PN: T03-53-465_1.0.

0_en

Tel：0716-8428889 / 8011730 Fax：0716-8016063

E-mail: [email protected] http: www.sjs.servacorp.com
 ACM-III Automatic Density Control Mixing System

Introduction to Automatic Density Control Mixing

System for the Recirculating Mixer
The Automatic Control Mixing System has many languages and units and logo for the
customer to choose as the screen below.

On the information screen, press “default” key to go to this screen.

Choose the language: press or key to move the cursor to the
“Chinese/English/Spanish/Russian” box and the press up or down key to select the language
and then press the enter key to confirm.

Choose the unit: press or key to move the cursor to the “English units/Metric units”
box and then press up or down key to select the unit and then press the enter key to confirm.

Choose the logo: press or key to move the cursor to the

“logo1/logo2/logo3/logo4/logo5” box and then press up or down key to select the logo and
then press the enter key to confirm.
This screen above, for example, indicates Automatic Density and Tub Level Control Mixing
System in Chinese language with Metric units and SJS logo.
After the configuration on this screen, press “INFOR” key to go to the Information screen.

The density can be controlled either manually or automatically. The following introduces the
automatic control mode features.

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The Automatic Cement Mixer with the Density Control is designed to meet the highest
specifications for High Energy Recirculating Mixing with the aid of the latest Computer
Control Technology. The ACM density control system consists of four component groups that
work interactively together to produce a consistent quality blend of cement and a wide range
of slurry densities. They are: 1) high energy mixer, 2) bulk cement metering valve and 3)
density control computer and 4) densitometer. These devices interact with the control
computer to automatically control the mixing to maintain a stable density.

The High-Energy Mixer is the heart of the system. It mixes the dry bulk cement with mix
water and recirculated slurry. The rate of mix water addition is controlled by a valve built
within the mixer (lever operated externally).

The cement-metering valve is mounted to the high-energy mixer inlet. It controls (meters) the
dry bulk cement rate entering the mixer. It is operated by a rotary hydraulic actuator which
incorporates a feedback potentiometer. The valve is approximately linear and will provide
near equal increases in bulk cement delivery per increment of rotation.

The mixing process is controlled by the density control computer system. The density control
computer is an Industrial Grade microprocessor that also has an operator interface control
panel. The control software that resides in the microprocessor analyses the measured mix
water rate, slurry density and the desired slurry design and determines the required bulk
cement metering valve position. This microprocessor sends a control signal to an electro-
hydraulic valve which in-turn operates the rotary actuator on the cement metering valve.

The “go-to” control algorithm calculates the cement that is required to meet the job design
density. The water flow meter transmits the rate when water is flowing into the mixer, and the
control algorithm calculates the percent opening of the cement-metering valve that will satisfy
the per-programmed desired density.

A PID loop dials in the fine setting of the metering valve as it reads the signal from the
densitometer.
The system has a non-radioactive densitometer mounted in recirculation piping. The
densitometer responses quickly and works reliably. It requires no calibration.

The system also has a training simulator mode that lets the operator practice running
cementing jobs without having bulk cement supplied to the unit. The operator can improve his
skills for controlling density in manual or automatic mode with no material cost or cleanup.
The microprocessor, while in simulation mode, provides system function verifications to test
all lines, cables, flow meter, hydraulic system, feed back system and the microprocessor itself.

Composition of Automation Density Control Mixing System

 Panelview plus
 Microprocessor and I/O modules
 Cement metering valve feedback sensor

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 Cement proportional control valve

 Water flow meter
 Densitometer
 Triplex pump slurry sensor
 Triplex pump pressure sensor

Features of Automation Density Control Mixing System

 Automatic Density Control
 Control Function Simulator
 Adjustments for Different Systems
 Key job Parameter Recording
 Trend display

Automatic Density Control

The control system responds to three possible changes during the job: throughput rate, density,
and cement bulk delivery. Throughput rate is reflected with changes in the water rate; changes
in set point density (so operators can thicken the slurry at the tail end of the slurry mix); and
changes in cement delivery due to irregular and or declining cement delivery from the bulk
supply.

The throughput rate is based on the water rate. The water flow meter measures this rate and
provides feedback to the operator interface panel and the microprocessor. Then the
microprocessor uses this data to set control gain values and the cement metering valve
nominal operating position. The result is that for whatever reasons the water rate changes, the
cement metering valve will be repositioned appropriately without waiting for the density
change (maintaining slurry density before errors occur).

Variance in the throughput rate may occur for several reasons. The pumping rate may have to
be changed due to possible pressure limitations on the casing or for job design reasons. Also
inadequate bulk cement delivery can require the job to slow down. In the case of such a
change, the ACM system immediately recognizes the change in water rate and moves the
cement metering valve to a new position based on current measured valve delivery rate. Thus
the density is only minimally disturbed. Correction is made before the density error shows up.
Typically, less than 0.1ppg change in density would occur.

