circulating throughdensometer).

RECIRCULATING DENSOMETER

press Menu 3press Auto Calpress Water

DOWNHOLE DENSOMETER

press Menu 7press Auto Calpress Water

4. Bring Up The density:ADC IdleStartStrt Cement

5. Begin Mixing Lead Slurry:ADC IdleStartMix 1

6. Begin Mixing Tail Slurry:Menu 8Change

<Next Stage = [2]

7. End Mixing. Close Valves:Menu 8Stop

Post-Job Clean-Up and Inspection1. After the mixing job is completed, flood the mixingtub with water and circulate clean water through allthe valves, and piping used in the mixing process.

2. Be sure the master cement valve is closed. Washthe cement throttling valve through the wash-upconnection, rotating the cement throttling valve plugin the process. The cement throttling valve thenshould be removed and cleaned of all remainingcement buildup.

3. While the cement throttling valve is off, wash outthe throat of the axial flow mixer with the wash-uphose. Also lift the rubber flap vent on the splashsheath to wash the inside of the splash sheath.

4. Wash off any cement slurry splash that hasaccumulated on the mixing tub, agitators, and theoutside of the splash sheath.

5. While the cement throttling valve is off, engagethe mixing water pump. With the automatic controlsin the “HAND” mode, open the water metering valveon the axial flow mixer and observe the water jetpattern. Six water jet slots should open first, then thenext six (making 12 total), then the final six (making18 total) should open.

As soon as the water jets start to open, a vortexshould form in the center of the mixer throat. If thevortex center is offset, the valve should bedisassembled and checked for wear or obstructionsbefore the next job.

6. Shut down the mixing water pump, engage therecirculation fluid pump and observe therecirculation fluid jets. They should both be jettingwater at equal velocities. If not, check the piping forobstructions.

Back-up Control With ADC System(See Print 277.43171 in Section 5)There are two back-up operating modesavailable with the RCM II system:

1. Potentiometers2. Full manual operation of the actuator

shafts.1. The first back-up is the row ofswitches and potentiometers located directlyabove the UNI-PRO ll. When the switchesare in the “HAND” position, thepotentiometers control the master watervalve, the water metering valve, and. thecement throttling valve while the UNI-PRO IIserves only as a display.

The ADC program is not controlling the valvepositions in this operating mode. Control by thepotentiometers is recommended only when theADC program will not perform as desired (i.e.recirculation densometer failure, flowmeter failure,or poor cement delivery).

In order to use the potentiometers, the hydraulicsystem (including actuators) must be functional. Ifproblems are occurring in the hydraulic system,the potentiometer controls will probably functioninaccurately. Turn the potentiometers clockwise toopen the water and cement throttling valves andcounterclockwise to close then.

Both the clean water rate and the bulk cementrate affect the down hole rate and density butgenerally, the water throttling valve is used tocontrol the mixing rate while the cement throttlingvalve is used to control the density.

If the water flow rate is working properly, it is notnecessary to switch both water and cementthrottling valves to full manual. If cement deliverywill not stay on line, switch to manual and controlcement flow with manual pot.

2.The second back-up operation mode is fullmanual and requires direct manipulation of thewater master, water throttle, and cementthrottling valves. In order to directly operatethe water master, water throttle and cementthrottle valves, the manual hydraulic bypassvalves must be in the bypass position. Whenone of the actuators needs to be operatedmanually with the operating bar, throw thehydraulic bypass valve for that actuator to thebypass position (the handle will be in line withthe piping) and engage the operating bar in

the bonnet on the actuator shaft. Figures3-3 and 3-4 show the operating bar beingused with the water value and cementthrottling value.

Turn the actuator shafts to directlyoperate the valves. If the second back-upoperation is required, the densometersand flow rate indicators could possiblynot be operating and a mud cup wouldhave to be used to determine the densityof

FIGURE 3-3

FIGURE 3-4

Operating TechniqueThere are numerous techniques that can beused to perform better cementing jobs. It ishoped that the operator will becomecomfortable with the system, and will be ableto predict which technique will work best in agiven situation.

The following techniques were developedduring field tests in which Automatic DensityControl (ADC) performed its first 20-30 jobs.1. Enter the water requirement, desireddensity, yield, and desired mixing ratefor the lead slurry.. If experience with this slurry suggeststhat air entrainment will cause therecirculating densometer to read 0.2pounds-per-gallon (ppg) lighter than thedown-hole densometer, the recirculationdensity set-point should be made 0.2 ppglighter than the slurry design density. Extreme caution should be exercisedbefore offsetting a densometer. If you feelthe difference between the recirculationand down hole densometers is notacceptable, the recirculation densometermay be offset to read the same as thedown hole unit after the slurry designdensity has been reached and you arecertain exactly the same slurry is in bothdensometers. To accomplish this, Press:Menu 3Press: AUTO CALPress: Enter ValueEnter density displayed on Down holeDensometer (Menu 7) or desired offsetdensity. Press: Enter If a high mixingrate (8 to 12 barrels-per-minute) is used,enter a lower rate to start with(approximately 5 bpm), and plan tochange to the higher rate, using ratechange procedure (step 26, page 3-3)after the HT-400 pump is on-line. At 12bpm, less than 20 seconds will elapsefrom the time the down-hole side of thetub is half full until the tub is over flowing.Enter the tail slurry. Turn the digitaldisplays “off” if it will be a considerableamount of time before the job will be run.These numbers may be entered prior toreaching the job location, if desired.Before running the job, check the cementblend information for each stage to be surethe lead slurry is correct. Before each job,open and close all the valves to ensureeverything is working correctly (step 6,page 3-1). Check the water jet pattern.

4. When bringing on start-up water (step 17,page 3-2), run the auxiliary engine at 1000 rpm tosave excess wear on the system.5. If the density is too low when the bulkcement metering valve closes during start-upcement, the density can be touched up byrepeating step 20, page 3-2.6. While mixing cement, run the auxiliaryengine at full speed to get consistent performancefrom the mixing and recirculating pumps.7. If cement delivery ceases for a time, thecorrection for the ADC system can be large,causing the cement wheel to open fully. Whencement delivery begins again, the correction maynot reduce as quickly as necessary.IMPORTANT: If this occurs, press [menu 81 then(start) [menu 21, then (mix) [menu 81, whichzeroes the I-term, and continue mixing.

If the density is off, it will correct itself at the rate of 1ppg every 17 seconds after (mix) [menu 8] has beenpressed. If the density is too low (9 to 10 ppg), itmay be better to stop mixing, then press StartCement to bring the density up, followed by (mix)[menu 8) which will bring the bulk valve back toresume mixing.

8. When a bulk storage tank is empty, switch toa new tank as the density of the premix side of thetub drops to no more than 0.5 ppg. Little effect willbe seen on the down hole density. If you can tell themixer is getting mostly air, don’t wait on the densityto drop before switching tanks or stopping mixing.

If the bulk cement metering valve is open too wideas the next bulk storage tank comes on line, press(mix) (menu 8). This will bring the bulk valve back toa calculated position.

Batch Mixing-Low-Rate (Squeeze)Jobs

Mix with the tub partition valve closed. Use a rate of3 to 5 bpm. When tub is full, press (adc) then press(stop) [menu 61 to stop mixing. When the level in thedown hole side of the tub is to the bottom of theagitator, press (adc), press (start), then press [menu8] to start mixing blend.

Manual Control of RCM* II System (withoutADC)

The manual control (non-ADC) operatingprocedures are listed in this section. The post-jobclean up and inspection procedures for themanual control units are the same as the ADCunits and is presented in the Standard OperatingProcedures section.

The inspection, maintenance, andtroubleshooting information for the manual controlunits are the same as for the ADC units and islisted in the Maintenance and Inspection section.

The inspection and maintenance procedures forthe cement throttling valve are the same for theADC and manual control units with the exceptionof the rotary actuator.

Spare parts list for the axial flow mixer are listedin the Spare Parts section. Drawings for themanual control system and the manual controlcement throttling vale are included in the Printsection at the back of this manual.

Manual Control (non-ADC)Operating Procedures

Cement Delivery Directly toRecirculating Mixer (RCM II)

1. Close the cement throttling valve and master(butterfly) valve on the mixer.

2. Build air pressure in the bulk equipment to 15to 20 psi in each tank to be unloaded. Grossaerated bulk equipment is stronglyrecommended for use with this mixer because itprovides a more steady delivery with lessdusting.

3. Open the bulk unit’s discharge valve (seeFigure 2-1, Loc. 6) on only one tank at a time.The bulk equipment operator should maintainsteady air pressure and should not operate thebutterfly valve again until the tank is emptied.

4. If more than one bulk unit is required, the units

Be sure to switch to a full tank when asharp drop in air pressure is noted. DONOT wait until delivery from the tank iserratic.

should be connected to the RCM II through a “Y”manifold with valves on the two branches. Thiswill allow both bulk units to unload to the RCM II,one at a time, without a delay in hook-up or longdelivery hoses. If unable due to tight locations to“Y” units together, connect units togetherkeeping conveying hoses as short as possible.Make certain that enough help is available toswitch tanks properly without disrupting flow tothe RCM

Cement Mixing Procedures(Assuming that the unit is already primed)

1. The axial flow mixer mixes substancesfrom three sources:a. Water from the water manifold.b. Recirculated slurry from the pre-mix side of

the RCM tub.c. Dry cement from the cement throttlingvalve.

2. Unit densometers must now be calibrated.The unit can be equipped with a 3-in. radioactivedensometer and a 2-in. high-pressuredensometer. These densometers must becalibrated “dry” and given sufficient amount oftime to warm up. Refer to “CalibrationProcedures” at the back of this manual for UNI-PRO II calibration (278.10158).

3. Make sure that the cement master valve andwater master valves are in the closed position.

4. Preset the cement throttling valve to a positionof 2 or 3 (20 to 30 percent). Preset the watermetering valves to one-third open or set for theapproximate mixing rate desired.

5. With the tub partition valve in the closedposition, open the water master valve and beginadding water to the pre-mix side of the tub. Fill itto a level which covers the agitator blades.When this level is obtained, close the masterwater valve.

6. With the recirculating pump engaged inaddition to the recirculating pump discharge andtub suction valves being open, water will becirculated from the pre-mix side of the tubthrough the mixer and back into the tub. DONOT proceed until the discharge from therecirculating pump is uniform and not surging.

7. Before continuing the mixing procedure, lowerthe water level in the down-hole side of the tubto the

11. Open the cement throttling valve tocompensate for the additional water beingadded through the water metering valves. Fresh water and dry cement are now beingadded to the recirculated slurry. Continuallymonitor the slurry density. Changes in slurrydensity can be corrected by increasing ordecreasing either the cement throttling valve orwater metering valve openings.

When the density is correct and the down holesection is above the agitator paddle, start theflow of cement slurry to the HT-400 pumps.Maintain the level of slurry in the down holecompartment about two inches below the top ofthe weir.

NOTE: If the slurry begins to pour over thepartition before the correct density is obtained,open the center partition valve. This allowsslurry in both sides of the tub to be circulatedthrough the system. When the tub is full ofslurry at the correct density, close the tubpartition valve and open the tub suction valveand start pumping slurry down hole.

top of the sump. The water out of thiscompartment could be pumped back into thedisplacement tanks. Check the densometerreadout to be sure it is zeroed for water (8.33). Ifnot, zero densometer at this time.8. Turn on the agitators.

9. Check with the bulk equipment operator toinsure a steady delivery of dry material. Beginadding cement by opening the master cementvalve. The cement then will start blending withwater in the pre-mix side of the tub. The slurrycomponents are circulated through thedensometer, mixing manifold and back into thepre-mix side of the tub.

10. Note the weight build-up on the visual gauge.As the weight builds, so will the volume in the pre-mix side of the tub. As a general rule, the weightprobably will be at or near the desired slurryweight as the slurry begins to pour over thepartition into the down hole compartment. When the slurry weight is within 1/2 lb/gal of

the desired weight, open the master water valveand begin adding water. Like the master cementvalve, the master water valve should never beused to meter water flow. The water flow shouldbe controlled by the water metering valve in theaxial flow mixer.

13. Slowly increase or decrease the water meteringvalves and the cement throttling valve openings untilthe desired mixing rate is obtained, maintaining thecorrect slurry density.14. During the mixing process it is important to:a. Maintain a full down-hole compartment.b. Continuously monitor slurry density, makingcorrections to the slurry as needed.

The recommended mixing procedure is to set the watervalue to establish the required mixing rate and to usethe cement throttling value to control the density. If thebulk cement flow is inadequate for proper densitycontrol, reduce the mixing rate.

c. Continue running the tub agitators because theagitators do the majority of the slurry blending.d. The water master valve and the cement mastervalve should be in the full-open position. These valvesshould never be used to control the rate of materialbeing added.15. In the event that the pumping operation mustbe shut down, first close the cement master valve,then the water master valve. Open the tub partitionvalve and continue recirculating the slurry. Whenpumping can be resumed, close the tub partitionvalve, open the water master valve, then the cementmaster valve. Slurry density and mixing rate will beapproximately the same as they were before pumpingstopped. Therefore, only minor corrections in thecement throttling valve or water metering valve will berequired.

16. After all the cement has been mixed, open thetub partition valve and pump the remaining cementfrom the tub. Close the down-hole tub suction valveand begin adding fresh water to the mixing tub. Thisfresh water must be circulated throughout thepumping of the displacement. Once the displacementhas been pumped down hole, a thorough cleaning ofthe RCM II can begin.

Clean-Up Procedures

1. As previously mentioned, after the mixing job iscompleted, it is advantageous to flood the mixingtub with water and continue circulating duringdisplacement. If water is not immediately available,circulate and agitate the slurry duringdisplacement. In either case, open the valvebetween the two compartments.2. When washing up, be sure to circulate cleanwater through the mixing pump, manifolding, andall the valves in the manifolding. Also circulateclean water through the tub’s suction valve.3. Be sure the master cement valve is closed.Wash the cement throttling valve through thewash-up connection, rotating the cement throttlingvalve in the process. The cement throttling valvethen should be removed and cleaned of allremaining cement build-up.

4. With the recirculating pump off, open themaster water valve, then open the water throttlingvalve. Visually check flow pattern and flow rate andlook for splashback into the mixer bowl. If the flowpattern is uneven or restricted, remove the slurryjet and check for foreign material or wear.

5. Close the master water valve, turn therecirculating pump on, and recirculate clean water.Visually check the recirculating discharge flow intothe tub and look for splashback into the mixerbowl. If discharge into the pre-mix side of the tubappears normal while testing the mixing manifold,but recirculating discharge is below normal, thedischarge line from the recirculating pump to therecirculating slurry jet should be removed andchecked for cement build-up.6. Visually inspect each air-operated valve on theunit to confirm each is operating properly whenactuated. Open and close each manually operatedvalve to check for cement build-up.7. If the clean-up procedures have been followedas outlined above, the unit is ready for the next job.

The Automatic Density control (ADC) system has anelectronic subsystem and a hydraulic subsystem

The electronic subsystem determines the requiredposition of the water and bulk cement actuators,senses the position of the actuators, and if needed,sends new position commands to the hydrauliccontrol valves.

These extremes, the relation between the valveposition and the white wire’s voltage is close to linear

The group of three wires is attached to a connector,P/ N 70.87297. The red wire is connected to Pin 3, thewhite wire to Pin 1, and the black wire to Pin 2. Pin 3should have IO volts, Pin I the sense voltage, and Pin2 should have 0 volts.

The hydraulic subsystem supplies the powerrequired to change the position of the actuators. Thehydraulic power is controlled through electric-overhydraulic valves and is supplied only to theactuators on a signal from the electronic subsystem.

The connector is attached to a short cable, P/N70.08536. Pin 3 is connected to the red/white wire,Pin 1 to the green wire and Pin 2 to the red/blackwire. The red/white wire should have 10 volts, thegreen wire the sense voltage, and the red/black wire0 volts

This section of the overall system manual consistsof detailed descriptions of the electronic andhydraulic subsystems.

Electronic Subsystem Description(Refer to drawings 278.98023 and 277.43171 in theSection 5 of this manual).

The short cable is connected to a 4 pin terminal strip,P/N 70.87899. The red/white wire is connected to Pin1, the green wire to Pin 2, and the red/black wire Pin3. Pin 1 should have 10 volts, Pin 2 the sensevoltage, and Pin 3 0 volts.

Cement Valve Position Sensing System

The RCM II requires sensory response in order todetermine the position of the cement valve andhelp position the valve correctly. The positioning ofthe valve will be described later.

The terminal strip is connected to an armored cable,P/N 70.05720. Pin 1 is connected to the black wire,Pin 2 to the white wire, Pin 3 to the red wire, and Pin 4is attached to the drain wire, which has no insulation.The black wire should have 10 volts, the white wireshould have the sense voltage, and both red anddrain wires should have 0 volts. The purpose of thedrain wire is to reduce the electrical noise that wouldotherwise be picked up by the other three wires.

The sensing is accomplished by the use of apotentiometer located in the oil of the cement valveactuator (P/N 70.87298). A potentiometer is a 3-wireelectrically resistive device. Two wires are used tosupply a biasing voltage (10 volts) to thepotentiometer. The third wire provides a sensevoltage to the electronics located outside thepotentiometer.

