Sbf-215 Gel-Gun PCM Operation and Parts Intouch 5520722

SBF-215 GEL-GUN PCM OPERATION AND PARTS
Part 01 - Section 01 – SBF-215 GEL-GUN PCM

OPERATION AND PARTS
Document Type OSP Manual template
Software Microsoft Word 2007

Source File SBF-215 GEL-GUN PCM OPERATION AND PARTS
Other Source File OSP Manual_MS_Word_Template.dot
Author Idalia Ovalle Stevenson

Author info PPC Sustaining Engineer
Review & approval Kim Hodgson

Revision History
Last saved 10-Aug-11 13:21
Confidential Copyright © Schlumberger

Doc # 100964659 SBF-215 GEL-GUN PCM OPERATION AND PARTS Page i
Revision # AA 10-August-2011
Table of Contents
1 General Description ......................................................................................1-1
2 Operation .......................................................................................................2-3
2.1 Normal Operation ................................................................................................................. 2-6
2.1.1 Start Eductor .............................................................................................................. 2-7
2.1.2 Mixing Gel ................................................................................................................ 2-11
2.1.3 Stop Eductor ............................................................................................................ 2-20
2.2 Staging................................................................................................................................. 2-20

2.2.1 Stage 1..................................................................................................................... 2-20
2.2.2 Stage 2..................................................................................................................... 2-21
2.2.3 Stage 3..................................................................................................................... 2-22
2.3 Mixing Gel-into-gel ............................................................................................................. 2-23
2.4 Bin Shakers ......................................................................................................................... 2-25
2.5 Unloader Auger ................................................................................................................... 2-27
3 Parts & Service............................................................................................3-28

3.1 Eductor Strainer ................................................................................................................. 3-28
3.2 Eductor Orifice Plate .......................................................................................................... 3-29
3.3 Eductor O-rings .................................................................................................................. 3-33
3.4 Eductor C-pump & Seals ................................................................................................... 3-35
3.5 Eductor Hydraulic Motor.................................................................................................... 3-36
3.6 Bin Shaker Parts & Air Lubrication .................................................................................. 3-36
3.7 Unloader Auger Parts......................................................................................................... 3-39
3.8 PCM Program Software...................................................................................................... 3-40

Doc # 100964659 SBF-215 GEL-GUN PCM OPERATION AND PARTS Page ii
List of Figures
Figure 1 Gel-gun Eductor in Front Hydration Tank ...................................................................... 1-1
Figure 2 Transfer Can for Suctioning Powder .............................................................................. 1-2
Figure 3 Isolation Valve for Suction Valve V13A .......................................................................... 2-3
Figure 4 Suction Valve V13A........................................................................................................ 2-4
Figure 5 Gel-gun PCM Schematic ................................................................................................ 2-4
Figure 6 Gel-gun PCM Process Valves, Curb Side View ............................................................. 2-5
Figure 7 Hand Wheel to Operate Valve V15 ................................................................................ 2-6
Figure 8 Valve Position for Normal Operation .............................................................................. 2-7
Figure 9 PCM Computer Screen: Eductor and Guar Control ....................................................... 2-8
Figure 10 Eductor Supply Valve Underneath Front Hydration Tank ............................................ 2-9
Figure 11 Eductor Air Stack Valve at Front of Hydration Tanks ................................................... 2-9
Figure 12 Eductor C-pump Underneath Front Hydration Tank (Not Installed Here) .................. 2-10
Figure 13 Vacuum Valve on Gel-gun Eductor Powder Inlet ....................................................... 2-10
Figure 14 Eductor Pressure Mechanical Gauge ........................................................................ 2-11
Figure 15 Eductor Pressure on Computer Screen (From Electrical sensor) .............................. 2-12
Figure 16 Eductor Strainer Housing and Blow-down Valve ....................................................... 2-13
Figure 17 Eductor Cylinder-style Strainer .................................................................................. 2-13
Figure 18 Blow-down Valve to Clean Eductor Strainer .............................................................. 2-14
Figure 19 Eductor Monitor of PCM Program .............................................................................. 2-15
Figure 20 Transfer Can Gate Open ............................................................................................ 2-16
Figure 21 Transfer Can Manual Wheel to Catch and Remove Clumps ..................................... 2-16
Figure 22 Transfer Can Clean-Out Door and Hose Connection ................................................ 2-17
Figure 23 Transfer Can Clean-out Door Latch Screw ................................................................ 2-17
Figure 24 Transfer Can Filled with Powder ................................................................................ 2-18
Figure 25 Hand Wheel for Valve V17 ......................................................................................... 2-19
Figure 26 Valve Position for Stage 1 Operation ......................................................................... 2-21
Figure 29 Valve Position for Mixing Gel-into-gel ........................................................................ 2-24
Figure 30 Bin Shaker (1 of 4) ..................................................................................................... 2-25
Figure 31 PCM Computer Screen: "Bin Shaker" Button ............................................................ 2-26
Figure 32 Air Tank for Bin Shakers and Feeder Fluidizer Manual Valves ................................. 2-26
Figure 33 Unloader Auger .......................................................................................................... 2-27
Figure 34 Unloader Auger Actuates from Auxiliary Apitech Valve Bank .................................... 2-28
Figure 35 Gel-gun Eductor: Orifice Plate Inside ......................................................................... 3-29
Figure 36 Eductor Assembly ...................................................................................................... 3-30
Figure 37 Eductor Orifice Plate and O-ring ................................................................................ 3-31
Figure 38 Items to Disconnect to Remove Eductor .................................................................... 3-31
Figure 39 Eductor Alignment Procedure .................................................................................... 3-32
Figure 40 Eductor Exit O-rings ................................................................................................... 3-33
Figure 41 Eductor Powder Tube O-rings .................................................................................... 3-34