The control system responds to density set points and densitometer measurements. The
microprocessor takes density readings every second and uses the data along with water rate to
adjust the opening of the cement metering valve. The algorithm is based on the calculated “go-
to” values plus proportional, integral, and derivative (PID) feedback, whose coefficients vary
with throughput rate and tub volume. Some operators like to change the set density so that
they can “thicken” the slurry at the tail end of the mixing. In this case, the ACM system reads
the current actual calibration scale of the cement metering valve. It calculates the new valve
position based on the current calibration, the new density and water rate. The new valve
position is not based primarily on an error signal but a known “go-to” position. Once it reaches

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that position and still there is some error, then the PID control takes over. This error is
normally minimal.
Position corrections of the cement metering valve can also be required due to irregular and/or
declining bulk cement delivery from the bulk supply. The ACM continually calculates the
actual calibration value of the valve, which is the amount of cement being delivered by the
valve at its current position. With the updated calibration and the known amount of cement
required for preset density (calculated by the ACM microprocessor) and slurry rate, the
cement valve again is driven to a “go-to” position.

The operator interface panel displays the changing valve calibration value. Therefore the
operator has an actual number on the ability of any given bulk supply to deliver cement. A
minimum bulk delivery calibration can be established so that if a particular system falls below
this value, then corrective maintenance would need to be planned.

Control Function Simulation

The microprocessor can be placed in a simulation mode, which is useful for operator training
and system functional verification. This mode allows the operator to control the complete
system as if he were doing a cement job but without cement. This quality training is available
for each cementer without added expense. It will help insure that operators are qualified and
confident in operating the system for an actual job. In the training mode, the operator would
circulate water through the mixer without mixing cement. The operator can adjust the cement
metering valve manually or have the ACM system control it automatically. The
microprocessor reads the valve position and calculates an assumed bulk flow based on a
microprocessor stored curve.

The microprocessor calculates the theoretical real-time density that would have been mixed in
the tub if cement had been used. This simulation takes into account the mix water flow (job
throughput rate), tub volume, water density, and dry bulk cement absolute density. The
systems functional verification works the same as when the microprocessor is in the training
mode. All lines, cables, flow meter, hydraulic system, feedback system and microprocessor are
tested during the simulation.

Adjustments for Different Systems

Since the system is intended to adapt to different designs, easy access to control design
parameters is provided. Mixing tank volume and proportional, integral, and derivative (PID)
feedback gain parameters are accessed from the operator panel. Flow meters, densitometers
and pressure transducers are also easily calibrated to the system using simple menu driven
screens.

Key Job Parameter Recording

Data storage system communicates and records history job data through the high speed
Ethernet and Rockwell PLC system. The history data are stored as files for convenience of job

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data management. A 4GB large capacity industrial grade memory card is used to ensure extra-
long time data recording and data safety. At the same time, USB port, RS232 serial port and
Ethernet port are available for the users to choose. The Ethernet communication can greatly
increase the data downloading and transmitting speed. The USB port can help to achieve data
downloading by USB flash disk at site.

Trend display
The ACM control system can display density trend, slurry rate trend and pressure trend on the
Main screen. Thus the operator can easily know the trend of the three parameters during the
job. The maximum scale can be changed on the Trend Set screen.

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General Descriptions of Automatic Density

Control Mixing System
ACM-III control system software has three types. They are 2 engine 2 pump type, 1 engine 1
pump type and mixing only type (Pressure Slurry Packet is optional) to adapt to the three types
of cementing units with different engine and triplex pump numbers. Several language versions
are available for customers.

This manual is an operating instruction to the 2 engine 2pump type.

Screens
Information Screen: It displays actual and desired values as well as various warnings.
Desired density, desired tub level, desired slurry rate, job No. and job marker are entered on
this screen. Cementing job is started and stopped from this screen.

Main Screen: It displays actual and desired values as well as various warnings. Desired
density, desired slurry rate, job No. and job marker are entered on this screen. Cementing job
is started and stopped from this screen.

Dens setup Screen: It is used to enter the desired slurry density, the water density and the dry
bulk cement absolute density.

Cal List Screen: It lists 5 calibration screens for the operator to select to go.

Density Calibration Screen: It is used to calibrate the densitometer. The water density and
the dry bulk cement absolute density are entered on this screen.

Cement Valve Calibration Screen: It is used to calibrate the cement valve feedback signal
and control signal.

Pressure1 Calibration Screen: It is used to calibrate the triplex pump pressure1 sensor.

Pressure2 Calibration Screen: It is used to calibrate the triplex pump pressure2 sensor.