The armored cable is connected to a terminal strip ina junction box, P/N 458.30118. The black wire isconnected to Pin 4, the white wire to pin 5, the redwire to Pin 6, and the drain wire to Pin 7. Pin 4 shouldhave 10 volts, Pin 5 the sense voltage, and both Pin 6and Pin 7 should have 0 volts.

The red wire carries 10 volts and the black wire 0(zero) volts. The electrical resistance between thesetwo wires is 5,000 ohms, causing 2 miIliamps ofcurrent to flow. The potentiometer, the actuator, andthe valve are connected to allow movement of thevalve; thus causing movement of the potentiometer’swiper. The potentiometer’s wiper is connected to awhite wire.

Signal Split - One goes toward the UNI-PRO II and theother to one of the Parker electric hydraulic valves.Signal Trace toward UNI-PRO II

As long as the electrical load applied to the white wireis not extreme, and as long as the proper biasingvoltage is applied, movement of the valve will causevoltage changes in the white wire. When the valve isclosed the white wire will have a load ofapproximately 2 volts. With the valve open, the whitewire will have approximately 7 volts.

The terminal strip in the junction box is connected to amultiple-conductor armored cable, P/N 70.05755. Pin4 is connected to the red wire, Pin 6 to the green wire,and Pin 7 to the drain wire associated with the redand green wires. The red wire should have 10 voltsand the green and the drain wires, 0 volts.

At various positions in between or on either side of

The armored cable is connected to the control standpanel, P/N 277.43171 or 277.43172. The red wire isconnected to Pin 34 of the UNI-PRO II, although itmay sometimes be connected to another pin,depending on how the jumpers are placed on circuitboard

Detailed ADC System Description

458.50047.

UNI-PRO II Pin 34 should have 10 volts. The 10 voltsoriginates on circuit board 458.50047, Circuit U4, Pin7. See Manual 458.50077 for more informationregarding the inside of UNI-PRO II. The green wireand the drain wire are connected to terminal stripTSUC1

TSUC1 may be considered to be the origin of the 0volts, although the true origin is the trailer’s lead-acidbatteries.

Signal Trace of sense voltage in the Junction Box

A white wire connects Pin 5 to Pin 18. Pin 18 shouldhave the sense voltage. From here the sense voltageenters the valve positioning system. See the valvepositioning section for more information.

Water Valve Position Sensing System

The RCM II needs to sense the position of the watervalve in order to help position the valve correctly. Thepositioning of the valve will be described later.

Sensing is done by a potentiometer inside the watervalve actuator. The potentiometer part number is70.52033. A potentiometer is a 3-wire, electricallyresistive device. Two of the wires are used to supply abiasing voltage (10 volts) to the potentiometer, andthe third provides a sense voltage to the electronicsoutside the potentiometer. Pin 1 receives 10 volts, and0 volts is applied to Pin 3.

The electrical resistance between these two pins is10,000 ohms, causing 1 milliamp of current to flow.The potentiometer, the actuator, and the valve areconnected so movement of the valve will cause move-ment of the potentiometer’s wiper. Thepotentiometer’s wiper is connected to Pin 2.

As long as the electrical load applied to Pin 2 is nottoo great, and as long as the proper biasing voltage isapplied, movements of the valve will cause voltagechanges in Pin 2. When the valve is closed, Pin 2 willhave a load of approximately 0.5 volts. When thevalve is open Pin 2 will have approximately a 3.5 voltload. At any position in between these extremes therelation between the valve position and Pin 2’s voltageis almost linear.

Pin 1 is connected to a black wire, Pin 2 to a whitewire, and Pin 3 to a red wire. Pin 1 should have 10volts, Pin 2 the sense voltage, and Pin 3 should have0 volts.

The wires are connected to a 4-pin terminal strip,P/N

70.87899. The black wire is connected to Pin 1, thewhite wire to Pin 2 and the red wire to Pin 3. Pin 1should have 10 volts, Pin 2 the sense voltage, and Pin3 should have 0 volts.

The terminal strip is connected to an armored cable,P/N 70.05720. Pin 1 is connected to the black wire,Pin 2 to the white wire, Pin 3 to the red wire, and Pin 4to the drain wire. The drain wire has no insulation.

The black wire should have 10 volts, the white wirethe sense voltage, and both the red wire and the drainwire should have 0 volts. The purpose of the drainwire is to reduce the electrical noise that wouldotherwise be picked up by the other three wires.

The armored cable is connected to a terminal strip ina junction box, P/N 458.30118. The black wire isconnected to Pin 8, the white wire to Pin 9, the redwire to Pin 10, and the drain wire to Pin 11.

Pin 8 should have 10 volts, Pin 9 the sense voltage,and both Pin 10 and Pin 11 should have 0 volts.

Signal Split - One goes toward the UNI-PRO II andthe other to one of the Parker electric hydraulicvalves.

Signal Trace toward UNI-PRO II

The terminal strip in the junction box is connected toa multiple-conductor armored cable, P/N 70.05755.Pin 8 is connected to the orange wire, Pin 10 to theblue wire, and Pin 11 to the drain wire associated withthe orange and blue wires.

The orange wire should have 10 volts and both theblue and the drain wires should have 0 volts.

The armored cable is connected to the control standpanel, P/N 277.43171 or 277.43172. The orange wireis connected to the UNI-PRO II, Pin 34. Sometimes itmay be connected to another pin, depending on howthe jumpers are placed on circuit board 458.50047.

UNI-PRO II Pin 34 should have 10 volts. The 10 voltsoriginates on circuit board 458.50047, circuit U4 Pin7. See manual 458.50077 for more informationregarding the inside of the UNI-PRO Il. The blue wireand the drain wire are connected to terminal stripTSUC1.

TSUC1 may be considered to be the origin of the 0volts, although the true origin is in the trailer’s leadacid batteries.

Signal Trace of sense voltage in the Junction Box

A white wire connects Pin 9 to Pin 25. Pin 25 shouldhave the sense voltage. From here the sense voltage

Signal Trace toward the control stand

The terminal strip in the junction box is connected to amultiple-conductor armored cable, P/N 70.05755. Pin12 is connected to the white/black wire, Pin 13 to thered/black wire, Pin 14 to the drain wire associated withthe white/black and red/black wires, and Pin 15 to thegreen/black wire.

Pin 16 is connected to the orange/black wire, and Pin17 to the drain wire associated with the green/blackand orange/black wires. The white/black wire shouldhave 12 volts, the red/black and the drain wiresshould each have 0 volts, the green/black wire thecommand voltage, and the orange/black wire 0 volts.

The armored cable is connected to the control standpanel, P/N 277.43171 or 277.43172 and The white/black wire is connected to terminal strip 3, Pin 5.

Terminal strip 3, Pin 5 may be considered to be theorigin of the 12 volts, although the real origin is thetrailer’s lead-acid batteries.

The red/black wire and the drain wire are connectedto terminal strip TSUC1. TSUC1 may be considered tobe the origin of the 0 volts, although the true origin isthe trailer’s lead-acid batteries. The green/black wireis connected to Switch 1, Pin 2. This switch allows thecommand voltage to originate from either of twodifferent sources.

The orange/black wire and the drain wire areconnected to terminal strip TSUC1. TSUC1 may beconsidered to be the origin of the 0 volts.

While Switch 1 is in the hand position, Pin 2 isconnected to Pin 1. This allows the operator to controlthe value of the command voltage, and the position ofthe cement valve.

-

unconnected. The red wire has the command voltage,the white wire has the feedback voltage, the brownwire has 0 volts, the black wire has 12 volts, and boththe yellow and orange wires have 0 volts.

The cable is connected to a terminal strip inside ajunction box, P/N 458.30118. The black wire isconnected to Pin 12, the brown wire to Pin 13, theyellow wire to Pin 14, the red wire to Pin 15, theorange wire to Pin 17, and the white wire to Pin 18.

Pin 12 has 12 volts, Pins 13 and 14 have 0 volts, Pin15 has the command voltage, Pin 17 has 0 volts, andPin 18 has the feedback voltage.

Signal Split - One goes toward the UNI-PRO II andthe other to the cement valve position sensingsystem.

enters the valve positioning system. See the ValvePositioning section for more information.

Cement Valve Positioning System

A Parker electro-hydraulic valve, P/N 70.87219, isused to position the cement actuator, P/N 70.87220.The cement actuator positions the cement valve, con-trolling the amount of cement allowed to enter themixing manifold.

As fluid flows out Port A of the block on which theParker valve is mounted, the cement valve opens.The red light will be on at this time.

As fluid flows out Port B, the cement valve closes.The green light will be on at this time. It is a commonmistake to have the hydraulic lines swapped. Whenthis happens the symptoms will be that the cementvalve will open or close all the way, and then refuse torespond to commands.

There must be jumpers at J3 and J6 of the Parkervalve. The spare jumper may be stored on TP1 andTP2. J6 is next to the potentiometers. These jumperscause the Parker valve to act as a valve positioningsystem.

The Parker valve has a 6-pin electrical connector. PinA is unused. Pin B is the command voltage and Pin Cis the feedback (position sense) voltage. Pin D iscommon ground. Pin E is 120volt power.

If Pin B voltage is greater than Pin C voltage,hydraulic pressure will be applied to Port A. If the PinC voltage is greater than the Pin B voltage, hydraulicpressure will be applied to Port B.

If the Pin B and Pin C voltages are equal, hydraulicflow will be blocked out of both Ports A and B. If Pin Band Pin C voltages are within about 200 millivolts,flow out the A or B Ports will be greatly restricted. PinD is 0 volts, Pin E is 12 volts (must be 11.5 volts orgreater), Pin F is unused.

The electrical connector on the Parker valve isconnected to an electrical connector, P/N 70.70687.Pin A is connected to Pin A, Pin B to Pin B, etc. Pin Ais unused, Pin B is the command voltage, Pin C is thefeedback voltage, Pin D is 0 volts, Pin E is 12 volts,and Pin F is unused.

The electrical connector is attached to a cable, P/N70.71013. Pin A is unconnected. Pin B is connectedto the red wire, Pin C to the white wire. Pin D to thebrown wire, Pin E to the black wire, and Pin F isunconnected. Both the yellow and orange wires are

While Switch 1 is in the auto position, Pin 2 isconnected to Pin 4. This allows the UNI-PRO II tocontrol the value of the command voltage.

Signal Trace the hand position A white wireconnects Switch 1, Pin 1 to potentiometer Rl, Pin 2.This is the origin of the hand command voltage. Awhite wire connects potentiometer RI, Pin 3 to UNI-PRO II, Pin 34 or some other pin depending on thejumpers on circuit 458.50047.

UNI-PRO II, Pin 34 should have 10 volts. The 10 voltsoriginates on Circuit Board 458.50047, Circuit U4, Pin7. See Manual 458.50077 for more information re-garding the inside of the UNI-PRO Il.

A black wire connects potentiometer Rl, Pin 1 toTSUC1. TSUC1 may be considered to be the origin ofthe 0 volts.

A white wire connects Switch 1, Pin 4 to UNI-PRO II,Pin 16, or some other pin depending on the jumperson Circuit 458.50047. UNI-PRO II, Pin 16 should havethe auto command voltage. The auto commandvoltage originates on Circuit Board 458.50047, circuitU5, Pin 8. See Manual 458.50077 for moreinformation concerning the internal details of the UNI-PRO II.

Terminal 18 in the junction box is connected to thecement valve position sensing system. Terminal 18has the position sensing voltage.

The cement valve positioning system works asfollows:

The UNI-PRO II originates an automatic commandvoltage. Potentiometer RI generates a hand commandvoltage. Switch 1 selects one of these two voltages tobe the command voltage.

The command voltage is conveyed to the junctionbox. The position sensing system originates a sensevoltage. The sense voltage is sent to the junction boxwhere it is renamed the feedback voltage.

The command voltage and the feedback voltage areconveyed to the Parker valve. The Parker valve willsense any difference in the command voltage and thefeedback voltage and will cause fluid to flow in theproper direction, causing the cement valve to move inthe proper direction.

This will cause the sense voltage to change to a voltage closer to the command voltage. This movement ofthe cement valve will continue until the command

voltage and the feedback voltage are close enoughto cause the Parker valve to block further fluid flow.

When the command voltage changes, the cementvalve positioning system will move the cement valvecorrespondingly.

Water Valve Positioning System

A Parker electro-hydraulic valve, P/N 70.87219, isused to position the water actuator, P/N 70.84839.The water actuator positions the water valve,controlling the amount of water allowed to enter themixing manifold.

As fluid flows out of Port A of the block on which theParker valve is mounted, the water valve opens. Thered light will be on at this time. As fluid flows out ofPort B, the water valve closes. The green light will beon at this time.

It is not uncommon to have the hydraulic linesswitched. When this happens the symptoms will bethat the water valve will open or close all the way, andthen refuse to respond to commands.

There must be jumpers at J3 and J6 of the Parkervalve. A spare jumper may be stored on TP1 andTP2. J6 is next to the potentiometers. These jumperscause the Parker valve to act as a valve positioningsystem.

The Parker valve has a 6-pin electrical connector. PinA is unused. Pin B is the command voltage and Pin Cthe feedback (position sense) voltage. If the Pin Bvoltage is greater than the Pin C voltage, hydraulicpressure will be applied to Port A.

If Pin C voltage is greater than Pin B voltage,hydraulic pressure will be applied to Port B. If the PinB and Pin C voltages are equal, hydraulic flow will beblocked out of Ports A and B. If the Pin B and Pin Cvoltages are within about 200 millivolts, flow out PortA or B will be greatly restricted.

Pin D is 0 volts and Pin E is 12 volts (must be 11.5volts or greater). Pin F is unused. The electricalconnector on the Parker valve is connected to anelectrical connector, P/N 70.70687. Pin A isconnected to Pin A, Pin B to Pin B, etc.

Pin A is unused, Pin B is command voltage, Pin C isfeedback voltage, Pin D is 0 volts, Pin E 12 volts, andPin F is unused.

The electrical connector is attached to a cable, P/N70.71013 and Pin A is unconnected. Pin B isconnected to the red wire, Pin C to the white wire,Pin D to the brown wire, and Pin E to the black wire.

Pin F, the yellow wire, and the orange wires areunconnected. The red wire has the command voltageand the white wire the feedback voltage. The brownwire has 0 volts, the black wire 12 volts, and both theyellow and orange wires have 0 volts.

The cable is connected to a terminal strip inside ajunction box, P/N 458.30118. The black wire isconnected to Pin 19, the brown wire to Pin 20, theyellow wire to Pin 21, the red wire to Pin 22, theorange wire to Pin 24, and the white wire to Pin 25.

Pin 19 has 12 volts and Pins 20 and 21 have 0 volts.Pin 22 has the command voltage, Pin 24 has 0 volts,and Pin 15 has the feedback voltage.

Signal Split - One goes toward the control stand andthe other toward the water valve position sensingsystem.

Signal Trace toward the control stand

The terminal strip in the junction box is connected to amany-conductor armored cable, P/N 70.05755. Pin 19is connected to the blue/black wire, Pin 20 to theblack/white wire, Pin 21 to the drain wire associatedwith the blue/black and black/white wires.

Pin 22 is connected to the red/white wire, Pin 23 tothe green/white wire, Pin 24 to the drain wireassociated with the red/white and green/white wires.

The blue/black wire should have 12 volts, theblack/white wire 0 volts, the drain wire 0 volts, thered/white wire the command voltage, and both thegreen/white wire and the drain wire should each have0 volts.

The armored cable is connected to the control standpanel, P/N 277.43171 or 277.43172. The blue/blackwire is connected to Terminal Strip 3, Pin 5. TerminalStrip 3, Pin 5 may be considered to be the origin ofthe 12 volts, although the real origin is the trailer’slead acid batteries. The black/white wire and the drainwire are connected to terminal strip TSUC1. TSUC1may be considered to be the origin of the 0 volts,although the true origin is the trailer’s lead-acidbatteries.

The red/white wire is connected to Switch 2, Pin 2.This switch allows the command voltage to originatefrom either of two different sources. The green/whitewire and the drain wire are connected to terminal stripTSUC1. TSUC1 may be considered to be the origin ofthe 0 volts.

While Switch 2 is in the hand position Pin 2 isconnected to Pin 1. This allows the operator to controlthe value of the command voltage and the position ofthe water valve.

While Switch 2 is in the auto position Pin 2 isconnected to Pin 4. This allows the UNI-PRO II tocontrol the value of the command voltage.

Signal Trace the hand position

A white wire connects Switch 2, Pin 1 to potentiometerR2, Pin 2. This is the origin of the hand commandvoltage. A white wire connects potentiometer R2, Pin3 to UNI-PRO II, Pin 34, or some other Pin dependingon the jumpers on Circuit 458.50047.

UNI-PRO II, Pin 34 should have IO volts. The 10 voltsoriginates on Circuit Board 458.50047, Circuit U4, Pin7. See Manual 458.50077 for more informationregarding the inside of the UNI-PRO II. A black wireconnects potentiometer R2, Pin 1 to TSUC1 .

TSUC1 may be considered to be the origin of the 0volts.

A white wire connects Switch 2, Pin 4 to UNI-PRO II,Pin 17, or some other pin depending on the jumperson Circuit 458.50047. UNI-PRO II, Pin 17 should havethe auto command voltage. The auto commandvoltage originates on Circuit Board 458.50047 CircuitU5, Pin 14. See Manual 458.50077 for moreinformation concerning the internal details of the UNI-PRO II.

Terminal 25 in the junction box is connected to thewater valve position sensing system. Terminal 25 hasthe position sensing voltage.

The water valve positioning system works as follows:

The UNI-PRO II originates an automatic commandvoltage. Potentiometer R2 generates a handcommand voltage. Switch 2 selects one of these twovoltages to be the command voltage. The commandvoltage is propagated to the junction box. The positionsensing system originates a sense voltage. The sensevoltage is conveyed to the junction box where it isrenamed the feedback voltage.

The command voltage and the feedback voltage aresent to the Parker valve. The Parker valve will sensethe difference in the command and the feedbackvoltages and will cause fluid to flow in the properdirection. This will cause the cement valve to move inthe proper direction and will cause the sense voltageto change to a voltage more near the commandvoltage. This movement of the cement valve willcontinue until the

Command voltage and the feedback voltage aresufficiently close to cause the Parker valve to blockfurther fluid flow

When the command voltage changes, the cementvalve positioning system will move the cementvalve correspondingly.

Any signal generated in the magnetic pickup will beconveyed to UNI-PRO II, pin 14 where it can bedetected and processed.

Master Water Valve Positioning System

The water valve will allow a small amount of water topass while closed. This is undesirable. To eliminatethis water flow, a master water valve is placed in thewater supply line with the water valve. This valve willeither be open or closed.Flow Rate Sensing Circuitry

A turbine flowmeter, P/N 991.40523, is placed intothe mix water manifold where it meters water enteringthe manifold. As the vanes of the flowmeter movepast a magnetic pickup, P/N 70.35638, a voltage isgenerated in the pickup.

The voltage will vary with time, the voltage at Pin B ofthe pickup increasing as vanes move toward themagnet, and decreasing as the vanes move away.Pin A is called +sig and Pin B is called -sig. Pin A ofthe pickup is connected to a white wire and Pin B to ablack wire. The white wire has +sig, and the blackwire has -sig.

The wires are connected to a terminal strip, P/N70.87899. The white wire is connected to Pin 1 andthe black wire to Pin 2. Pin 1 has +sig and Pin 2 -sig.

The terminal strip is connected to an armored cable,P/N 70.03350. Pin 1 is connected to the white wire,Pin 2 to the black wire, Pin 3 to the drain wire. Thewhite wire is +sig, the black wire -sig, and the drain is0 volts. The drain is present to reduce the electricalnoise that would otherwise be present on the othertwo wires.

The cable is connected to a terminal strip inside ajunction box, P/N 458.00118. The white wire isconnected to terminal 1, the black wire to terminal 2,and the drain wire to terminal 3. Terminal 1 has +sig,terminal 2 -sig, and terminal 3 has 0 volts.

The terminal strip is connected to a many-conductorcable, P/N 70.05755. Terminal 1 is connected to ablack wire, Terminal 2 to a white wire, and Terminal 3to a drain wire. The black wire has +sig, the whitewire has -sig, and the drain has 0 volts.

The armored cable is connected to panel, P/N277.43171 or 277.43172. The black wire is connectedto UNI-PRO II, Pin 14, or some other pin dependingon how the jumpers are placed on circuit board458.50047.

UNI-PRO II, Pin 14 has +sig. The destination of +sigis circuit board 458.50047, Circuit U8, Pin 3. Thewhite wire and the drain wire are connected toTSUC1. TSUC1 may be considered the source of 0volts.

There is no way for this valve to be placed partiallyopen. For this reason, there is no valve positionsensing system. A Parker electro-hydraulic valve, P/N70.90836, (unlike the others) is connected to theactuator for the master water valve. The hydraulicsare plumbed so that the master valve will be open ifthe electro-hydraulic valve is de-energized.

It is not uncommon to have the hydraulic linesswapped. The symptom will be that the valve will beopen when it should be closed, and vice versa. Thereare two black wires coming from the electro-hydraulicvalve. It takes 12 volts difference in either polarity toenergize this valve. The black wires are connected toa terminal strip, P/N 70.87899. One is connected toPin 1, and one to Pin 2. Pin 1 may be considered tobe +sig, and Pin 2 may be considered to be -sig.

The terminal strip is connected to an armored cable.Pin 1 is connected to a white wire. Pin 2 is connectedto a black wire. Pin 3 is connected to a drain wire. Pin1 is +sig, Pin 2 is -sig, and Pin 3 is 0 volts. The drainwire is in place to reduce the amount of noise emittedby the cable.

The cable is connected to a terminal strip inside thejunction box, P/N 458.30118. The white wire isconnected to Pin 26, the black wire to Pin 27, and thedrain wire to Pin 28. Pin 26 is +sig, Pin 27 is -sig, andPin 28 is 0 volts.

The terminal strip is connected to a many-conductorarmored cable, P/N 70.05755. Pin 26 is connected tothe blue/white wire, Pin 27 to the black/red wire, andPin 28 to the drain wire. The blue/white wire has +sig,the black/red wire -sig, and the drain wire has 0 volts.

The cable is connected to the panel, P/N 277.43171or 277.43172. The blue/white wire is connected toSwitch 3, Pin 4. The black/red wire and the drain wireare connected to Terminal Strip 3, Pin 2. Switch 3, Pin4 is connected to Switch 3, Pin 3 only when the switchis in the auto position. Terminal Strip 3, Pin 2 may beconsidered to be a source of 0 volts.

Switch 3, Pin 3 is connected to Relay 1, Pin 1 andRelay 1, Pin 1 is connected to Relay 1, Pin 2 onlywhile the relay is energized. Relay 1, Pin 2 is con-nected to Terminal Strip 3, Pin 5 which may beconsidered to be a source of 12 volts. Relay 1, Pin 4is connected to TSUC1 which may be considered tobe a source of 0 volts. Relay 1, Pin 3 is connected toUNI-PRO II, Pin 18, or another pin depending uponhow the jumpers are placed in Circuit Board458.50047.

UNI-PRO II, Pin 1 has the “close valve” signal. Theorigin of this signal is Circuit Board 458.50047, CircuitU5, Pin 7. See manual 458.50077 for moreinformation on the internal details of the UNI-PRO II.

The master water valve positioning system performsas follows:If Switch 3 is in the hand position, energized voltagecannot reach the electro-hydraulic valve; therefore thevalve will be open. If Switch 3 is in the auto position asignal can travel from the relay.

If UNI-PRO II, Pin 18 is 10 volts, relay 1 will beenergized, allowing 12 volts to pass to Relay 1, Pin 1.If UNI-PRO II, Pin 18 is 0 volts, Relay 1 will be de-energized, and Relay 1, Pin 1 will be 0 volts. Thevoltage on Relay 1, Pin 1 will be sent to the electro-hydraulic valve. If 12 volts reaches the valve, it willclose. If 0 volts reach the valve, it will open.

Density Sensing System

A radioactive density sensor is placed in therecirculating line of the mixing system. The densitysensor has a 5-pin connector. Pin A is for 12 volts topower the sensor. Pin B is for +sig and Pin C is for -sig. Pin D is for 0 volts to power the sensor. Pin E isunused.

The connector is attached to a connector, P/N70.70684. Pin A is connected to Pin A and Pin B toPin B, etc.

Pin A is 12 volts, Pin B is +sig, Pin C is -sig, and bothPins D and E are 0 volts. The 0 volts on Pin E reducethe electrical noise that would otherwise exist on theother pins.

The connector is attached to a cable, P/N 70.71012.Pin A is connected to the white wire, Pin B to theblack wire, Pin C to the red wire, Pin D to the brownwire, and Pin E to the shield. The white wire is 12volts, the black wire is +sig, the red wire is -sig, thebrown wire and the shield are 0 volts.

The cable is connected to the panel, P/N 277.43171or 277.43172 and the white wire to the UNI-PRO IIPWR. This may be considered as a source of 12 volts.The black wire is connected to the UNI-PRO II Pin 11,or

another pin depending on how the jumpers are madeon Circuit Assembly 458.50047.

UNI-PRO II, Pin 11 is +sig. The final destination ofthis signal is Circuit Board 458.50047, Circuit U1O,Pin 15. For more information on the internal details ofthe UNI-PRO II, see Manual 458.50077.

The red and the brown wires are connected toTSUC1TSUC1 may be considered the source for 0 volts. Theshield is unconnected.

Density signals generated inside the density sensorare conveyed to the UNI-PRO II, Pin 11. There it canbe detected and processed.

Summary

The UNI-PRO II gathers sufficient information fromthe mix water rate and density sensors to determinewhat adjustments are needed on the three valves itcontrols. Density is displayed next to MENU 3. Mixwater rate is displayed next to MENU 4.

The operator may enter commands into the ADC byusing MENU 8. Other values are displayed next toother menu buttons, but these are not necessary forADC to work. Additional information concerning theADC is found within this manual.

Hydraulic Subsystem Description

Refer to Drawing No. 278.98022 in section 5 of thismanual for schematic information on the hydraulicsystem. Refer to test procedure (278.98024) forspecific information on how to set up and test thehydraulic system.

The hydraulic subsystem consists of a hydraulic fluidreservoir, pressure-compensated hydraulic pump,inline filter, system relief valve, and an ON-OFFcontrol valve. It also has two electric over hydraulicproportional flow control hydraulic valves, one electricover hydraulic ON-OFF valve, and three hydraulicactuators.

Two of the hydraulic actuators have integral positionpotentiometers, the water throttling actuator and thecement throttling actuator. The third actuator servesan on/off function and has no position potentiometer.

PUMP The hydraulic pump is a pressure-compensated model which means that it adjusts itsoutput flow as required to maintain a preset constantpressure 1500 psi. If there is no flow required of thepump, it adjusts its stroke so that essentially no oilflow results while maintaining the 1500 psi pressure.

If the pump discharge is wide open, the pump will adjustits output to maximum, trying to pump enough oil to makethe preset pressure.

In effect, a pressure-compensated pump keeps oil inthe system at a preset pressure, ready for use whenrequired.

FILTER - The filter for the system is in the high-pressure side of the system and is positioned in frontof any control valves.

RELIEF - The system relief valve is set at 2000 psiand protects the system components in the event thepressure compensator on the hydraulic pump fails.

ON/OFF CONTROL VALVE - This value is used toactivate the ADC hydraulics and is usually locatedjust below the face panels in the control stand. Whenthe valve is in the ON position, hydraulic oil issupplied to the ADC proportional values andactuators at about 1500 psi. When the valve is in theOFF position, the ADC hydraulics are bypassed andthe hydraulic oil is circulated back to the tank. Ingeneral, the ADC hydraulics should be bypassed onpumping jobs when ADC is not required.

ELECTRIC OVER HYDRAULIC FLOW CONTROLVALVES - There are two proportional valves used,one to control oil flow to the cement throttling valveactuator and one to control the oil flow to the watervalve actuator.

The proportional flow control valves control theamount of oil flow in relation to the electrical signalapplied to the valve. They also have on-boardelectronics that compare a control voltage to afeedback voltage.

The electronic subsystem calculates a commandsignal based on the job requirements. The electronicsin the proportional flow control valve compare thecommand signal to the feedback signal coming fromthe actuator. If they are not the same, the valveelectronics will open the hydraulic valve and bring theactuator to the position that makes the command andfeedback signals equal.

The third electric over hydraulic valve is used foron/off control only, and controls the water mastervalve. It is plumbed so that the absence of anelectrical signal will open the master water valve. It isprogrammed so that the master valve is open whenthere is a water requirement for the job.

Two actuators have position feedback potentiometersin them. These potentiometers supply actuatorposition information to the hydraulic valve electronics.

Both the actuators for the cement throttling and thewater throttling valves have feedback potentiometers.The master water valve actuator has no positionfeatures.

All the actuators have a hydraulic bypass valve whichallows the oil to flow freely between the pistons. Thisfeature enables the actuators to be operatedmanually in an emergency situation by inserting aoperating bar in the bonnet on the actuator andturning the stem.

The hydraulic by-pass valves are small ball valveslocated in the hydraulic plumbing. The valves are inthe bypass position if the operating handle is in linewith the hydraulic piping.

COOLER - The hydraulic oil is routed from the mainON-OFF valve under the control stand and from theelectric over hydraulic valve return ports to an air tooil cooler in front of the auxiliary engine for cooling.

The oil then returns to the hydraulic reservoir.

HYDRAULIC ACTUATORS - The valve actuatorsare hydraulically operated. They are rack-and-piniontype rotary actuators.

Section 4Maintenance andTroubleshooting

RCM II Inspection and Maintenance Procedures

A good cementing job depends upon how wellthe cement slurry is mixed. If the slurry is notmixed to the right density or if it is not correctlyblended the cementing job could fail

There are several things that could causeproblems in mixing. For example, if therecirculating cement mixing RCM II) system isnot adequately cleaned after each job, cementcan build up rapidly around various componentsof the unit. In time, this build-up can causeserious restrictions in the slurry or dry cementflow. It also can cause slurry to be mixed tooslowly or it can cause the mixing system to stopcompletely. All of these problems can be avoidedwith careful, routine maintenance.

Cement Throttling Valve Maintenanceand Inspection Procedures

Maintenance should start a couple of hours priorto the job. Thorough visual inspections areparticularly important when one operator isrelieving another.

Start by removing the cement throttling valve.Loosen the 5-1/2-in. union and the throttlingvalve wash-up connection (Fig. 4-1). Lift thethrottling valve off the mixing bowl.

THROTTLING VALVE WASH-UP CONNECTION

CEMENT THROTTLING VALVE

CEMENT MASTER VALVE.

VACUUM BREAKER ASSEMBLYCHECK THROTTLING VALVE FOR CEMENT BUILDUP

FIGURE 4-2

If at any time cement build-up is noticed on anycomponent, remove the build-up immediately.

Push the vacuum breaker in and out to makesure it is operating freely (Figure 4-2).

Check the vacuum breaker seat for cementbuild up or imperfections.

If the vacuum breaker will not seat properly,replace it. The vacuum breaker must operateproperly.

Check the cement master valve forsmooth operation, cement build-up, orbutterfly valve problems (Figure 4-2).

Make sure the cement throttlingvalve can be operated easily. The cementthrottling valve should be greased beforeevery job.

If the cement throttling valve is hard to operate,there may be cement build-up between the plugand throttling valve body. Remove the plug byloosening the clamp on top of the throttlingvalve body. Lift the actuator and throttling valveplug out of the cement throttling valve body(Fig. 4-3). This can be done with the throttlingvalve off.

CLAMP\

+LIFT“UP,” WHEN LOOSENED

THROTTLING VALVE ACTUATOR

FIGURE 4-3

After removing the assembly, remove allcement build-up, then grease and reinstall.While the assembly is out, remove all cementbuild-up from the throttle valve body

With the throttling valve removed, check themixer throat for cement build-up (Fig. 4-4)and clean it thoroughly.

CHECK FOR CEMENT BUILD-UPMIXER BOWL

FIGURE 4-4

Axial Flow Mixer Maintenance andInspection Procedures

Refer to Pages 4-8 and 4-9 for schematic andlocation numbers referenced below. The axialflow mixer consists of several high-toleranceparts. If certain parts are worn or damaged,performance will decrease.

Condition of the wearing parts of the axial flowmixer usually can be determined by the mixingwater pattern. Some of the symptoms of a wornor damaged mixer are:

If the mixing water flow pattern in the throat ofthe mixer forms a vortex, with the center of thevortex in the center of the throat, the mixing jet isprobably in good condition (see 4-5).

If the vortex does not form, or forms off center to themixer throat, the water jet probably is worn or ispartially plugged and the mixer should be inspectedas per the following instructions:

With the water throttling valve full open, there shouldbe 18 water jets open. If less than 18 are visible, thejets probably are plugged and the mixer will need tobe torn down and inspected as per the followingdisassembly instructions:

If the water flow exceeds 15 gpm with the mixingwater throttling valve in the full OFF position, thewater valve plate and the water orifice plate probablyare damaged and the mixer will need to be torn downand inspected.

FI’GURE 4-6

Disassembly

The following steps outline the teardown and re-assembly procedure.

NOTE: Before disassembly, mark the relative positionsof the water manifold to the water valve plate, the waterorifice plate and the mixer body. This will ensure thatthe parts are reassembled in the correct positions. If thebolts, mixing manifold and the orifice plate are notreplaced in the same position, the water jet (Loc I 0) willnot line up with the orifice plate (Loc 8) holes and waterflow will be blocked.

Step 1. Remove the cement throttling valve from themixer body by knocking loose the 5-1 /2 inch Wecoconnection. Either disconnect the hydraulic lines fromthe actuator mounted on top of the mixer or, lay thethrottling valve over on its side, away from the mixer,taking care not to kink the hydraulic hoses or pinch theelectrical connections. If the hydraulic hoses areremoved, mark the hoses and ports on the actuators sothat the proper ports and hoses are reconnected at re-assembly.

Step 2. Disconnect the water throttling valve linkagefrom the water valve plate. Remove the water throttlingvalve mounting bracket and actuator in one piece.Either disconnect the hydraulic lines from the actuatoror move the whole assembly off to the side taking carenot to kink the hydraulic hoses or pinch the electricalconnections. If the hydraulic hoses are removed, markthe hoses and ports on the actuators so that the properports and hoses are reconnected at re-assembly (seeFig.4-6).