Flow Rate Calibration Screen: It is used to calibrate the water flow sensor and the slurry
flow sensor.

Low Flow Rate Calibration Screen: Low flow rate sensor is installed for some system that
can not measure the low slurry rate correctly. This is used to calibrate the low slurry rate
sensor.

Simulation Test Screen: It permits the user to set a design, and "RUN" a cement job in
automatic or manual without cement.

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Download Screen: It is used to download the key job parameters.

System Design Inputs Screen: It is used to enter the system parameter to adapt to different
designs.
NOTE: Factory setting is strongly suggested.

Time Set Screen: It is used to set the time of the processor, which is used for data download.

Trend Set Screen: It is used to set the maximum scale for the 3 trends.

Function keys
CAL: Press this key on the Main screen to go to the Calibration List screen.

M SCRN: Press this key to go to the Main screen.

INFOR: Press this key on the Main screen to go to the Information screen.

SIMUL: Press this key on the Main screen to go to the Simulation Test screen.

DOWNLOAD: Press this key on the Main screen to go to the Download screen.

SYSTEM: Press this key on the Main screen to go to the System Design Inputs screen.

TRENDSET: Press this key on the Main screen to go to the Trend Set screen.

INC: When job is stopped and simulation is off and the valve is controlled in automatic mode,
press this key on the Cement Valve Calibration screen to increase the voltage to the cement
valve.

DEC: When job is stopped and simulation is off and the valve is controlled in automatic mode,
press this key on the Cement Valve Calibration screen to decrease the voltage to the cement
valve.

0 CAL: On the Pressure Calibration screen, press this key for zero calibration.

RANGE CAL: On the Pressure Calibration screen, press this key for full scale calibration.

DENS SIMUL: On the Main screen or on the Simulation Test screen, press this key to switch
density simulation back and forth between on and off.

CMT SIMUL: On the Main screen or on the Simulation Test screen, press this key to switch
cement valve simulation back and forth between on and off.

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WTR SIMUL: On the Main screen or on the Simulation Test screen, press this key to switch
water simulation back and forth between on and off.

JOB#: On the Main screen, press this key to enter the job No. for data recording.

OVERP1 RST: On the Main screen or the Pressure1 Calibration screen, press this key to reset
the overpressure protection.

P1 LMT: On the Main screen, press this key to enter the pressure1 limit.

P1 TEST: On the Main screen or on the Pressure1 Calibration screen, press this key to
calibrate through a test (used on Viatran type transducers).

PASSWORD: Press this key to enter the password.

DEFAULT: On the Calibration List screen, press this key to restore the system parameters
and calibration parameters to the factory settings.

OVERP2 RST: On the Main screen or the Pressure2 Calibration screen, press this key to reset
the overpressure protection.

P2 LMT: On the Main screen, press this key to enter the pressure2 limit.

P2 TEST: On the Main screen or on the Pressure2 Calibration screen, press this key to
calibrate through a test (used on Viatran type transducers).

DENS DES: On the Main screen, press this key to go to the density setup screen.

JOB FLAG: On the Main screen, press this key to enter the job markers.

AUTO/MAN: On the Main screen, press this key to switch the valve control mode back and
forth between in manual and automatic.

WTR TTL: On the Main screen, press this key to clear the water total.

SLRY TTL: On the Main screen, press this key to clear the slurry total.

SLRY DES: On the Main screen, press this key to enter the desired slurry rate.

START: On the Main screen, press this key to start a cementing job.

STOP: On the Main screen, press this key to stop a cementing job.

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Information Screen

This is the first screen running after power on. It displays the P/N number and the version of
the terminal program and the PLC program. It also displays the type of the control system, the
job No. for data recording and data and time.

OPN: T03-53-465 Rev 1.0.0 is the P/N and version for terminal program.

SLC: T03-53-465 Rev 1.0.0 is the P/N and version for control program.

Auto Density Control System is the type of the control system and 00 is used for wireless data
acquisition to distinguish the different devices.

On this screen press the “M SCRN” button to go to the Main Display

Press digital button to enter password 135790 and then press“SYSTEM” key on this screen,
there will pop up a hint box as the following. Press “SYSTEM” key again to shut down the
application and go to the terminal settings. Press “INFOR” key to go back to the Information
screen.

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Main Screen

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The Main screen is where the job is run from. It displays actual and desired values as well as
various warnings; the automatic or manual control modes are displayed on this screen. The job
is started or aborted from this screen.
Press “M SCRN” key on this screen to display the trend. Press the key again to close it and go
back to the main screen.

Desired density, desired slurry rate, pressure limit, job No. for data recording and job markers
are entered on this screen.