Step 3. Mark the mixer body (Loc 11) where the waterinlet connection enters the water manifold (Loc 2).Remove the six g/16-in. diameter bolts from the watermanifold (Loc 2). Mark the mixer body flange holeswhere the six bolts were removed. Lift the watermanifold off and carefully remove the O-rings (Locs 3and 4) from the water manifold and inspect them fordamage. Replace them if necessary (see Fig. 4-7).

FIGURE 4-7

Step 4. Remove the six spacers (Loc 12) from thewater orifice plate.

Step 5. Mark the location of the water valveplate handle on the mixer body for referencewhen reassembling. Lift off the water valveplate (Loc 7) and inspect it for damage.

Damage will show up as deep surfacescratches from debris or worn edges due towater erosion. Excessive wear and deepsurface scratches are hard to define and onlyexperience will determine if the part isacceptable. Possible evidence of excessivewear-or deep scratches is poor water shut-off./If the water flow, with the throttling valve off, isin excess of 15 gpm, either the water orificeplate (Loc 8) and/or the water valve plate (Loc7) probably are worn and need to be replaced.

FIGURE 4-9

FIGURE 4-8

Step 6. Make alignment marks on the orificeplate (Loc 8) and the mixer body (Loc 11) forreference when reassembling. Lift off the waterorifice plate (Loc 8). Remove and inspect thequad-ring (Loc 5) and replace if necessary.Inspect the water orifice plate for wear aroundthe orifice holes. If excessive wear is evident,replace the part (see Fig. 4-8 and 4-9).

Step 7. The water jet (Loc 10) will now be inview. Inspect the bottom of the water groovesfor wear. Wear will show up as erosion of thebottom of the water jet grooves (see Fig. 4-10).

Evidence of excessive wear is an eccentric orscattered water pattern. If the water pattern isoffset (the center of the vortex or “eye” is not inthe center of the mixer throat when water isbeing pumped through), the water jet probablyis worn and needs to be replaced.

Again, only experience will determine if the partis acceptable.

FIGURE 4-10

NOTE: If the water jet is removed, it must bereplaced with the same orientation as it wasremoved. It is oriented by a locating pin (Loc 15)near the outside diameter of the water jet bodyand will reassemble only in the correct positionas long as the locating pin is in place (see Fig. 4-10).

Step 8. While the water jet is out of the mixerbody, inspect and clean the inside of the mixerbody.

Re-Assemebly

Step 1. All O-rings and the quad-ring should begreased before they are re-installed.

Step 2. Install the water jet if it was removed inStep 7. Make sure the locating pin is in itsproper place.

Step 3. Lay the water manifold (Loc 2) over onthe 5 1/2-in. Weco union half and install the O-ring (Loc 4) in the flange face. Install the O-ring(Loc 3) on the outside diameter (OD) of thewater manifold throat (see Fig. 4-11).

FIGURE 4-12

Step 5. Lay the water orifice plate (Loc 8) overthe water valve plate installed in Step 4 andpress it on over the O-ring (Loc 3) installed in theOD of the mixer throat. Make sure the spacers(quantity 6, Loc 12) are in their proper holes asthe orifice plate is being pressed on (see Fig. 4-13, 4-14, and4-15).

FIGURE 4-11

Step 4. Lay the water valve plate on the flangeface of the water manifold with the handle in theproper position as marked in Step 5. The watervalve plate has the word “up” or “top” stamped init and the plate must be positioned such that theword reads correctly from the 5-1/2-in. Weco halfend of the water manifold (see Fig. 4-1 2).

FIGURE 4-13

FIGURE 4-14

Step 6. Install the O-ring (Loc 9) in the flange ofthe mixer body.

Step 7. Hold the water manifold, water valveplate, and the water orifice plate together andturn it right-side-up so that the word “up” or “top”reads correctly from the 5-1/2-in. Weco end ofthe mixer body. Lay the assembly on the flangeof the mixer body taking care not to disturb theO-ring (Loc 9). Rotate the assembly asnecessary to align the water valve plate, watermanifold, and the mixer body as per thealignment marks made at the first of thisprocedure (see Fig. 4-15).

FIGURE 4-16

Step 9. Install the water throttling valve linkageand actuator bracket. Reconnect any wiring orhydraulic piping that was disconnected earlier(see Fig. 4-16 and 4-17).

NOTE: The open and closed voltage for thewater metering valve should be reset when thewater metering valve actuator is reinstalled.Reference drawing 278.98024 for details.

FIGURE 4-17

FIGURE 4-15

Step 8. Install the six, 9/16-in. diameter boltsand torque them evenly in a criss-crosspattern to approximately 60 ft-lb

Step 10. Install the cement throttling valve.Reconnect any wiring or hydraulic piping thatwas disconnected earlier.

412.15018G MIXER ASSY - CEMENT - RCM II -WITH CONED DIFFUSER

LOC PART NO. QTY DESCRIPTION

1 412.15027 1

2 412.15002 13 70.34056 1

4 70.33215 1

5 70.33233 16 70.44927 67 412.15003 18 412.15004 1

70.33927 1

10 412.15034 1

11 412.15017 1

12 412.15007 6

14 70.32049 6

15 55.64310 1

16 70.43812 618 412.15020 119 412.15019 120 70.43404 121 70.32738 122 412 15032 2

23

24412.1503

3

25 412.1502

SLEEVE - MANIFOLD - WATER - 4.75 I.D.- 4.5 IN. LONG - AXIALFLOW MIXERMANIFOLD -WATER - MIXER -CEMENT - RCM IIO-RING - 90D - 6-l/2 X 6-l/4 X l/8568-259 - SPEC 599.33001 SPEC70.72000O-RING - 70D - 8-3/4 X 8-1/2 X 1/8 -568-268 - SPEC 70.33000 SPEC-70.72000O-RING - QUAD-RING - 700 – 8 1/4 lD -1/8 IN - SEC BUNA-N - #4267 Q4267-3664

SCREW - HEX CAP - 9/l 6-12NC X 3 -SPECPLATE - VALVE - WATER - MIXER - CEMENT - RCM IIPLATE - ORIFICE - WATER - MIXER - CEMENT - RCM IIO-RING - 9OD - 9 x 8-3/4 x 1/8 568-269 - SPEC 599.33001 SPEC70.72000JET - MIXER - WATER - AXIAL FLOW MIXER - 6.25 OVER ALL LENGTH - RCM II

BODY - MIXED - RCM II -W/CONED DIFFUSER

SPACER - WATER MANIFOLD TO ORIFICE PLATE - MIXER - CEMENTRCM IINUT - ELASTIC STOP - 9/16-12 NCEl0469 ESNA-AMERACE CORP SELF LOCK NUT - 9/l-12NC

STEEL-ROD-CF-STNLS-303- 1/8 - SPEC 70.82212

SCREW - HEX CAP - 3/8=16NC X 3/4 - PL SPEC 70.43917SHEATH - SPLASH - 16 IN ID X 18 IN ID X 14.5 IN. LONG - RCM IICLAMP - BAND - SPLASH SHEATH - RCM IISCREW - HEX SOC - 3/8-16NC X 2-1/2 -SPEC 70.43270NUT - ELASTIC STOP - 3/8-16NC - HVY -PL - SPEC 70.32769ADAPTER - HOSE - TEE - MODIFIED -3/8 MPT BRANCH X #6 JIC RUNS - 3/8 MPTBRANCH TAPPED F/ 1/4-18 FEMALE PIPE THREADNOZZLE - SPRAY - l/4 IN MALE NPT CONN- WIDE ANGLE - FULL CONE - 9/64IN.NOMINAL ORIFICE DIA. - 303 STAINLESS STEEL - 1 PIECE BODY El 2557SPRAYING SYSTEMS CO1/4-HH-SS-14W

ADAPTER - HOSE - CROSS - MODIFIED -3/8 MPT X #6 JIC - 3/8 MPT BRANCHTAPPED F/ l/4-18 FEMALE PIPETHREADTUBE - WASH DOWN NOZZLE - AXIAL FLOW MIXER WITH SPLASHSKIRTSPEC SPECIFICATION - COATING SYSTEM - THREE COMPONENT ORGANICZINC-RICH PRIMER, EPOXY INTERMEDIATE, &ACRYLICURETHANE- FOR OFF-SHORE AND COASTAL AREAS -U.K.EQUIVALENT - COATING SYSTEM -ARBROATH SPECS AE-C-001/ AE-C-004/AE-C-003

NOTES: 412.15018 G - MIXER ASSY - CEMENT - RCM II - WITH CONED DIFFUSER

1. INSTALL LOC 7 WITH THE LETTERS FACE UP.2. USE NEVER-SEEZE ON ALL FASTENERS.3.CENTER VENT FLAP ON SPLASH SHEATH (LOC l8) ON THIS CENTER LINE.4.LEAK TEST THE ASSEMBLED MIXER. PRESSURE UP ON THE 3” VICTAULIC INLET PORT WITH 150 PSI

WATER. CHECK FOR LEAKAGE THRU THE WATER THROTTLING PLATE IN THE FULL OFF POSITION. IFTHELEAKAGE RATE IS GREATER THAN 15 GPM CONSULT ENGINEERINGFOR REPAIR INSTRUC TIONS.

5.APPLY TEFLON TAPE TO LOC 23 AND THREAD INTO LOC 22 & 24 AS SHOWN.6.TORQUE 9/16” BOLTS TO 45-50 FT-# LUBRICATED. DO NOT OVER TORQUE.7. PAINT RED.

RCM II Troubleshooting ProceduresTroubleshooting the RCM II System is aided bythe confidence of knowing the system.

By being extremely familiar with the overall unit,initial troubleshooting time can be reduced.

Every component has a purpose and if thatcomponent does not function properly, thesystem will not operate properly. The operatorshould become extremely familiar with theoperation, clean-up, and maintenanceprocedures of the RCM II System.

The operator should also be familiar with theoperation of components that affect the RCM IISystem, with valve locations and also with thecement and water flow paths.

With experience, potential problems can berecognized. With this experience, a logicalsequence for troubleshooting can also bedeveloped. The RCM II System is an excellentsystem for mixing cement slurries. If properlymaintained, it will increase efficiency,performance, and ease of operation whiledecreasing troubleshooting procedures.

PROBLEM CAUSES REMEDIES

Slow Mixing Rates Restricted mix water manifold

Dusting Improper bulk delivery pressure

Restricted throttling valve

Low bulk cement delivery rate

Partially plugged cementdelivery hose

Dirty bulk unit or manifold

Low bulk air pressure

Low mixing pressure

Low recirculating pumppressure

Bulk system being purged byair

Low or no recirculating pumpflow

Low or no mixing pumpflow

Clean immediately.

Clean immediately.

Check bulk unit thoroughly.

Check bulk unit delivery hose thoroughly.

Check bulk unit thoroughly.

Check pressure (See bulk systemmanual).100-160 psi normal closed-inpressure. Check centrifugal pumptroubleshooting procedures. Check forproper rpm and impeller adjustment.

25-35 psi normal closed-in pressurewith water. Check centrifugal pumptrouble shooting procedures. Checkfor proper rpm, partially cloggedsuction or impeller adjustment.

Check bulk pressure (See BulkEquipment Operator’s Manual).

Check bulk operation (See BulkEquipment Operator’s Manual).

Check centrifugal pumptroubleshooting procedures. Checkpump speed and pressure. Check forblocked suction from RCM tub.

Check centrifugal pumptroubleshooting procedures. Checkpump speed and pressure.

PROBLEM CAUSES REMEDIES

Moisture in bulk Vacuum breaker not operatingequipment or hose properly

Excess cement build-up in throttling valve

Unable to maintainconstant density

Losing prime ofrecirculating pump(gauge pressure tozero [O] psi)

Losing prime ofrecirculating pump

Splashback

Restriction of cement

Throttling valve wash-up valve open

Vacuum breaker not operatingproperly

Throttling valve wash-up valve open

Splashback

Restriction of cement build-up inmixer throat

Improperly maintained RCM@ IISystem

Erratic delivery of bulk cement

Erratic mixing pressure

Improper operation of ADCsystem

Slurry bridging off in suction ordischarge of recirculating pump

Closed valve from tub torecirculating pump

Centrifugal pump stopped turning

Air entrained in volute ofrecirculating pump

Recirculation pump defective

Check for cement build-up around vacuumbreaker.

Check mixing jets for restrictions or wear.Tub level excessively high.

Check mixer bowl and remove allcement build-up.

If open, close immediately.

Check for cement buildup aroundvacuum breaker.

If open, close. If valve leaking, replace.

c

Check mixing jet for restrictions OR WEARTub level too high during mixing.

Check mixer throat and remove all cementbuild-up.

See RCM@ II maintenance procedureslisted earlier in this section.

Check bulk equipment operator’s &maintenance manuals

Check mixing pump. 100-160 psi normalclosed-in pressure. 100-120 psi is theoptional mix water pressure.

Check ADC operating procedures inSection 1.

Check manifold for obstructions.

Check valve, if closed, open. See RCM IIoperating procedures.

Check centrifugal pump drive system.

Add slurry de-foaming agent.

Check rpm of recirculation pump (1450-1750 normal) 25-35 closed in pressure.Check impeller adjustment or seal leakingallowing air to be pulled in during operation.

PROBLEM CAUSES REMEDIES

Low mixing pumppressure

Losing prime onmixing pump

Low recirculatingpump pressure

Centrifugal pump not turning atproper speed

Partial plug of cement in suction

Air entrained in slurry

Gauge or gauge protector notoperating properly

Centrifugal pump seals leakingpressure or vacuum

Centrifugal pump not turning atproper speed

Restriction in suction side ofcentrifugal pump

Centrifugal pump seals leaking

Gauge not operating

Centrifugal pump stopped

Hard to operatecement throttlingvalve (wheel)

Source of water shut off Check water supply.

or

Running out of water Check water supply

Insufficient head from the water Check water supply. Also elevation ofwater supply in relation to volute ofmixing pump.

Check suction manifold and/orcentrifugal pump packing for leaks.Suction leaks

Cement build-up between plug

Inadequate

Inadequatedrive

lubrication of plug valve

lubrication of right-angle

Check centrifugal pump drive system.(1450 rpm)

Check manifold for obstructions.

Add de-foaming agent to slurry.

Check, repair and/or replace asnecessary.

Check seals and replace as necessary.

Check centrifugal pump drive system.(2350-2650 normal rpm)

Check manifold for obstructions.

Check seals and replace as necessary.

Replace Gauge.

Check centrifugal pump drive system.

Check for foreign object in volute ofpump. If pump is hydraulically driven, thesystem pressure will be at maximum.

Clean out cement build-up

Check RCM II valve maintenanceprocedures listed earlier in this section.

Lubricate plug valve (See RCM IImaintenance procedures).

Check lubricant in box. Add lubricant ifneeded.

PROBLEM CAUSES REMEDIES

Bulk cement stops Plugged bulk delivery line or hose

Dry cement inmixing tub slurry

Lumps in slurry Erratic delivery of bulk cement

Plugged or eroded mixing jet

Improper agitation

Inadequate air supply to bulk system

Out of cement

Plugged discharge valve in bulk tank

Inadequate air supply to bulk system

Cement

Cavitation ofHT.400 pump

Agitators not turning

Losing prime of mixing pump

No mixing water being added to slurry

Low pressure of recirculation pump

Trying to pump too fast for density ofslurry being mixed

Blockage in suction line from RCM IIto tub displacement pump(s)

Restriction at tub’s suction valve

Improper HT.400 pump operation

Control valve in “off” position

Improper function of hydraulic system

Check bulk equipment Operator’sMaintenance manuals.

Clean or replace mixing jet (See Loc. 10,Page 1-29).

Check that agitators are turning andoperating properly (200 rpm minimum).

Check air supply and proper bulkequipment operation.

Check cement delivery line or hose forrestrictions, or build-up.

Check cement level in bulk tanks.

Clean or replace.

Check air supply and proper bulk equipmentoperation.

Reduce or close cement slurry throttlingvalve. Add water and mix dry cement. Shutdown and break up cement with wash-uphose if necessary.

Check centrifugal pump system.

Check centrifugal pump system.

Check recirculation pump for proper rpmand pressure. Check for cement build-up orblockage on recirculating pump tub suction.1450 rpm minimum. 20-35 psi normalclosed-in pressure with water.

Reduce pumping rate.

Check tub suction manifold.

Check tub suction valve.

Check RCM II clean-up procedures.

Check HT.400 Pump manuals.

Turn control valve to “on” position.

Check hydraulic system troubleshootingand maintenance manuals.

-

PROBLEM CAUSES REMEDIES

Erratic delivery Improperly maintained bulk equipment

Improperly operated bulk equipment

Non-gross aerated bulk equipmentbeing used

Dirty throttling valve

Dry cementdischarging out ofvacuum breaker

Air in slurry

Hard-to-operatebutterfly valves

Cement buildup inmixer bowl

Wild fluctuation inrecirculation density(* -3 PPS)

Erratic delivery of dry cement

Vacuum breaker poppet not seating Check/clean/repair vacuum breakerproperly as required.

Improper slurry level in down holeside of tub

Maintain proper tub level.

Type of cement used

Air purging of cement

Vacuum leak at circulating pump seals

Cement buildup in valves

Improperly lubricated valves

Faulty valve Improper clean-up

Improper RCM II operation

Add de-foaming agent.

Check bulk equipment operation.

Replace or re-grease seals.

Clean thoroughly.

Lubricate properly.

Repair or replace valve.

Check and observe axial flow meterclean-up procedures.

Clean thoroughly.

Replace immediately.

Check RCM II operating procedures.

Check centrifugal pump systems.

Partially plugged jet

Eroded mixing jet

Improper RCM II operation

Low or no mixing or circulatingpressure

Excessive air entrainment

Faulty densometer

See “Air in slurry” problem above.

Circulating pump seals leaking onvacuum. Replace or re-grease seals.

Check densometer cable or repairdensometer.

Check bulk equipment maintenancemanual.

Check bulk equipment operation inSection 1 of this manual.

Addition of or repair of gross-aeration

cartridges in bulk tanks.

Clean throttling valve (See RCM IImaintenance procedures).

Check bulk equipment operationmanual.

‘. PROBLEM CAUSES REMEDIES

Recirculationdensometer and downhole densometerdon’t match

Excessive air entrainment in slurry

.4 to .5 ppg normal in some slurries.Down hole heavier

Either densometerreads 21 O-220 ppg

Water valve orcement throttlingvalve oscillateswith no command

Signal from densometer lost

Power card faulty or other problemin densometer

Faulty connection on feedbacksystem

Faulty feedback potentiometer

Some cement blends require addition ofdefoamer additive.

If not desirable, offset of recirculationdensometer to match down hole will makeboth read the same. ADC system willautomatically lower the density back to setpoint.

Check cables for good connections.

With power on, open actuator manually.Feedback voltage should read closed voltagewhen closed and gradually increase to openvoltage when fully open.

Refer to 278.98018 in Section 5 for pinlocations.

Have densometer repaired.

Check feedback wiring andconnection for looseness.

Automatic Density Control

Troubleshooting

1. No Reading (0 gpm) From Main Flowmeter:

A.B.CDE.F.GH.I.J.K.L.MN.0.PQR.

Main mix water valve closed.Clutch not engaged.Outside suction valve closed.Debris caught in flow meter.Seized bearings in flow meter.Magnetic Pick-up not adjusted.Auxiliary engine not running.Power take-off (mixing pump) not running.Plugged mix water manifold.Mix water master valve closed.Lost prime on mixing pump.Display power off (Display blank).Signal disconnected in junction box.Signal disconnected on back of ADC processor.ADC broken.Jet plugged.Incorrect flow meter factor entered.Erratic reading - Loose or improperly adjustedpickup on flowmeter.

2. No Reading (99.99 ppg) From Density Sensor:

A. Density sensor broken.

B. Cable disconnected.C. Calibration knob positioned incorrectly.D.ADC processor broken.E. Incorrect density/frequency calibration.F. Wires on back of ADC processordisconnected.

3. Bulk Cement Metering Valve Not

A. Automatic/manual switch in wrong position.B. Valve cemented in position.C. Hydraulic bypass valve open.D. Auxiliary diesel engine not at operating speed.E. Main hydraulic bypass valve open.F. Feedback potentiometer or signal cable

broken.G. Feedback potentiometer loose or adjusted

incorrectly.H. Parker positioner broken.I. ADC processor broken.J. 12V minimum power supply.K. Water flowmeter signal lost. (Cement valve will

not operate in AUTOMATIC position.) Will workin MANUAL position.

L. Hydraulic system faulty. Check pressure gaugewith main bypass closed. (1500 psi normal)

4. Water Throttling Valve not working:

A. Hydraulic bypass valveopen.

B. Auxiliary diesel engine not at operatingspeed.

C. Main hydraulic bypass valve open.D. Feedback potentiometer or signal

cable broken.E. Feedback potentiometer loose or adjusted

incorrectly.F. Parker positioner broken.G. ADC processor broken.H. 12V minimum powersupply.I. Hydraulic system faulty. Check pressuregauge with main bypass closed (1500 psinormal).

ADC System Spare Parts (for 1 Year’s Operation)

Part No. Qty. Description

458.50050 1 Dual DAC

458.50047 1 I/O power

70.23851 5 15A fuse

70.03916 2 Box of paper

Part No. Qty.

70.23664 5

458.70077 1

70.83682 1

Description

3A fuse

3-in. flow meter kit

Lithium battery

Hydraulic System Spare Parts

(For 1 Year’s Operation)

Part No. Qty. Description70.81458 3 Filter element

(For Extended Operation)

Part No. Qty. Description70.87230 1 Pump70.87219 1 Valve70.90836 1 Master valve

Axial Flow Mixer Spare Parts

(Recommended spare parts for 1 year) If water supply is typically sandy these additionalspare parts are recommended.

Lot Part No. Qty Description Lot Part No. Qty Description

3 70.34065 4 O-ring 7 412.15003 1 Water valve plate4 70.33215 4 O-ring 8 412.15004 1 Water orifice plate5 70.33233 4 Quad-ring9 70.33927 4 O-ringIO 412.15005 2 Water Jet12 412.15007 4 Spacer17 70.87306 4 O-ring

Parker Hydraulic Actuators (for ADC System)

Water Valve Actuator

Item

Parker Hydraulic

Seal Kit

Feedback Potentiometer

Item Halliburton P/N

Parker Hydraulic 70.87220

Seal Kit 70 87296

Linear FeedbackPotentiometer(internally mounted)

Electrical Connector

70 87298

70 87297

Halliburton P/N Vendor P/N

70 84839 Parker HTRI .8-090-Xx193-A18

70 87295 Parker SK-HTRI .8

70 52033 Bourns (no P/N)

Cement Valve Actuator

Vendor P/N

Parker HTR7.5.360.XXI g-A41

Parker SK-HTR7.5

Teknar 302-041-055

Teknar 302-008-027

Section 5Drawings

. . I

278.98014 lnstln - Equip - Std - Mix Module - RCMII-ADC - 8 bbl Alum Tub

Lot Part No. Qty Descrlptlon

1

23456789

1011121314151617181920212223242526272829303132333435363738394041

277.13136 1

13.0345 170.03485 270.29222 2

277.43302 2277.13037 2277.13163 1280.19535 1

70.62898 270.87344 170.35724 213.20234 212.50821 2

270.87669 113.20118 1

412.15018 170.32786 370.27155 170.26865 170.32914 870.43866 270.58959 870.27161 270.74922 SPEC

68.00101 SPEC70.62897 2277.01310 1277.43257 1277.01826 170.26732 270.26644 270.77872 470.87250 1277.48107 1277.48108 1277.48106 270.62899 2412.13553 1277.01809 1277.48111 1277.48112 1

TUB - MIXING - RECIRCULATION - LOWERED - 75TC4

VALVE - BUTTERFLY - BULKHEAD - 6-IN.MOTOR - HYDRAULIC - GEROTOR - 17.7 CIRLAMP - CLEAR - FLOOD - 12V - SEALEDAGITATOR - TURBINE – RCM II - 8-BBL.FLANGE - DRIVE - 73-2RX - TURBINEEXTENSION - BUTTERFLY VALVEHOUSING - BUTTERFLY VALVE EXT - 3.5WIRE - 18-GA. - STRANDED - WHITECLAMP - TUBING – 3/4 NOMPIN - COTTER - 5/32 X 1-1/4 - STL - PLPLATE - DETENT - 2-POSITIONHANDLE - OPERATING - 4-, 5-, AND 6-IN. WECOVALVE - BUTTERFLY - 6-IN. - MODIFIEDFLANGE - SOCKET WELD - 6-IN. BUTTERFLYMIXER ASSY - CEMENT – RCM II - WITHNUT - EYE - 5/8 TAP - 3600# - SAFE ADAPTER - HOSE - 900598-10S - PLUGADAPTER - HOSE - 202702-1OS-12s - STRNUT - HEX - 1/2-13NC - SPEC 70.32869SCREW - HEX CAP - l/2-13NC X 1-1/4WASHER - LOCK – 1/2 - STL - PLADAPTER - HOSE - 2062-10-12S - 90 DEGSPECIFICATION - WELDING - GROUPSPECIFICATION - COATING SYSTEMWIRE - 18-GA. - STRANDED - REDACTUATOR ASSY - AXIAL FLOW MIXER – RCM IIMOUNT - ACTUATOR - ADC – RCM IITUBE - HYDRAULIC - STNLS - NO. 12ADAPTER - HOSE - 2062-6-6s - 90 DEGADAPTER - HOSE - 2021-4-6s - STRADAPTER - HOSE - 210292-6S - 3/8-IN. ODVALVE - BALL - 1/4-IN. - 7250 PSITUBE - HYDRAULIC - NO. 6 - STNLS - ROTARYTUBE - HYDRAULIC - NO. 6 - STNLS - ROTARYTUBE - HYDRAULIC - NO. 6 - STNLS - ROTARYWIRE - 18-GA. - STRANDED - BLACKVALVE ASSY - 5-IN. - CEMENT THROTTLINGBRACKET - MOUNTING - AGITATOR - 2TUBE - HYDRAULIC - NO. 12 - STNLS - 8 BBLTUBE - HYDRAULIC - NO. 12 - STNLS - 8 BBL

278.98014 lnstln - Equip - Std - Mix Module – RCM II-ADC - 8 bbl Alum Tub

Lot Part No. Qty Description

42 70.84829 1 ACTUATOR - ROTARY - RACK AND PINION

43 277.01821 1 MANIFOLD - RECIRC - 3-IN. - INBOARD44 277.01822 1 MANIFOLD - RECIRC - 3-IN. - OUTBOARD46 277.01819 1 MANIFOLD - WATER - 3-IN. VIC NIPPLE47 11.7517 1 VALVE - BUTTERFLY - HALLIBURTON - 3-IN.48 70.44179 6 SCREW - HEX CAP - 3/8-16 X 2-3/449 70.26665 1 ADAPTER - HOSE - 2024-4-68 - 90 DEG 51

27.02618 6 COUPLING - VICTAULIC - 3-IN.52 277.01827 1 EXTENSION - STEM - PARTITION BUTTERFLY53 30.41076 1 NIPPLE - STD - 3 X 19 - VICTAULIC GR54 70.42597 1 ROD - THREADED - 7/16-20NF - STL55 70.32898 2 NUT - HEX JAM - 7/l 6-20NF - PL56 70.71036 2 BEARING - ROD END - FEMALE 7/16-2057 277.41033 2 SPACER - AGITATOR MOTOR - RCM TUB58 277.43064 4 GUARD - FLANGE - AGITATOR MOTOR- 75TC459 70.45565 8 SCREW - SELF DRILLING - 1/4-14 X 160 70.53474 1 ADAPTER - HOSE - 203005-6-6 6S61 277.01825 1 BUSHING - PLASTIC - 314 X 1.62 X 1IN.62 70.43895 3 SCREW - HEX CAP – 5/8-1 1 NC X 1-11463 70.58814 6 WASHER - FLAT - 5/8 NOMINAL - STL - .69 ID64 70.26364 4 ADAPTER - HOSE - 2071-6-6s - 90 DEG65 70.77796 3 ADAPTER - HOSE - 203003-6-6s - 3/8 OD66 70.58952 8 WASHER - LOCK - 5/16 - STL - PL67 70.58805 8 WASHER - FLAT - 5/16 NOMINAL - STL - 0.37568 70.32911 8 NUT - HEX - 5/16-18NC - PL69 70.43792 8 SCREW - HEX CAP - 5/16-18NC X 1 3/470 70.43816 27 SCREW - HEX CAP - 3/8-16NC X 1-1/471 70.32912 33 NUT - HEX - 3/8-16NC - PL72 70.58806 33 WASHER - FLAT - 3/8 NOMINAL - STL - 0.44 ID73 70.58955 27 WASHER - LOCK - 318 - STL - PL74 70.34028 2 O-RING - 90D - 2-2/8 X 2-5/8 X 1/875 412.15013 2 JET - RECIRCULATING - RCM II - WITH 3 X 2 REDUCING ELL76 70.71170 3 NOZZLE - SPRAY - l/4-IN. MALE NPT CONN77 70.83634 3 ADAPTER - HOSE - 2030-6-6s - TEE – 3/878 70.72607 1 ADAPTER - HOSE - 2033-6-68 - TEE79 70.26778 1 ADAPTER - HOSE - 2024-8-6s - 90 DEG80 70.26561 1 HOSE - I-WB - NO. 6 - SPEC 70.7197581 70.26916 10 FlTTlNG - HOSE - 411-6s - STR - SWIVEL82 4.2322 1 VALVE - BALL – 12-IN. - 1500 CWP83 70.23054 1 ADAPTER - HOSE - 2083-8-88 - STR84 277.43244 1 POINTER - VALVE POSITION - ADC - 75TC485 70.00029 2 ADAPTER - HOSE - 2071-12-128 - 90 DEG86 277.12019 1 HOUSING - BUTTERFLY VALVE EXTENSION87 277.01831 1 COVER - 8 BBL 2-COMPT RCM TUB - AXIAL FLOW MIXER88 11.03114 1 FLANGE - SOCKET WELD - 3 IN. BUTTERFLY VALVE89 13.0322 1 VALVE - BUTTERFLY - 5 IN. - GEN SER90 412.13532 1 CHANGEOVER - 5 IN. BTFLY - 5 IN. NUT91 70.43881 6 SCREW - HEX CAP - 1/2-13NC X 4 - PL92 70.32914 6 NUT - HEX - 1/2-13NC - SPEC 70.32869

NOTES: 278.98014 - INSTLN-EQUIP-STD-MIX MODULE-RCM II-ADC-8-BBLECL NW

1. Prior to mounting the hydraulic actuator (Loc 27) onto the mixing manifold,adjustment of the feedback potentiometer is required:

A. Remove the base cover plate (at bottom as shown in Detail H).B. Solder three 12-in. leads to the three terminals located on the potentiometer

found inside the feedback housing.

Terminal 1-18 ga. black wire (Loc 37)Terminal 2-18 ga. white wire (Loc 9)Terminal 3-18 ga. red wire (Loc 26)

C. Loosen the retaining screws securing the potentiometer body sothat it rotates freely.

D. Remove the four mounting bolts that attach the feedback housing to the actuatorbody. Then, gently rotate the housing to orient the conduit port opposite of the end portsin the caps. Do not lift of pull on the housing or potentiometer in any way. Once thehousing is positioned correctly, re-install the four mounting bolts and secure.

E. With actuator oriented as shown in Detail H, rotate shaft fully clockwise.

F. Attach a volt-ohm meter to the red (Terminal 3) and white (Terminal 2) wires. With theactuator in the full clockwise position, the resistance should read 860 ohms +/- 50 ohms.If not, gently rotate the potentiometer body until the resistance is correct.

G. Secure the potentiometer position by tightening the retaining screws.

H. Place the wire leads inside the feedback housing and re-install the basecover plate.

2. Match drill 0.406 (13/32) Holes.3. Rotate cylinder caps as shown. C2 ports on top & C1 ports on bottom.

278.98023 lnstln - Kit - Retrofit - UNI-PRO II and...

Loc Part No. Qty Description

123456789

101112131415161718192021

22232425262728293031

3233

3435

3637383940

4142434445

458.3011870.1762670.1603670.1191370.8789970.8810170.1130870.0845470.0572370.3321970.0574470.0335070.7101370.0572070.7068770.7410570.0853670.0849270.0840930.1300470.8067670.0849570.3563870.0335070.0572070.0574070.05745

70.05743 70.12012 70.12013 70.12014 70.12023

70.12015 70.12016

70.1202070.80375277.43070277.43171458.81348281.10569277.4317170.07628458.81194458.81193

111141126441212211111211111112222221002111PRNT1222458.98000

JUNCTION BOX - AUTOMATIC DENSITYCONNECTOR - MS31 06A-1OSL-4S - PLUGCLAMP - CABLE - M85049/41-4A - CANNONCABLE - 2 NO. 18 - RUBBER COVER - 1702STRIP - TERMINAL - COMPACT - KL16/4JUNCTION BOX - CONDULET - EXP PRFBUSHING - CONDUIT - 1 X 3/4GLAND - CABLE - EEXE - F/WIRE BRAIDGLAND - CABLE - EEXE - F/WIRE BRAIDNUT - LOCK - CONDUIT FlTTlNG – 1/2GASKET ASSEMBLY - SEALING - STEEL BACKEDCABLE - 1 PR18 - EXANE ARMOREDCABLE - 6 - NO. 18-GA. COND - SPECCABLE - 3 NO. 18 - EXANE ARMOREDCONNECTOR - CABLE - MS TYPE 14S-6sCONNECTOR - LEXAN CORD GRIP TO BOXCONNECTOR - MOLDED - 3-CONDUCTORJUNCTION BOX - CONDULET - EXP PRFCOUPLING - FLEXIBLE - EXPLOSION PROOFNIPPLE - STD - 112 X AT - BW - A120BODY - CONDUIT OUTLET - W/GASKETPLUG - PIPE - l/2-IN. NPT - SQUARE HEADPICKUP - FLOW METER - 3030 ANCABLE - 1 PR18 - EXANE ARMOREDCABLE - 3 NO. 18 - EXANE ARMOREDGLAND - CABLE - EEXE - F/WIRE BRAIDGASKET ASSEMBLY - SEALING - STEEL BACKEDLOCKNUT - CONDUIT - STL - 1-1/4-IN.MARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER -WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER -WIRE - VINYL CLOTHTERMINAL - PIN - 18-22-GA. - PV18-P47PANEL - COVER - CUTOUT - TDRAD - 10.28PANEL ASSEMBLY - CONTROL STAND - UNI-PRO IIMODULE - POWER FILTER - 12VDCBRACKET - POWER FILTER - UNI-PRO PANELASSEMBLY - CONTROL STAND - UNI-PRO IIRELAY - SOLID STATE - SPST - NO - 20CABLE ASSEMBLY - FLOW - UNI-PRO - 15 FTCABLE ASSEMBLY - PRESSURE - UNI-PROCABLE ASSEMBLY - 5 PIN AND SPADE LUGS

278.98023 lnstln - Kit - Retrofit - UNI-PRO II and...