Slurry ---- It displays the actual slurry flow in BPM and slurry total in BBL. The slurry flow
meter transmits the value to the computer. To calibrate the slurry flow meter, refer to the
description of "Flow Rate Calibration screen".

For the system installed low rate sensor for slurry measure, on the main screen press “DEC”
button or “0 CAL” button respectively to select the measuring sensor slurry1 and slurry2.
When low rate sensor is selected, a red “LOW” will display behind “SLURRY1” or
“SLURRY2”.

Press “SLRY TTL” key to clear the water total.

Press “SLRY DES” key to enter the desired slurry rate.

Water ---- It displays the actual water flow in GPM and water total in GAL. The water flow
meter transmits the value to the computer. To calibrate the water flow meter, refer to the
description of "Flow Rate Calibration screen".

The desired water flow rate to reach the slurry rate shown is calculated from the water density,
the dry bulk cement absolute density, the desired slurry density and the slurry rate. The slurry
rate will be the actual value if the actual slurry rate is not zero and it will be the desired slurry
rate if there is no slurry rate or the actual slurry rate is zero. If a new desired density is entered,
the system recalculates the desired water rate.

Press “WTR TTL” key to clear the water total.

Density ----The Actual density measured by the densitometer. For more information see
description of "Density Calibration screen".
Press “DENS DES” key to go to the “density setup” screen and enter the desired density, the
water density and the dry bulk cement absolute density. Press “M SCRN” key to go back to
the main screen.

Cement Valve Position ---- The Actual valve position (opening from 0 to 100%) is generated
from a position pot located on the cement metering valve actuator. If the valve position
simulator is on, it displays the simulated valve % opening. For valve position simulator
operation instructions refer to the description of "Emulator Test screen". To calibrate the valve
position, refer to the description of "Cement Valve Calibration screen".

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The desired valve position to obtain the desired density is calculated by the computer.

Cement Valve Gain (lbs./sec/ %) ---- This is the bulk cement deliverability number, in
lb/sec/%. If this number reads 1.2 lb/sec/% at 100% valve opening position, the theoretical
delivery rate would be 120 lb/sec/%.
At 10% valve opening position, the delivery would be 12 lb/sec and at 50% valve opening
position, the delivery would be 60 lb/sec.

The condition of the air compressor, the line size and condition, the distance and the bulk tank
air pad condition decide the total system deliverability. If the compressor was weak, lines
partly plugged or air pads plugged, the number would register a much smaller and/or
fluxuating number. Values less than .9 lb/sec/%, at the beginning of a job, would suggest that
the bulk system was marginal in the ability to perform. During the job, particularly during high
rate jobs, the compressor may not keep up with demand and therefore the bulk line pressure
will fall and subsequently, the lb/sec/%, will also fall typically to .5 or lower before a tank
change is required. The lower the bulk deliverability falls before switching tanks, the more
difficult it is to maintain reasonable density control.

Pressure ----Displays the down hole pressure from the pressure transducer. To calibrate the
pressure transducer, refer to the description of "Pressure Calibration screen". It displays the
bar for the maximum desired pressure (limit) and actual pressure.

Trend ----There displays density trend, slurry rate trend and pressure trend.

Auto/Man ----“Auto” indicates that the cement valve is controlled by the computer. “Man”
indicates that the cement valve is controlled by the handle. Even the system is in manual mode,
as long as the job is started, all calculations are still done and the system records the job if
desired. The Auto/Man mode can be switch back and forth by pressing the “AUTO/MAN” key
on the Main screen.

Emulate On/Off ----“WTR SIMUL ON” indicates water simulator on and it displays
“WATER” when water simulator is off. Press “WTR SIMUL” key to switch water simulator
back and forth between on and off.
---- “DENS SIMUL ON” indicates water simulator on and it displays “DENSITY” when
density simulator is off. Press “DENS SIMUL” key to switch density simulator back and forth
between on and off.
---- “CMT VPOS SIMUL ON” indicates cement valve position simulator on and it displays
“CMT VPOS” when cement valve position simulator is off. Press “CMT SIMUL” key to
switch cement valve position simulator back and forth between on and off.

Record On/Off ----After “STOP” key is pressed, the main screen will display the indication
“IN DATA STORAGE, PLEASE DON’T PRESS “START” BUTTON”. The indication will
disappear automatically after the data storage finishes.

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During the data storage, there will be the following errors:

1) Synchronous time error. Press “Job#” to clear it.
2) Failed to start the FTP server. Press “Job#” to clear it.
3) Failed to save data to SD. Please contact manufacturer to solve the problem. Press “Job#”
to clear it.
4) CD card not found. Press “Job#” to clear it.

Job Start/Stop---- “JOB IN PROGRESS” indicates that the system is operating (manual or
auto mode) and data is being recorded (if required). “JOB STOP” indicates that the JOB has
been stopped, recording is automatically stopped and the cement metering valve returns to the
minimum position.