Loc Part No. Qty Description

46 70.70692 1 RECEPTACLE - FLANGED - MS TYPE 14S-5s47 254.00156 1 SWITCH - PUSH BUT-TON - MOMENTARY48 278.98023 PRNT INSTLN-KIT-RETROFIT-UNI-PRO II AND49 277.43099 1 NAME PLATE - POWER F/ELECTRONIC50 70.09607 1 BLOCK - TERMINAL JUNCTION - 6-POST51 70.70690 1 RECEPTACLE - FLANGED - MS TYPE 14S-6P52 70.12591 2 CAP AND CHAIN - DUST - NO. 14

NOTES: 278.98023 - INSTLN - KIT-RETROFIT-UNI-PRO II AND ECLA

1. Twist these wires,

2. Mount Lot 42 inside of control stand in proximity of power filter.

278.98018 lnstln - Wiring - ADC - RCM II - 8 bbl - 75TC4

Loc Part No. Qty Description

1 458.30118 1 JUNCTION BOX - AUTOMATIC DENSITY2 70.17626 1 CONNECTOR - MS31 06A-1 OSL4S - PLUG3 70.16036 1 CLAMP - CABLE - M85049/41-4A - CANNON4 70.11913 1 CABLE - 2#18 - RBR COVER - 17025 70.87899 3 STRIP - TERMINAL - COMPACT - KLl6/46 70.88101 1 JUNCTION BOX - CONDULET - EXP PRF7 70.12025 1 BUSHING - CONDUIT - 1 X 1/2 - CLASS I8 70.84142 1 BUSHING - CONDUIT - 3/4 X 1/2 - CROUSE9 70.05723 8 GLAND - CABLE - EEXE - F/WIRE BRAID

10 70.33219 4 NUT - LOCK - CONDUIT FlTTlNG - 1/211 70.05744 4 GASKET ASSY - SEALING - STEEL BACKED12 70.03350 1 CABLE - lPR18 - EXANE ARMORED &13 70.71013 2 CABLE - 6 - #18 GA COND - SPEC14 70.05720 1 CABLE - 3#18 - EXANE ARMORED &15 70.70687 2 CONNECTOR - CABLE - MS TYPE 14S-6S16 70.74105 2 CONNECTOR - LEXAN CORD GRIP TO BOX17 70.08536 1 CONNECTOR - MOLDED - 3 CONDUCTOR18 70.08492 1 JUNCTION BOX - CONDULET - EXP PRF23 70.35638 1 PICKUP - FLOW METER - 3030 AN24 70.03350 1 CABLE - lPR18 - EXANE ARMORED &25 70.05720 1 GABLE - 3#18 - EXANE ARMORED &27 70.05745 1 GASKET ASSY - SEALING - STEEL BACKED28 70.05743 1 LOCKNUT - CONDUIT - STL - 1-1/4 IN29 70.12012 1 MARKER - WIRE - VINYL CLOTH36 70.02371 100 TERMINAL - PIN -CRIMP - 18 AWG (1 SQ

277.437 77 Panel Assembly - Control Stand - UNI-PRO II

Lot

1 458.50019 12 70.92280 43 70.92274 24 70.92275 35 70.92883 46 70.08486 27 70.92276 18 70.79016 29 70.23664 1

10 70.2385 1 111 458.30109 112 70.05740 213 70.05743 214 70.05755 115 70.32706 216 70.44125 417 458.31050 118 458.31060 119 70.33065 220 70.58791 221 70.12052 122 70.12055 123 70.12047 124 70.12046 125 70.12014 226 70.12013 127 70.12058 128 70.12059 129 70.12048 230 70.12015 231 70.12022 232 70.12016 233 70.12020 234 458.50083 135 70.05745 136 70.02371 6037 70.02372 12

Part No. qty Description

BASIC ASSEMBLY - UNI-PRO II - DIGITALOPERATOR - SWITCH - 2-POSITIONOPERATOR - POTENTIOMETER - COMPACTBLOCK - CONTACT - NORMALLY CLOSEDBLOCK - CONTACT - NORMALLY OPEN - LOWPOTENTIOMETER - 10000 OHM - 10 TURNBLOCK - CONTACT - NORMALLY OPEN - LOWHOLDER - FUSE - PANEL MOUNTINGFUSE - 3A - 250V - 3AGFUSE - 15ASTRIP - TERMINAL - BUSSED - 600VGLAND - CABLE - EEXE - F/WIRE BRAIDLOCKNUT - CONDUIT - STL - 1 -1/4-IN.CABLE - 1OPR18 - BRONZE ARMOREDNUT - ELASTIC STOP - 10-24NC - HEAVYSCREW - FIL HD MACH - NO. 10-24NC X 5/8PANEL - CONTROL STAND - CEMENTINGBRACKET - MOUNTING - CABLE GLANDNUT - HEX - 10-24NC - STNLSWASHER - FLAT - NO. 10 - STNLSMARKER -WIRE - VINYL CLOTH - SOLIDMARKER -WIRE - VINYL CLOTH - SOLIDMARKER -WIRE - VINYL CLOTH - SOLIDMARKER - WIRE - VINYL CLOTH - SOLIDMARKER - WIRE - VINYL CLOTHMARKER -WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTH - SOLIDMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHMARKER - WIRE - VINYL CLOTHFIRMWARE - UNI-PRO II - ADCGASKET ASSEMBLY - SEALING - STEEL BACKEDTERMINAL - PIN - CRIMP - 18 AWG (1 SQTERMINAL - PIN - CRIMP - 16 AWG (1.5

NOTES: - 277.43171 PANEL ASSEMBLY - CONTROL STAND - UNI-PRO II ECL C

1. This component will be mounted later. Place the appropriate wire on existing components leaving 4 feet free.Label the wires.

2. Install firmware (Loc 34) into CPU card (458.50036) positions U9 and U10. CPU card is inside UNI-PRO II(Loc 1).

3. Mark all the wires with the number of the terminal to which it hooks.

278.98022

Lot

lnstln - Kit - Retrofit - Hydraulic System

Part No. Qt Description

123456789101112131415161718192021222324252627282930313233343536373839404142434445

70.26586 1 HOSE - M-WB - 272-8 - 0.500 ID X 0.96970.93943 3 KIT - BOLT - PARKER DO1 SUBPLATE VALVE70.26844 2 FITTING- HOSE - 320-8-8s - STR70.81459 1 FILTER - HYD - INLINE - 3000 PSI - 370.87219 2 VALVE - HYDRAULIC - PROPORTIONAL70.83793 1 VALVE - RELIEF - 0 TO 25 GPM - 150 - 600070.90836 1 VALVE - HYDRAULIC - DIRECTIONAL - DO170.27129 1 ADAPTER - HOSE - 2024-16-12s - 90 DEG70.26738 2 ADAPTER - HOSE - 2062-12-12s - 90 DEG70.26732 17 ADAPTER - HOSE - 2062-6-68 - 90 DEG

70.26797 2 ADAPTER - HOSE - 202702-12-12s - STR 70.74534 1 ADAPTER - HOSE - 2080-12-12s - TEE 70.27020 1 ADAPTER - HOSE - 2216-12-12s - STR 70.74727 1 ADAPTER - HOSE - 2083-12-8s - STR 70.27012 1 ADAPTER - HOSE - 2021-12-8s - STR 70.82424 1 ADAPTER - HOSE - 2028-8-88 - TEE 70.23066 1 ADAPTER - HOSE - 2083-12-12s - STR 70.80099 1 ADAPTER - HOSE - 203301-12-12s - 314 70.43538 1 SCREW - HEX CAP - 3/8-24NF X 1-1/4 70.83636 6 ADAPTER - HOSE - 202702-8-6s - STR 70.26883 1 ADAPTER - HOSE - 2085-12-12s - 90-DEG277.48050 1 BRACKET - MOUNTING - PROPORTIONAL 441.3068 1 GAUGE - PRESSURE - 0 TO 3000 PSI 70.72783 1 ADAPTER - HOSE - 2090-12-12s - TEE 70.72019 1 ADAPTER - HOSE - 221501-8-6s - STR 70.72279 1 ADAPTER - HOSE - 2033-8-88 - TEE 70.75924 1 ADAPTER - HOSE - 2024-12-6s - 90-DEG 70.26858 1 ADAPTER - HOSE - 2024-12-8s - 90-DEG 70.90394 1 ADAPTER - HOSE - 2081-16-12s - STR 70.26362 1 ADAPTER - HOSE - 2022-4-65 - STR 70.26588 1 HOSE - M-WB - 272-6 - 0.375 ID 70.26784 14 FlTTlNG - HOSE - 320-6-68 - STR 70.27155 1 ADAPTER - HOSE - 900598-10S - PLUG 70.06576 2 ADAPTER - HOSE - 2062-10-6s - 90 DEG 70.26587 1 HOSE - M-WB - 272-12 - 0.750 ID 70.26690 2 FITTING- HOSE - 320-12-12s - 3/4 OD 70.26359 1 ADAPTER - HOSE - 2071-8-8s - 90 DEG 70.26608 1 ADAPTER - HOSE - 202702-10-6s - STR 70.26364 1 ADAPTER - HOSE - 2071-6-68 - 90 DEG 70.43784 4 SCREW - HEX CAP - 5/l 6-18NC X 314 - PL 70.26561 1 HOSE - 1-WB - NO. 6 - SPEC 70.71975 70.26916 4 FITTING - HOSE - 411-6s - STR - SWIVEL 70.26563 1 HOSE - 1 -WB - NO. 8 - SPEC 70.71975 70.26917 6 FITTING - HOSE - 411-8s - STR - SWIVEL 70.26565 1 HOSE - 1-WB - NO. 12 - SPEC 70.71975

278.98022

Loc Part No.

46 70.26937 2 FITTING - HOSE - 411-12s - STR47 70.87240 1 MANIFOLD - 3-STATION - DO3 - PARALLEL48 70.87230 1 PUMP - HYDRAULIC - PRESSURE49 102.27501 1 GASKET - 5188755 - GM50 102.27502 1 ADAPTER - 5122386 - CAM - GM51 102.27534 1 SPROCKET - HYD PUMP DRIVE - GM CAM52 102.27512 4 BOLT - 5145092 - DRIVE PLATE - GM53 102.27492 1 COUPLING - 5143616 - 21T - GM54 102.27515 1 DISC - DRIVE - GEN - GM 517045055 102.27495 1 SPACER - 5177026 - CAM - GM56 102.77856 1 GASKET - 5104506 - AIR COMPRESSOR MOUNTING57 70.35692 1 PIN - COTTER - 3/32 X 1-1/2 - STL - PL58 4.712 1 VALVE - SHUT-OFF - BARKSDALE59 278.98022 PRNT INSTLN-KIT-RETROFIT-HYDRAULIC SYSTEM

lnstln - Kit - Retrofit - Hydraulic System

Qty Description

NOTES: 278.98022 - STLN-KIT-RETROFIT-HYDRAULIC SYSTEM ECLA

1. Connect hoses to control stand bulkhead adapters as indicated by the numbers in these boxes.2. Bend Cotter pin back so that Loc 51 will fit into Loc 53.

458.50019 Basic Assembly - UNI-PRO II - Digital

Loc Part No. Qty

12345678910111213141516171819202122232425262728293031

458.50029 1 ENCLOSURE ASSEMBLY -W/TERMINATION BOARD458.00390 1 KEYBOARD ASSEMBLY - UNI-PRO II458.50027 1 CABLE ASSEMBLY - 4-PIN DISCRETE - BOARD458.50036 1 CIRCUIT ASSEMBLY - MICROPROCESSOR - 68K458.50040 1 CIRCUIT ASSEMBLY - RAM - 256K - LITHIUM458.50044 1 CIRCUIT ASSEMBLY - Z80 ILAN - 68K458.50047 1 CIRCUIT ASSEMBLY - INPUT/OUTPUT/POWER458.50050 1 CIRCUIT ASSEMBLY - POWER - 68K - 4-FLOW 70.08591 6 SCREW - HEX SOC - NO. 4-4OUNC X 3/8 70.45604 45 SCREW - BIND HD - NO. 6-32NC X 1/4 70.45605 16 SCREW - BIND HD - NO. 4-40UNC X 3/4 458.50020 1 CABLE ASSEMBLY - 26-PIN - DISPLAY TO CPU 70.58993 16 WASHER - LOCK - NO. 4 - INT - STNLS 458.50051 2 RETAINER - CARD - UNI-PRO II 70.10305 1 GASKET - CORK/RUBBER - 3/32 THICK 458.50022 1 FIRMWARE - UNI-PRO II - 089/68000 458.50023 1 LABEL - FIELD TERMINATION - REAR PANEL 458.50024 SPEC SPECIFICATION - TEST - PROCESSOR BOX 458.50025 SPEC SPECIFICATION - ASSEMBLY - UNI-PRO II 458.50061 1 FIRMWARE - LOCAL AREA NETWORK 70.04942 1 DISPLAY - MODULE - 4 LINES X 20 458.50056 2 BAR - BACKUP - KEYBOARD MTG - UNI-PRO 458.50057 2 BAR - BACKUP - KEYBOARD MTG - UNI-PRO 70.10702 2 SPLICE - LINE - LUG - SPADE - 0.187W 70.10698 2 LUG - SPADE - RECEPTACLE - 187 SERIES 70.20052 1 LICENSE - KERNEL - OS-9/68000 70.59267 2 WEATHERSTRIP - 3/8 X 5/16 - DOR-TITE 458.83916 1 CABLE ASSEMBLY - 26-PIN RIBBON - 1.25-IN. 458.50064 1 CIRCUIT ASSEMBLY - RAM - 512/i 024K 458.50071 2 BAR - FRONT - KEYBOARD MOUNTING - UNI-PRO 458.50072 2 BAR - FRONT - KEYBOARD MOUNTING - UNI-PRO

412.13553 Valve Assembly - 5-in. - Cement Throttling

Lot Part No. QtY Description

123456789

101112131415161718192021222324252627282930313233343536373839404142

412.13366 1412.13454 1412.13372 1412.13457 1412.13359 1 70.19380 1 70.42179 1 70.36016 1 54.20305 2 70.33893 2 70.43766 4 70.58951 4412.13552 1 70.44786 1412.13554 1 70.43804 2 70.58955 2 70.87220 1 70.43373 2 70.30006 2 497.1412 1 497.1413 1 70.33997 1 70.22911 1412.13459 1 9.10941 1 38.081 1 36.01 1 70.34020 1 22.8 1412.13546 1 70.24626 1 70.00042 1 70.27084 8 70.26732 8 70.26644 4 70.77872 4 70.87250 1277.48105 2277.48109 1277.46110 1 70.74922 SPEC

HOUSING - 5-IN. CEMENT THROTTLINGBONNET - VALVE -THROTTLING -5-IN.PLUG - 5-IN. CEMENT THROTTLING VALVEHUB - ADAPTER - 5-IN. CEMENTWASHER - THRUST - TEFLON - 5-IN.COUPLING - V-BAND - 5-1/2-IN.RING - RETAINING - 5108-112 - EXTPIN - ROLL - 59-040-187-0625 - 3/16STL-SQ-CF-C1018- 114O-RING - TEFLON - 5-l18 X 4-7/8 X 1/8SCREW - HEX CAP - 1/4-20NC X 1 - PLWASHER - LOCK - 114 - STL - PLINDICATOR - POSITION - 5-IN. CEMENTSCREW - SET - 1/4-20NC X 518 - CUP PTPOINTER - POSITION - 5-IN. CEMENTSCREW - HEX CAP - 3/8-16NC X 1/2 - PLWASHER - LOCK – 3/8 - STL - PLACTUATOR - ROTARY - RACK AND PINIONSCREW - HEX SOC - 3/8-16NC X 1PIN - SPRING - 5/16 X 112 LG - STEELMALE HALF - 5-1/2 - SOCKET WELDNUT - WING - HALLIBURTON - 5-1/2O-RING - 90D - 6 X 5-1/2 X 1/4FlTTlNG - GREASE - 1/8-27 NPT - STRBODY - VACUUM BREAKER -5-IN.POPPET ASSEMBLY - REPLACEMENT - 2-IN. NO. 300UNION - WING - 1-1/2 - 2000# TESTPLUG - BULL - 1-1/2 - STL - HEX HDO-RING - 90D - 1-7/8 X 1-5/8 X 1/8ELL - STREET - 90 DEG - 1-1/2 - 150 LBHANDLE - TEE - V BAND CLAMP - JETGREASE - SPECIAL AUTO-MARINEADHESIVE - SILASTIC - BLACKADAPTER - HOSE - 900598-69 - PLUGADAPTER - HOSE - 2062-6-6s - 90 DEGADAPTER - HOSE - 2021-4-6s - STRADAPTER - HOSE - 210292-69 - 3/8 ODVALVE - BALL - l/4-IN. - 7250 PSITUBE - HYDRAULIC - NO. 6 - STNLS - ROTARYTUBE - HYDRAULIC - NO. 6 - STNLS - ROTARYTUBE - HYDRAULIC - NO. 6 - STNLS - ROTARYSPECIFICATION - WELDING - GROUP

NOTES: 412.13553 VALVE ASSEMBLY - 5-IN. - CEMENT THROTTLlNG ECL B

1. Mount plug (Loc 3) to hub (Loc 4), then rotate hydraulic actuator (Loc 18) through fullrotation. Check that plug rotates from fully closed to fully open in continuous sweep. (i.e.actuator limits should not cause plug to stop partially open or partially closed). If plug is notoriented correctly, remove and rotate plug 90 degrees, reassemble and repeat checkprocedure.