Note: Once the "STOP" key is clicked the computer auto control system will stop working.

Job marker---- is accessed by pressing “JOB FLAG” key. See the following list of possible
“job markers”. Enter job markers during the job and the number and corresponding job event
description will appear in the job chart when using SERVAview data recording and charting
software.

Job markers
Primary cementing Foam cementing
1.Start job 30. Pump cap
2. Prime Pumps 31. Start additives
3. Test lines 32. Start N2
4. Circulate well 33. Pump foam
5. Pump flush 34. Stop additives
55.End flush volume 35. Stop N2
6. Pump spacer 11. Start displacement
66.End spacer volume 111.Stop displacement
7. Drop bottom plug 36. Shut in well
8. Start lead slurry
88.End lead slurry volume Miscellaneous
9. Start tail slurry 40. Open multi stage cementer
99.End tail slurry volume 41. Close multi stage cementer
10.Drop top plug 42. Drop plug
11.Start displacement 43. Drop ball
111.End displacement 44. Pause
12. Bump plug 45. Resume
13. End job 46. Pump well fluid
Squeeze cementing 47. Clean lines
48 Other
20. Clean hole
21. Set packer
22. Establish pump rate
23.Pump cement
11.Start displacement
24. Final squeeze
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25. Release packer

26. Reverse out

Job No.---- is accessed by pressing “JOB#” key and it is used to divide the stored data into
different group. A hint box will pop up if no new job No. is entered before a job is started.

Running a Job
1) Press “DENS DES” key to go to the “density setup” screen and enter the desired density,
the water density and the dry bulk cement absolute density.
The default of the water is 8.34 ppg and the default of the dry bulk cement absolute density
is 26.29 ppg. The accuracy of the two densities effects on the control accuracy. Please
enter the correct value.

2) Press “SLRY DES” key on the Main screen to enter the desired slurry rate.
3) If a simulation is required, press “SIMUL” key to go to the Simulation Test screen for
settings. Refer to the description of “Simulation Test screen” for more information.
4) Press “START” key on the Main screen to start a job.
5) When the job is finished, press “STOP” key on the Main screen to stop a job.
6) Press “DOWNLOAD” key to go to the Download screen for downloading data. Refer to
the description of “Download screen” for more information.

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Calibration List Screen

This screen lists the following calibration screens:

 DENSITY CAL for Density Calibration screen
 CEMENT VALVE CAL for Cement Valve Calibration screen
 PRESSURE1 CAL for Pressure1 Calibration screen
 PRESSURE2 CAL for Pressure2 Calibration screen
 FLOW RATE CAL for Flow Rate Calibration screen
 LOW SLRY RATE CAL for Low Slurry Rate Calibration screen

Press up/down key to select one of the above and press enter to go to the selected calibration
screen.

Press “CAL” key on the Main screen to go to this screen and press “M SCRN” key on this
screen to go back to the Main screen.

Press “DEFAULT” key on this screen, pop up the following hint box. Press “DEFAULT” key
again to restore the system parameters and calibration parameters to the factory settings. Press
“M SCRN” key to close this box.

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Density Calibration Screen

The Density calibration screen is used to calibrate the system to a given densitometer. It is also
useful in troubleshooting. The displays are "DENSITY" and "CURRENT" and four entries for
calibrating the densitometer.

Press “CAL” key on the Main screen to go to the Calibration List screen and press up/down
key to select “DENSITY CAL” and press enter to go to this screen. Press “M SCRN” key to
go to the Main screen after the calibration is finished.

DENSITY: The density displayed indicates the slurry density from the densitometer. This
value will be affected by densitometer calibration on this screen. The value displayed will be
the same as actual density displayed on the Main screen. If the emulator is used, the emulator
density is displayed.

CURRENT (analog signal in): The current displayed indicates the actual current into the
computer and it will not be affected by the calibration values on this screen or on the
Simulation screen.

Densitometer Calibration

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The densitometer cannot be calibrated. It is already calibrated at the factory and this
calibration should not change during the normal life of the meter. What is done on the
densitometer calibration screen is to match on the Allen-Bradley operator interface panel the
densitometer calibration numbers.

Calibrating steps
1) Press or key to move the cursor to DENS MIN and enter 0 PPG.
2) Press or key to move the cursor to DENS MAX and enter 25.04 PPG.
3) Press or key to move the cursor to CURRENT MIN and enter about 4 mA, the
value to make density 0 PPG.
4) Press or key to move the cursor to CURRENT MAX and enter about 20 mA, the
value to make density 8.34 PPG when the densitometer is filled with water.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.