2. Remove retaining nut on Loc 6 and replace with T-handle nut (Loc 31).3. Check that position nameplate on Loc 13 is oriented correctly with valve plug.4. Pack this area between O-ring (Loc 29) and actuator (Loc 18) with grease (Loc

32).5. Coat surface between actuator (Loc 18) and bonnet (Loc 2) with silastic (Loc 33).6. Coat O-rings with grease (Loc 32) - O-rings only.7. Tag with: 412.13553 - current change letter.8. Replace plastic port plugs in Loc 18 with steel plugs (Loc 34) for contamination

protection.

277.01300 Kit - Retrofit- Axial Flow Mixer to 2=Compartment, 8-bbl RCM

Loc Part No. QtyDescription

These parts nut on print files print1. 412.15004 0 MIXER ASSEMBLY - CEMENT - RECIRCULATING2. 277.43301 0 FRAME - MOUNTING - MIXER - RCM II - 83. 277.43302 0 AGITATOR - TURBINE - RCM II - 8-BBL.4. 277.43303 0 PLATE - COVER - FRAME - RCM II MIXER5. 277.43304 0 SPACER - POLYETHYLENE - RCM II MIXER6. 277.43305 0 GASKET - FRAME - RCMII MIXER - 8-BBL.7. 277.43306 0 PLATE - MOUNTING - AGITATOR MOTOR - 88. 277.43307 0 SHIELD - SPLASH - AGITATOR SHAFT - 89. 277.43308 0 GUARD - FLANGE - AGITATOR MOTOR - 810. 277.43309 0 SPACER - POLYETHYLENE - MOUNTING PLATE11. 70.441 87 0 SCREW - HEX CAP -3/8-16 X 1-1/212. 70.33238 0 NUT - HEX - 3/8-16NC - COATED13. 70.58003 0 WASHER - FLAT - 3/8 - COATED14. 70.58006 0 WASHER - LOCK - 3/8 - COATED15. 70.44188 0 SCREW - HEX CAP -7/16-14X 1-1/416. 70.33240 0 NUT - HEX - 7/16-14NC - COATED17. 70.58014 0 WASHER - LOCK - 7/16 - COATED18. 70.58809 0 WASHER - FLAT - 7/16 NOM - STL - 0.5 ID19. 70.64201 0 YOKE - END - 7/l 6 X 7/16 - CD-PL20. 70.36037 0 PIN - YOKE - 7/l6 X 1-1/4 - OA LENGTH21. 70.35691 0 PIN - COTTER - 3/32 X 1 - STL - PL22. 70.32898 0 NUT - HEX JAM - 7/l6-20NF - PL23. 70.32973 0 NUT - HEX JAM - 3/8-24NF - PL24. 70.42643 0 BEARING - ROD END - 0.38B - 3/8-24 RH25. 412.13368 0 DRIVE - WORMGEAR -5-IN. CEMENT26. 277.13077 0 WHEEL - HAND – 1.0 B - 12.0 DIA27. 70.42597 0 ROD - THREADED - 7/l6-20NF - STL28. 70.43760 0 SCREW - HEX CAP - l/4-20NC X 112 - PL29. 412.13362 0 INDICATOR - POSITION - 5-IN. CEMENT30. 70.44786 0 SCREW - SET - 1/4-20NC X 5/8 - CUP PT31. 412.13369 0 POINTER - POSITION - 5-IN. - CEMENT32. 277.83064 0 ARM - LINKAGE - ACTUATOR - MIX WATER33. 277.83065 0 BRACKET - GEAR BOX - RCM II – CMR100R34. 70.43868 0 SCREW - HEX CAP - 1/2-13NC X 1-1/235. 70.32914 0 NUT - HEX - 1/2-13NC - SPEC 70.3286936. 277.27000 0 WASHER - FLAT – 1/2 - TEFLON - 1-3/837. 70.43862 0 SCREW - HEX CAP - 1/2-13NC X 3/4 - PL38. 70.26922 0 FITTING - HOSE - 401-4B - SWIVEL39. 940.00506 0 Y - TRUE - VICTAULIC - 3-IN.40. 27.02642 0 COUPLING - VICTAULIC - 5-IN. - STYLE41. 27.02618 0 COUPLING - VICTAULIC - 3-IN.42. 27.02621 0 COUPLING - VICTAULIC - 2-IN. - STYLE43. 277.01300 0 KIT - RETROFIT - AXIAL FLOW MIXER TO44. 70.42597 0 ROD - THREADED - 7/16-20NF - STL45. 30.41036 0 NIPPLE - STD - 3 X 3-1/2 - LIQUID46. 70.25009 0 STRAINER - Y-TYPE - 3-IN. NPT47. 22.8 0 ELL - STREET - 90-DEG - 1-1/2 - 150#48. 30.29002 0 NIPPLE - STD - 1-1/2 X AT50 8 7473 0 VALVE - BALL - 1 -1/2 - 600 PSI - FPTend of additional parts

277.01300 Kit - Retrofit- Axial Flow Mixer to 2-Compartment, 8-bbl RCM

Loc Part No. qty Description

101 277.43302 2 AGITATOR - TURBINE - RCM II - 8-BBL.102 280.19535 1 HOUSING - BUTTERFLY VALVE EXT - 3.5103 9.78049 1 EXTENSION - STEM - 5-IN. - SELF104 277.13077 1 WHEEL - HAND - 1.0 B - 12.0 DIA105 277.01809 1 BRACKET - MOUNTING - AGITATOR - 2106 277.01821 1 MANIFOLD - RECIRC - 3-IN. - INBOARD107 277.01822 1 MANIFOLD - RECIRC -3-IN. – OUTBOARD108 277.01820 1 MANIFOLD - WATER - 3-IN. - 8-BBL.109 277.01819 1 MANIFOLD - WATER - 3-IN. VIC NIPPLE110 11.7517 1 VALVE - BUTTERFLY - HALLIBURTON - 3-IN.111 30.41080 1 NIPPLE - STD - 3 X 12-1/2 - GR AND GR112 277.83066 1 STRAINER - MIX WATER ASSEMBLY – RCM113 277.01827 1 EXTENSION - STEM - PARTITION BUTTERFLY114 277.41033 2 SPACER - AGITATOR MOTOR - RCM TUB115 277.01824 1 MOUNT - U BOLT - RECIRC MANIFOLD116 277.01823 2 MOUNT - U BOLT-WATER MANIFOLD117 277.26298 1 MANIFOLD - DISCHARGE - REDUCER SECT - 6X5118 412.15018 1 MIXER ASSEMBLY - CEMENT – RCM II - WITH201 70.24628 2 GROMMET - SPLIT – 3/4 OD TUBING202 70.51613 4 STUD - STACKING - F/C1-32 AND C3-32203 70.12485 4 CLAMP - TUBING - END - 1/4-1-IN. OD204 70.32914 14 NUT - HEX - 1/2-13NC - SPEC 70.32869205 70.43866 6 SCREW - HEX CAP - 1/2-13NC X 1-1/4206 70.58959 14 WASHER - LOCK - 1/2 - STL - PL207 70.27161 4 ADAPTER - HOSE - 2062-10-12s - 90 DEG208 277.43257 1 MOUNT - ACTUATOR - ADC - RCM II209 412.13368 1 DRIVE - WORMGEAR -5-IN. CEMENT210 277.01826 1 TUBE - HYDRAULIC - STNLS - NO. 12211 412.13362 1 INDICATOR - POSITION - 5-IN. CEMENT212 412.13369 1 POINTER - POSITION - 5-IN. - CEMENT213 277.83064 1 ARM - LINKAGE - ACTUATOR - MIX WATER214 70.44786 1 SCREW - SET - l/4-20NC X 5/8 - CUP PT215 9.78221 1 HANDLE - OPERATING - 2 AND 3-IN. - MODEL216 277.01810 1 TUBE ASSEMBLY - NO. 12 - STNLS - RCM II217 277.01818 1 TUBE ASSEMBLY - NO. 12 - STNLS - RCM II218 27.02618 8 COUPLING - VICTAULIC - 3-IN.219 70.42597 1 ROD - THREADED - 7/l 6-20NF - STL220 70.32898 2 NUT - HEX JAM - 7/16-20NF - PL221 70.71036 2 BEARING - ROD END - FEMALE 7/16-20222 277.43064 4 GUARD - FLANGE - AGITATOR MOTOR- 75TC4223 70.45565 8 SCREW - SELF DRILLING - 1/4-14 X 1

277.01300 Kit - Retrofit- Axial Flow Mixer to 2=Compartment, 8-bbl RCM

Loc Part No. Qty

224225226227228229230231232233234235236237238239240241242243244245

277.01825 1 BUSHING - PLASTIC - 3/4 X 1.62 X 1-IN.70.10978 4 BOLT - U - 1/2-13NC - 2 X 5.00070.58952 8 WASHER - LOCK - 5/16 - STL - PL70.58805 8 WASHER - FLAT - 5/16 NOM - STL - 0.37570.32911 8 NUT - HEX - 5/l6-18NC - PL70.43792 8 SCREW - HEX CAP - 5/16-18NC X 1-3/470.43816 23 SCREW - HEX CAP - 3/8-16NC X 1-1/470.32912 23 NUT - HEX - 3/8-l6NC - PL70.58806 23 WASHER - FLAT - 3/8 NOM - STL - 0.44 ID70.58955 23 WASHER - LOCK - 3/8 - STL - PL

441 .I054 1 GAUGE - PRESSURE - 0 TO 100 PSI - 3-1/225.3004 3 BUSHING - HEX - 3/8 X 1/4 - Cl 70.71170 3 NOZZLE - SPRAY – 14-IN. MALE NPT CONN70.83634 3 ADAPTER - HOSE - 2030-6-6s - TEE - 3/870.72607 1 ADAPTER - HOSE - 2033-6-6s - TEE

70.26778 1 ADAPTER - HOSE - 2024-8-6s - 90-DEG 70.26561 1 HOSE - 1-WB - NO. 6 - SPEC 70.71975 70.26916 10 FITTING - HOSE - 411-6s - STR - SWIVEL 4.2322 1 VALVE - BALL - 1/2-IN. - 1500 CWP 70.23054 1 ADAPTER - HOSE - 2083-8-88 - STR 70.74922 SPEC SPECIFICATION - WELDING - GROUP 277.01300 PRNT KIT - RETROFIT - AXIAL FLOW MIXER TO

NOTES: - KIT-RETROFIT-AXIAL FLOW MIXER TO P-COMPARTMENT, 8-BBL RCM

1. This kit will retrofit the axial flow mixer to an 8-bbl, 2compartment tub.

General Procedure for Installation

A. Remove all manifolding and components from the top of the tub.B. Install agitator mount, agitators and hydraulic piping.C. Install the mixer assembly and water valve actuator.D. Install the piping (water and slurry recirculation) components.E. Install the cement throttling valve.F. Fabricate and install the piping from the water pump to the water manifold on the tub. Fabricate and install

the piping from the recirculation pump to the 5-in. X 3-in. ‘Y” on the tub.

2. Operation - The operation of the axial flow mixer is very similar to the standard RCM. The exception is thesingle water metering valve on the axial flow mixer which replaces the mixing water valve, by-pass valve andtouch-up valve on the standard RCM. Cleanup should also be similar to the standard RCM with the addition oflifting up the vent flap on the splash sheath and washing up inside the sheath.

Note: Sheath water jet piping on Sheet 6 of 6. Valve (Loc 242) should be open anytime mixing is in processto control dusting and keep sheath clean.

3. Packaging - Package the kit in crating suitable for ocean freight shipping. Group 200 Series part numberstogether in one box. Include group 100 Series parts and group 200 Series box into a second box as finalshipping package. Identify with plainly marked pan number and current change letter.

4. Match drill 0.406 (13/32)holes.

5.Seal between bolt heads and RCM tub with silasticsealant.

6. Match drill 0.56 diameter (9/l6) holes.

This is not on print from print files

7. The kit does not provide the necessary manifold modifications. It will benecessary to construct a new slurry line to run from the discharge of the recirculatingpump to both 2-in. victaulic slurry inlets on the mixer.

It also will be necessary to construct a water line from the master water valve to the waterinlet. The following steps are recommended:

A. Slurry manifold The manifold should start off from the pump discharge and “Y” into two 3-in. lines. One of the 3-in. lines can be used to mount a 3-in. low-pressure radioactivedensometer. Each 3-in. slurry line should reduce to a 2-in. line as close as possible to themixer.The two 2-in. lines will connect to two 2-in. victaulic nipples onthe mixer.

B. Mixing water manifold The line should start at the outlet of the master water valve andconnect to 3-in. victaulic water inlet on the mixer. If the unit does not have a masterwater valve one should be installed because the valve plate on the mixer will not stopthe water flow totally.

8. Install the cement throttling valve to the top of the mixer.

9. Kit to be crated for ocean freight transportation. Components to be segregatedand boxed according to the following groupings to provide uniform packing for fieldpersonnel installing the kits.

Group A - Lot’s 1-10, 39-43Group B - Lot’s 25-38Group C - Lot’s 1 1-24

Locate group B and C boxes in group a box.

412.13367 Valve Assembly - 5in. - Cement Throttling

Loc Part No.

1 412.133662 412.1

33643 412.133654 412.133635 412.133596 412.133687 412.133698 412.133629 70.1938010 54.2030511 70.3402012 70.4226913 70.3601614 70.3389315 70.4376616 . 70.5895117 70.4478618 70.4343619 70.3000620 497.141221 497.141322 70.3399723 70.2291124 412.1345925 9.1094126 38.08127 36.01

Qty

111111111211124412211111111

Description

HOUSING - 5-IN. CEMENT THRO-ITLINGPLUG - 5-IN. CEMENT THROTTLING VALVEBONNET - 5-IN. CEMENT THROTTLING VALVEHUB - ADAPTER - DURST WORM GEARWASHER - THRUST - TEFLON - 5-IN.DRIVE - WORMGEAR -5-IN. CEMENTPOINTER - POSITION - 5-IN. - CEMENT INDICATOR - POSITION - 5-IN. CEMENTCOUPLING - V-BAND - 5-1/2-IN.STL-SQ-CF-C1018- 1/4O-RING - 90D - 1-7/8X 1-5/8 X 1/8RING - RETAINING - 5100-125 - EXTPIN - ROLL - 59-040-187-0625 - 3/16O-RING - TEFLON - 5-1/8 X 4-7/8 X 1/8SCREW - HEX CAP - 1/4-20NC X 1 - PLWASHER - LOCK – 1/4 - STL - PLSCREW - SET - 1/4-20NC X 5/8 - CUP PTSCREW - HEX SOC - 1/2-13NC X 3/4PIN - SPRING - 5/16 X 1/2 LG - STEELMALE HALF - 5-1/2 - SOCKET WELDNUT - WING - HALLIBURTON - 5-1/2O-RING - 90D - 6 X 5-1/2 X 1/4FITTING - GREASE - l/8-27 NPT - STRBODY - VACUUM BREAKER -5-IN.POPPET ASSEMBLY - REPLACEMENT - 2-IN. NO.300 UNION - WING - l-1/2 - 2000# TESTPLUG - BULL - 1-1/2 - STL - HEX HD

278.98024 Test - ADC-RCMII - Incl/Set-up, Tuning, and Test - Cement Units

Refer to Drawing 278.10158 for UNI-PRO II pressure, rate and density calibrationprocedures. (Menu) refers to the actual key to press. On the UNI-PRO II, “ “ refers to theoption displayed on the UNI-PRO II screen.1. Calibrations:

A. Parker Electra-Hydraulic Valve CalibrationThe purpose of this calibration is to get the water and bulk cement valves to moverapidly to the position commanded by the ADC processor.

1. Before the auxiliary engine is started and without power to the digital displays,open the junction box, JA1.

(See also Schematic 278.98023 or 278.98018).Manually close the water and bulk cement valves.

2. Remove the white wire from Terminal 5, and the red wire from Terminal 6.Measure the resistance across the two wires. It must be 750 ohms to 1750 ohmswith the cement actuator in the closed position.

Replace the wires. If this resistance is incorrect, the most likely cause isimproperly wired bulk cement valve feedback potentiometer.3. Remove the white wire from Terminal 9, and the red wire from Terminal 10.Measure the resistance across the two wires. It must be 500 ohms to 1300 ohms withthe water valve actuator in the closed position.

If this resistance is incorrect, remove the jet actuator, remove the base coverplate, loosen the two screws holding the feedback potentiometer, and turn thepotentiometer case to get 960 ohms across the white and red wires. Secure thepotentiometer with the two screws and reassemble the manifold. Replace the wires.

CAUTION: Pulling the potentiometer can damage the mechanism.

4. Remove the cover plates from the Parker electro-hydraulic valves and turnpotentiometers P3, P4, P5, and P6 all the way counter-clockwise (CCW). (P1 isclosest to Jumper J6, P6 is farthest from J6).

These potentiometers are 30-turn potentiometers. Place the jumpers at J3,and J6.It may be convenient to leave a spare jumper on TP1, or TP2.5. Turn P4 clockwise 10 turns. Turn P3 clockwise 3 turns.

6. Fill all hydraulic lines with oil.

7. Remove case drain adapter on Parker pump and fill pump case with oil.Replace adapter and hose.

8. Back relief adjustment screw for Sun relief all the way out (CCW). Someearly units with Sun reliefs (cartridge P/N RPEC-FBN) require the adjusting screw tobe removed and replaced with a longer screw - 3/8-24 UNF X 1 1/4 LG. If Sun Relief(P/N 70.83793) cartridge is stamped RPECFCN, this change is not required.

9. Turn adjustment screw for pressure compensator all the way in (CW). Do not over-tighten.10. Put ADC master hydraulic bypass valve in the off position. (Use knob under the control stand and turn to the right.)11. Close all bypass valves on the hydraulic actuators.12. Place the Manual/Automatic switch in the Automatic position for the cement valve, water jet valve,

and water master valve.13. Start the auxiliary engine and leave it idling.14. Watch for leaks and make sure that the oil in the reservoir does not drop below the low levelmark.

15. Allow the oil to circulate for about 5 minutes.16. Increase auxiliary engine speed to 1200 rpm.

17. While viewing the ADC hydraulic pressure gauge, begin turning clockwise on Sun reliefadjustment screw.

18. Set the Sun relief valve at 2000 psi at 2000 RPM. Tighten the locknut.19. Take auxiliary engine to idle. Pressure should remain at 2000 psi.

20. With auxiliary engine at 2000 rpm, back the Parker pump compensator adjustment sscrew CCW until the pressure in the system drops to 1500 psi.

B. Bulk Cement Valve Calibration

1. Press “ADC Idle” (Menu 8). Press “Test” (Menu 8) press “OSC Valves” (Menu 6) press“OSC Cement” (Menu 3) this will cause the bulk cement valve to go to Position 2 for 1second, followed by Position 8 for 1 second, and then continue to repeat untilinterrupted.

2. To begin the tuning of the bulk cement valve for opening, start the following adjustmentsusing Pot P5. To tune for closing, start the following adjustments using Pot P6.To improve the opening response of the valve, turn P5 CW.

To improve the closing response of the valve, turn P6 CW.

Gradually improve the opening and closing response of the valve by turning these potsa turn or two at a time.

Best response is when the valve quickly (approximately 1/10 second) move to positionand stops without over-shooting or under-shooting.

Note: Under-shoot is when the valve moves short of the required position, then creepsup. Over-shoot is when the valve moves past the required position, then moves back.

Turn the pot CW to remove under-shoot.

Turn the pot CCW to remove over-shoot.

Continue adjusting P5 and P6 until all undershoot is removed. A good technique touse is to adjust the potentiometer 1 or 2 turns, then watch the valve.

Another good technique is to use the red/green light. Best response is obtained when the lightflashes red briefly, then goes off, then the light will flash green briefly, then go off. The mostcommon problem that occurs is to get one potentiometer too far clockwise. At that time P5 andP6 begin to interact in a non-intuitive and inconsistent manner. If you suspect this has happened,turn both pots counter-clockwise a few turns until you have mild undershoot on opening andclosing, then begin adjusting again.

3. Turn P3 clockwise until uncontrolled over-shooting of the valve occurs. Turn P3 counter-clockwise until the uncontrolled over-shooting stops. Turn P3 counter-clockwise 7 more turns.

4 Turn P5 and P6 counter-clockwise a couple of turns to get mild undershoot on openingand closing Then adjust them as in Step B2

Stop the cement valve oscillation by pressing (Menu 8) and then “Stop” (Menu 6).

Seal Pots P3, P4, P5, and P6 with silastic compound.C. Jet Water Valve Calibration

Press “ADC Idle” (Menu 8), ‘Test” (Menu 8), “OSC Valves” (Menu 6) and “OSC Jet” (Menu 7). Thiswill start the jet water valve oscillating. Adjust P3, P4, P5, and P6 for the jet water valve just as P3,P4, P5, and P6 for the bulk cement valve were adjusted. The only exceptions are:

The valve cannot move to Position 2 or 8 as this valve is unmarked.Instead the valve will openabout 20%and 80% respectively. It should be possible to adjust the jet water valve to arrive at therequired position faster than it was possible with the bulk cement valve due to the smallercylinders in the actuator.

D. Completion of Calibration Procedures:

Press (Menu 8) and “Stop” (Menu 6) on the UNI-PRO II to make the jet valve stop oscillating.Replace the covers on the Parker electro-hydraulic valves.

2. Determining valve voltages:

A. Cement Closed

Have the UNI-PRO II close all valves. Run auxiliary engine at 2000 rpm. Place auto/manualswitch in auto position, press “C/O Volts” (Menu &) press “Cement Lo Volts” (Menu 2) enter anew voltage value unit until the cement throttling valve is approximately 1/4-in. past closed.

The cement closed voltage is the final number pressed. Record on “ADC Test Report”-Part 3.

B. Cement OpenHave the UNI-PRO II open all valves.

Press: “Cement Hi” (Menu 6).

Enter a new voltage value unit until the cement throttling valve is fully open.

The cement open voltage is the final number pressed. Record on “ADC Test Report” - Part 3.

D. Jet Open

C. JET CLOSED

Put system in MANUAL VALVE mode.Press: ADCPress: TESTPress: MANUAL VALVEPress: JET VALVEPress: MENU 4 to increase to 10%Press: MENU 4 to increase to 20%

Flowmeter reading should be between 40 and 60 GPM. If not, increase closed voltageto get a flow rate between these two values. Put system back into MANUAL mode. Runwater at 10, 20, 30, etc. up to 100 %, then back down. Compare values going up withvalues coming down. If GPM readings are within 20 GPM of each other and water isshut off at zero percent, the closed voltage is correct.

Have the UNI-PRO II open all valves.

Press “Jet Hi” (Menu 7), enter a new voltage value, until water rate indicated by theflowmeter no longer increases. The jet open voltage is the last number entered.Record on “ADC Test Report” - Part 3.

3. UNI-PRO II/RCM II Test ReportRecord the following information and file as part of the Unit Test Report and install a copy of this sheet inplastic bag (P/N 70.00307) and store in the holder in the underside of the control stand cover.

-. RCM II W/UNI-PRO II AND ADC TEST REPORTPROJECT NO._________UNIT NO_________ DATE______Passenger SideFrequency PSI_____ 0HT-400 Rate Plunger Size ______HT-400 Rate Plunger Size

Rate (bpm) Pulses Rate (bpm Pulses______ _______ _______ ______

RCM II DensometerSerial No._______

RCM II DensometerSource Serial No

Down Hole DensometerSerial No.______

Down Hole DensometerSource Serial No.____

Frequency ppg________ __________________ __________________ __________________ __________________ __________________ __________________ __________

Low Cal_________ _________

Low Cal____________ __________

High Cal___________ __________

Frequency ppg__________ ____________________ ____________________ ____________________ ____________________ ____________________ ____________________ __________

3-In. Flow MeterSerial No._______

Water Delivery ValueFlowmeter Factor

To determine the water delivery value: (use “4.00” in emergency situation)1. Engage the water pump and run engine at normal operating speed. 2. Open the water jet valve to 50% open and note the water flow rate.

High Cal _________ __________

3. Divide the water flow rate at 50% open by 50. This is the water delivery value. Record it on theappropriate line below.

RCM lI SYSTEM WITH UNI-PRO II

ADC Parameters 8-bbl Tub 25bbl Tub

Premix Tub VolumeWater Proportioning TermWater Integral TermWater Differential TermCement Proportioning TermCement Integral TermCement Differential TermCement Control LimitWater Control LimitAnticipation Control LimitBulk Cement Del factorWater Delivery Value

85 1270 00.75 0.0750.2 0.200.85 1.250.019 0.0151.44 1.44100,000 100,0004,800 4,8003.0 3.03.3 3.3_______ ______

Jet Low Volt _________-Jet High Volt _________

Cement Low Volt _______Cement High Volt _______

LAN Address 1

��These values should not be changed.

Inspector Signature

278.10158 lnstln - Calibration - UNI-PRO II - Cementing

This procedure describes the buttons to press on a UNI-PRO II to calibrate the various sensors.

1 Tell the UNI-PRO II the type of system on which it is installed.Turn the power off.Press and hold the menu key.Turn the power on and wait for “Reset Mem”.Release menu key.Press Yes. Enter.Menu.Start.System.Select system (usually “ADC”).

2. Zero the passenger-side pressure transducer.Menu 1.Cal/Tst.Disp Count.

Read the count rate from the upper left display (e.g. 19828). Menu 1.

Cal/Tst.Recalibrate.Enter.Enter.Enter.2.

Enter the previous count (e.g. 19828 Enter).Enter.Enter.Enter.Enter.Enter.Enter.

3. Zero the driver-side pressure transducer.Menu 5.CaliTst.

Disp Count.

Read the count rate from the upper right display (e.g.19718).Menu 5.Cal/TstRecalibrate.Enter.Enter.Enter.2.

Enter the previous count (e.g. 19718 Enter).Enter.Enter.Enter.Enter.Enter.Enter.

4. Calibrate the passenger-side rate pickup. Split out the rate readings.

2.Menu 2.Test/Calib/n’.Recalibrate.Enter.Enter.Enter.Enter.Enter.Enter.2.Enter.Enter.Enter.

Enter the rate which would cause a 2kHz electrical signal. This rate will depend on the fluid end size, and canbe found in following table.

Fluid End Size3 3/844 1/256Enter.

Rate (bpm)11.90773816.75350521.09059426.09262837.524859

Enter the number of pluses one barrel of fluid would cause.Fluid End Size Pulses3 3/8 10,077.484 7162.684 ½ 5689.745 45996 3197.88

Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.

4. Calibrate the driver-side rate pickup.Menu 6.Test/Calib/n’.Recalibrate.Enter.Enter.Enter.Enter.Enter.Enter.2.Enter.Enter.Enter.

Enter the rate which would cause a 2kHz electrical signal. This rate will depend on the fluid end size, and canbe found in the following table:

Fluid End Size Rate

331844 l/256Enter

11.90773816.75350521.09059426.09262837.524859

Enter the number of pulses one barrel of fluid would cause.

Fluid End Size Pulses

3/844 1/256Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.

10077.487162.685689.74 45993197.88

Combine the rates.1.

6.Calibrate the low-pressure density sensor,Menu 3.

Cal/TstRecalibrateEnter.Enter.Enter.Enter.Enter.Enter.7.

Enter the frequencies and densities from the density sensor calibration sheet, followed by “Enter” each time.

Enter the low cal density.Enter.Enter.Enter.

7. Calibrate the high-pressure density sensor.Menu 7.Ca/lTstRecalibrate.Enter.Enter.Enter.Enter.Enter.Enter.7.

Enter the frequencies and densities from the density sensor calibration sheet, followed by “Enter” each time.

Enter the low caldensity.Enter.Enter.Enter.

8. Calibrate the 3-in. flowmeter.

Menu 4.Test/Calib/n’.Recalibrate.Enter.Enter.Enter.Enter.Enter.Enter.2.EnterEnterEnter.

Calculate 120,000 divided by the flowmeter factor, and enter the result.Enter.

Calculate 42 times the flowmeter factor and enter the result.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.Enter.

Section 6Bulletins

HALLIBURTON Engineering BulletinP.O. Drawer 1431, Duncan, Oklahoma 73536-0312 USA

SUBJECT: Axial Flow Mixer Update

No. 10-93

Date 8-23-93

In recent months, several improvements have been made to the axial flow mixer. The first two changes(below) can be applied to existing mixers in the field. All new mixers will reflect the changes that follow.

First, the mixer and the cement throttling valve was modified to decrease the amount of splashback(and subsequent cement buildup) in the throat of the mixer. Most splashbacks occur while batch mixingas the mix water is started and stopped. The following changes significantly reduce the splashback andcan be applied to mixers in the field.

a) The new style, tapered, upper body sleeve (P/N 412.15027-see Figure 1A) was designed toprevent mix water backwash into the mixer throat during periods of high vacuum.

b) A new, longer skirted water jet (P/N 412.15034) was implemented to prevent recirculated slurrybackwash in the water jet area

c) A second vacuum breaker was added to the cement throttling valve to limit the vacuum beingpulled by the mixer (see Figure 4). Tests indicate that this will significantly reduce splashback.

Illustrations on the following pages show the modifications and applicable Halliburton part numbers.They can be ordered from stock Please observe the notes pertaining to each modification.

Secondly, the metering plug in the cement throttling valve assembly was redesigned to open from thetop-down instead of from the bottom-up. This new design enables the valve to meter bulk cement at alower rate without plugging off or decreasing the high rate metering capability. The new plug (P/N412.13372) is a direct replacement for the older bottom-up metering plug. Actual minimum flow rate ofthe new plug depends on the condition of the bulk unit, but will probably be in the10-15 sack/minute

It is recommended that the seal kit be ordered at the same time the new valve plug isordered.

Thirdly, a bolting flange was added to the upper body of the new mixers to allow the cement throttlingvalve break over hinge to be bolted on instead of welded-as in the previous design. This new featureis not adaptable to existing mixers.An O-Ping Kit (P/N 412.15035) is available from stock which includes the O-rings of the axial flowmixer.

A Seal Kit (P/N 412.15036) is available from stock for the cement throttling valve. The kit includes athrust washer, roll pin, and Teflon O-rings.

Calvin StegemoellerSenior Engineer II

.

NOTICE: This document is confidential, proprietary property of Halliburton Energy Services. It issupplied for use by Halliburton Energy Services employees only and shall not be copied,published or disclosed in whole or in part without the prior written consent of Halliburton EnergyServices.

HALLIBURTON Technology BulletinP.O. Drawer 1431. Duncan, Oklahoma 73536-

No. CEQ-95-002Date 5-22-95

.~ SUBJECT: New Material Introduced for the RCM811 Water Jet

Introduction

Because of excessively high rates of wear on some original RCM II water jets (P/N 412.15034) a replacement water jet is now available. This new water jet (P/N 412.15039)is composed of ultra-high molecular weight polyethylene, which can withstand morewear than the original part. In fact, field tests performed in the Bakersfield districtindicated that the new material more than doubles the life of the part. Since the new jetis dimensionally identical to the jet it replaces, the mixer does not require modification.

Wear Rates

The underlying cause of the excessively high wear rates is probably the pressure on themix water manifold. Testing performed immediately after the axial flow mixer wasintroduced showed that the water jet’s rate of wear increased substantially when themix-water pressure was over 120 psi.

In addition to excessive pressure, the wear rate of the water jet can vary from location tolocation as a result of different operating methods (full throttle vs. part throttle on theauxiliary engine), mix-water pumps (Halliburton 4 x 4 vs. Deming 44L), and pump drives(pump speeds may vary). Job frequency and job characteristics also determine the wearrate.

Operation Recommendations

The optimum mix-water pressure for the RCM II axial flow mixer is about 100 psi.Higher pressures reduce the required opening of the water valve and force the waterthrough smaller orifices, which increases the velocity of water going through the orificeplate, valve plate, and water jet. This increased velocity provides no measurable orobservable benefit during mixing; it simply results in a much higher rate of wear on themixer’s internal parts.

The most recently manufactured mix-water pump drives have been set up to run theHalliburton 4 x 4 mix-water pump at 2,800 rev/min when the auxiliary engine is at fullthrottle. This pump should be slowed down to run at 2,200 rev/min.

On direct-drive units, such as the 75TC4, the gear ratio is fixed and little can be done toslow the pump down unless the power takeoff (PTO) is changed or the engine is run atreduced speed.

NOTICE: This document is confidential, proprietary property of Halliburton EnergyServices. It is supplied for use by Halliburton Energy Services employees only and shallnot be copied, published or disclosed in whole or in part without the prior writtenconsent of Halliburton Energy Services.

No. CEQ-95-002Date 5-22-95

Technology Bulletin

NOTE: If the recirculation pump requires full speed, do not slow the enginedown. On units with hydraulic drives, such as the HCS Advantage, the hydraulicpump can be destroked to limit the top speed of the 4 x 4 pump.

For specific recommendations for changing the pump speed, contact Andy Jones (405)25 l-4891 or Lanny Landrum (405) 25l-4051, Cementing Equipment Technology.