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Cement Valve Calibration Screen

This screen is used to calibrate the cement metering valve position and its control voltage. It is
also very useful in troubleshooting. The displays are "VOLT ", “VPOS” and “CNTRL VOLT”.
There are four entries for the cement metering valve position calibration and five entries for its
control calibration.

Press “CAL” key on the Main screen to go to the Calibration List screen and press up/down
key to select “CEMENT VALVE CAL” and press enter to go to this screen. Press “M SCRN”
key to go to the Main screen after the calibration is finished.

VPOS: The VPOS displayed indicates the valve position from the cement metering valve
sensor. It is dependent upon the valve calibration for its accuracy. This is the same value that
is displayed on the run screen. If the emulator is used, the emulator valve position is displayed.

VOLT (analog signal in): The volt displayed indicates the actual voltage into the computer
and it will not be affected by the calibration values on this screen or on the Simulation screen.

CNTRL VOLT (analog signal out): This is the actual voltage from the computer to the
cement proportional valve. When job is stopped and the simulator is off and the valve is
controlled in automatic mode, press “INC” key on this screen to increase the control voltage to

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the proportional valve and press “DEC” key on this screen to decrease the control voltage to
the proportional valve.
Calibrating Cement Valve
Make sure that the job is stopped and the cement valve position simulator is off before
calibration.

Calibrating
1) Make the cement valve controlled in automatic mode.
2) Enter a value for CNTRL VPOS SENSI.
3) Press “DEC” key to reduce the control voltage to the cement valve. When the opening of
the valve is close to the minimum %, reduce the control valve position sensitivity.
Continue press “DEC” key until the opening of valve is exactly nearly the minimum %
(for example 5%). Enter the valve position as CNTRL VPOS MIN and enter the valve
position as VPOS MIN. Press “0 CAL” key to calibrate the VOLT MIN and CNTRL
VOLT MIN.
4) Press “INC” key to increase the control voltage to the cement valve. When the opening of
the valve is close to the maximum % (for example 80%), reduce the control valve position
sensitivity. Continue press “INC” key until the opening of valve is exactly nearly the
maximum %. Enter the valve position as CNTRL VPOS MAX and enter the valve position
as VPOS MAX. Press “RANGE CAL” key to calibrate the VOLT MAX and CNTRL
VOLT MAX.
5) Press “DEC” key and “INC” key to verify the movement of the valve agrees with the
voltage variance. If not so, repeat step1-4 to calibrate it again.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.
THE ACCURACY OF THE VALVE CALIBRATION EFFECTS ON THE ACCURACY OF
THE DENSITY CONTROL, PLEASE CALIBRATE THE VALVE CORRECTLY.

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Pressure Calibration Screen

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This screen is used to calibrate the pressure transducer installed. It is also very useful in
troubleshooting. It has an actual voltage input display as well as a pressure display. It has the
ability to put the transducer in the test mode to run it to full scale, (This is only applicable if
transducer is Viatran type with test feature built in). The range of the transducer is selectable
to match customer transducer. Using this screen, transducers can be easily calibrated.

Press “CAL” key on the Main screen to go to the Calibration List screen and press up/down
key to select “PRESSURE1 CAL” or “PRESSURE2 CAL” and press enter to go to the
selected screen. Press “M SCRN” key to go to the Main screen after the calibration is finished.

PRESSURE: The pressure displayed indicates the down hole pressure from the pressure
sensor. This value will be affected by the pressure calibration on this screen.

VOLT (analog signal in): The volt displayed indicates the actual voltage into the computer
and it will not be affected by the calibration values on this screen.

Pressure Transducer Calibration

1) Press or key to move the cursor to PRESSURE LIMIT and enter the pressure limit.
2) Press or key to move the cursor to TRANSDUCER RANGE and enter the actual
gauge limit.
3) Press “P TEST” key to calibrate through a test (used on Viatran type transducers).
4) Press “0 CAL” key for zero calibration.
5) Press “RANGE CAL” key for full scale calibration.

Note: If a Viatran style transducer is used, the normal value range of the "VOLT" displaying
on the screen will be "0.9-5.2 VDC". Otherwise, it may indicate that an error has occurred.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.

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 ACM-III Automatic Density Control Mixing System

Flow Calibration Screen

This screen is used to calibrate the water flow sensor and slurry flow sensor being used. It is
also very useful in troubleshooting.

It has three actual frequency input displays as well as three flow rate displays. There are 3
entries for flow meter calibration. Using this screen, transducers can be easily calibrated.

Press “CAL” key on the Main screen to go to the Calibration List screen and press up/down
key to select “FLOW RATE CAL” and press enter to go to the selected screen. Press “M
SCRN” key to go to the Main screen after the calibration is finished.

FREQUENCY: This is the real frequency that the computer has detected from the water
flow sensor. Turning on the water simulator or inputting the calibration factor will not affect it.

WATER RATE: This is the display for water flow rate in GPM. It is dependent on what flow
meter calibration factor that is entered. If the water simulation is on, the water simulator value
is placed in the water rate display. The water rate displayed on this screen is the same as the
actual water rate displayed on the Main screen. This screen also displays the water total in
BBL.

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 ACM-III Automatic Density Control Mixing System

FREQUENCY1: This is the real frequency that the computer has detected from the slurry1
flow sensor. Inputting the calibration factor will not affect it.
SLURRY1 RATE: This is the display for slurry1 flow rate in BPM. It is dependent on what
flow meter calibration factor that is entered. The slurry1 rate displayed on this screen is the
same as the actual slurry1 rate displayed on the Main screen.

FREQUENCY2: This is the real frequency that the computer has detected from the slurry2
flow sensor. Inputting the calibration factor will not affect it.

SLURRY2 RATE: This is the display for slurry2 flow rate in BPM. It is dependent on what
flow meter calibration factor that is entered. The slurry2 rate displayed on this screen is the
same as the actual slurry2 rate displayed on the Main screen.

Calibrating Flow Rate

1) Press or key to move the cursor to FOCTOR and enter the water flow factor.
2) Press or key to move the cursor to FOCTOR1 and enter the slurry1 flow factor.
3) Press or key to move the cursor to FOCTOR2 and enter the slurry2 flow factor.

Note that when using the pump stroke counter system, the volumetric efficiency of the pump
should be factored into entered number. Typically, the pumps operate at an average efficiency
of 95%. In other words, it will take more pulses to obtain the actual volume and therefore the
theoretical factor should be divided by the efficiency.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.

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 ACM-III Automatic Density Control Mixing System

Low Flow rate Calibration Screen

Low flow rate sensor is installed for some system that can not measure the low slurry rate
correctly.
This screen is used to calibrate the low slurry flow sensor being used. It is also very useful in
troubleshooting.

It has two actual frequency input displays as well as two flow rate displays. There are 2 entries
for flow meter calibration. Using this screen, transducers can be easily calibrated.

Press “CAL” key on the Main screen to go to the Calibration List screen and press up/down
key to select “LOW SLRY RATE CAL” and press enter to go to the selected screen. Press “M
SCRN” key to go to the Main screen after the calibration is finished.

FREQUENCY1: This is the real frequency that the computer has detected from the slurry1
low flow sensor. Inputting the calibration factor will not affect it.
SLURRY1 RATE: This is the display for slurry1 low flow rate in BPM. It is dependent on
what flow meter calibration factor that is entered. The slurry1 low rate displayed on this screen
is the same as the actual slurry1 rate displayed on the Main screen when it is selected.

FREQUENCY2: This is the real frequency that the computer has detected from the slurry2
low flow sensor. Inputting the calibration factor will not affect it.

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 ACM-III Automatic Density Control Mixing System

SLURRY2 RATE: This is the display for slurry2 low flow rate in BPM. It is dependent on
what flow meter calibration factor that is entered. The slurry2 low rate displayed on this screen
is the same as the actual slurry2 rate displayed on the Main screen when it is selected.

Calibrating Flow Rate

1) Press or key to move the cursor to FOCTOR1 and enter the slurry1 low flow factor.
2) Press or key to move the cursor to FOCTOR2 and enter the slurry2 low flow factor.

Note that when using the pump stroke counter system, the volumetric efficiency of the pump
should be factored into entered number. Typically, the pumps operate at an average efficiency
of 95%. In other words, it will take more pulses to obtain the actual volume and therefore the
theoretical factor should be divided by the efficiency.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.

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 ACM-III Automatic Density Control Mixing System

Emulator test Screen

The emulator mode is a unique feature available only in the ACM system. This feature permits
the user to set a design, and "RUN" a cement job in auto or manual without cement. If desired
the operator could use the built-in water simulator. Then water would not even be required to
run a simulated job. Finally, if there was not even a metering valve hooked up the operator
could be trained on the system by using the built in valve position simulator along with the
water simulator and density emulator. Simulating jobs change on the fly and do data
acquisition with nothing on but the computer.

Press “SIMUL” key on the Main screen to go to the Simulation Test screen. Press “M SCRN”
key on this screen to go to the Main screen.

The Emulator Test Screen contains ON/OFF indicators and switches for three simulators. It
also has an entry for emulator starting density as well as an entry for the water simulator.
When the system is first powered up, all simulators are placed in off condition and must be
selected if desired.
Water Simulation-simulates water flow rate. Note: Real water flow rate is disabled. To turn
on the water simulator, from the Main screen or the Simulation Test screen press “WTR
SIMUL” key. The water simulator is indicated as being “ON” if the button on the Simulation
Test screen is green and the water rate display on the Main screen is “WTR SIMUL ON” ,
“red” for “OFF”. To turn off the water simulator, press “WTR SIMUL” key again. The value

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that the water simulator will use is the value entered as “WATER MAX. FLOW RATE. The
water rate value simulating is calculated from this valve and the act water valve position.

Cement Valve Position Simulator - the cement valve position simulator replaces the actual
cement valve position with what the calculated new valve position would be. If the cement
valve position simulator is ON then the cement valve control outputs are disabled. To turn the
cement valve position simulator ON press "CMT SIMUL" key. The cement valve simulator is
indicated as being “ON” if the button on the Simulation Test screen is green and the cement
valve position display on the Main screen is “CMT VPOS SIMUL ON” , “red” for “OFF”. To
turn off the cement valve position simulator, press “CMT SIMUL” key again.

Density simulation – This enables the simulator to simulate density. To use the density
simulator, first enter the starting density. To turn “ON” the density simulator, just press
"DENS SIMUL" key. The density simulator is indicated as being “ON” if the button on the
Simulation Test screen is “green” and the density display on the Main screen is “DENS
SIMUL ON”, “red” for “OFF”. To turn off the density simulator, press “DENS SIMUL” key
again.

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 ACM-III Automatic Density Control Mixing System

System Design Inputs Screen

This screen is used to adapt the ACM control system to different designs. Normally there is no
reason for the operator to access this screen or change the values that are there. The following
is a brief explanation of the values there:

PROCON is a proportional constant coefficient for the PID control loop.

DIFCON is the derivative constant coefficient for the PID control loop.

INTCON is the integral constant coefficient for the PID control loop.

“D” and “B” are factors in a curve fit for proportional and derivative feedback factors.

CEMENT VALVE GAIN is the default value for the bulk delivery factor, normally 1.8
lbs/sec/%. This is the bulk delivery value that will be used when the system first starts in the
automatic mode. After 10 sec the system will be using only measured values. This may need
to be higher if the bulk supply system has a pressure greater than 25 psi and the distance to the
bulk tank is short. Low pressure supply systems that have a bulk tank pressure of 16-18 psi
will likely require a low bulk delivery default value, maybe 1.2 lb/sec/%. The actual value
should be 25% higher than the normal starting value observed for a new bulk tank. Those

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areas that have both low and medium pressure supply systems, the value should be set for the
higher value.

MIX TUB VOLUME is the approximate working volume of the mix tank in bbl if using
English units.

DELAY K is a factor that relates to the system design. Factors such as tank volume,
agitation and recirculation rate affect the time delay of the measured density relative to
actual time a density adjustment is made.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.

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 ACM-III Automatic Density Control Mixing System

Time Set Screen

This screen is used to set the displayed and data recording times. Normally this time should
not need to be adjusted unless time zones were changed. Follow the instructions on the screen
to change the time. If the SLC and PV times do not agree, follow the procedure.

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 ACM-III Automatic Density Control Mixing System

Trend Set Screen

This screen is used to modify the maximum scale for density trend, slurry rate trend and
pressure trend.

Press “TRENDSET” key on the Main screen to go to this screen and press “M SCRN” key on
this screen to go to the Main screen.

Trend Set
1) Press or key to move the cursor to DENSITY SCALE MAX and enter the
maximum scale for density trend.
2) Press or key to move the cursor to SLRY RATE SCALE MAX and enter the
maximum scale for slurry trend.
3) Press or key to move the cursor to PRESSURE SCALE MAX and enter the
maximum scale for pressure trend.

NOTE: THE PARAMETERS CAN NOT BE MODIFIED UNLESS THE CORRECT

PASSWORD (188) IS ENTERED.

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 ACM-III Automatic Density Control Mixing System

Download Screen

This screen display internal storage % of the storage module and SD card usage %. You can
download the job data to the USB stick according to the operation step displayed on the screen.

During data storage, this screen will display “IN DATA STORAGE, PLEASE DON’T PRESS
“START” BUTTON.
After data storage finished, they can be deal with according the following steps.
1. Press “INC” key to export the last job data to USB stick.
2. Press “DEC” key to export last 10 job data to USB stick.
3. Press “0 CAL” key to export all job data to USB stick.
4. Press “Password” key to enter the correct password and then press “RANGE CAL” key to
clear all job data.

During the above operation, the screen will display “DATA PROCESSING” . If the data are
deal with successfully, “SUCCESSFUL” will be displayed on this screen. If data are not deal
with successfully, the following indications will be displayed.
1. CAN’T FIND USB STICK
2. NO DATA IN SD CARD
3. FILED OPERATION FAILED
4. ILLEGAL FILE MANAGE CALLING

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