Doc # 100964659 SBF-215 GEL-GUN PCM OPERATION AND PARTS Page iii
Figure 42 Eductor2 IN Sanitary Clamps ..................................................................................... 3-34

Figure 43 Parts for Bin Shakers Installation ............................................................................... 3-37
Figure 44 Relay for Bin Shaker Solenoid ................................................................................... 3-39
List of Tables
Table 1 Gel-gun PCM Manual Valve Settings .............................................................................. 2-5
Table 2 Gel-gun PCM Valve Response ....................................................................................... 2-6
Table 3 Eductor Strainer Ordering.............................................................................................. 3-29
Table 4 Eductor Seals ................................................................................................................ 3-35
Table 5 Eductor C-pump & Seals ............................................................................................... 3-35
Table 6 Hydraulic Motor for Eductor C-Pump ............................................................................ 3-36
Table 7 Parts for Bin Shaker Installation .................................................................................... 3-38
Table 8 Hydraulic Motor for Unloader Screw ............................................................................. 3-39

Doc # 100964659 SBF-215 GEL-GUN PCM OPERATION AND PARTS Page 1-1
1 General Description
The gel-gun SBF-215 PCM has a Semi-Bulk-Systems eductor that installs high inside
the front tank of the PCM, Figure 1. A dedicated Mission 4x3 C-pump pushes water
through the eductor at 8.0 BPM. The water flow through the eductor creates vacuum.
This vacuum suctions dry powder from the Transfer Can, Figure 2, at the exit of the
feeder through a hose and tube. The feeder meters the amount of powder in the same
way as the previous version of the SBF-215, up to 125 lbs/min. This PCM can pull up to
80.0BPM total suction flow rate, with both the eductor and main C-1 pump running. This
PCM has the added capability to mix gel-into-gel if needed.
Figure 1 Gel-gun Eductor in Front Hydration Tank

Figure 2 Transfer Can for Suctioning Powder
The gel-gun PCM has four pneumatic shakers to help loosen the powder in the bin when
it becomes compacted. One shaker installs on each side of the bin. The shakers actuate
from a button on the computer touch screen. The gel-gun PCM also has an unloader
auger that installs on the curb side to help empty powder out of the bin if needed. The
unloader auger is actuated manually from the second section, from the front of the unit,
on the auxiliary Apitech hydraulic valve bank which installs on the road side of the unit
by the trailer gooseneck.
The Vortex Ventures eductor, knife gate, slam gate, and related piping have been
removed from this gel-gun version of the PCM. The KCL metering system has also being
removed. The section of the mixer Apitech hydraulic valve bank that ran the KCL system
now runs the new Eductor C-pump described above. The C-4 rate upgrade pump and
piping have also being removed from the unit. The C-4 rate upgrade pump is no longer
needed because the PCM can reach its maximum flow rate of 80.0 BPM with the C-1
pump by itself.

2 Operation
The gel-gun PCM operates very similarly to the previous dry powder PCM version. A
difference is an additional pneumatic valve, Figure 3, dedicated to open and close only
the suction valve 13A, Figure 4. This valve is labeled as the “Isolation Valve”. In the
previous PCM versions valves 13A and 13B were operated by the same valves to be out
of phase with each other. With the new Isolation Valve the operation of valves 13A and
13B is decoupled. The sections below describe how each stage of the PCM operates
with this new valve. The additional capability of mixing gel-into-gel is also described.
Refer to Figure 5, Figure 6, Table 2, and Table 2 for depiction and state of the valves
during the various stages.
Figure 3 Isolation Valve for Suction Valve V13A

Figure 4 Suction Valve V13A
Figure 5 Gel-gun PCM Schematic

CURB SIDE VIEW

VACUUM VALVE DILUTION CHIMNEY
V19
V21
V15
V16
EDUCTOR
SUPPLY VALVE
V14
C1
V23 G2 V18
V22 V13A ISOLATION

V20 C2 V17 VALVE V13B G1
Figure 6 Gel-gun PCM Process Valves, Curb Side View
Gel‐gun PCM Manual Valve Settings for Operation Stages

ISOLATION VALVE FILL and STAGE II and FILL and
Manual Label on Top Hand Wheel Hand Wheel
CLOSED SHUTDOWN STAGE III STAGE III
Valve / Valve in Comp Valve, Bet.
OPEN NORMAL STAGE I STAGE I and
Operation Label on Bottom 1., V15 Tanks, V17
OPERATION STAGE II
Normal down down down down open closed
Stage 1 up up down down closed closed
Stage 2 up up up down closed closed
Stage 3 down up up up closed closed
Gel‐into‐gel up down down down open open
Table 1 Gel-gun PCM Manual Valve Settings

Gel‐gun PCM Valve Response During Operation: X = Closed, O = Open

Valves / Suction Isolation Valve in Comp. 3, Valve in Comp. 5, Gate Between
Operation Valve, V13A V13B V16 V19 Comp. 1 & 4, G1
Normal O X X X X
Stage 1 X O O X X
Stage 2 X O X O O
Stage 3 O X X O X
Gel‐into‐gel X X X X X
Table 2 Gel-gun PCM Valve Response
2.1 Normal Operation
During normal operation water is pulled from the frac tanks by centrifugal pump C-1
through valve V15 and the chimney into compartment 1. The hand wheel on the
operator’s console, Figure 7, operates valve V15. Water then flows in under-and-over
fashion into compartments 2, 3, 4, 5, and 6, see Figure 5. During Normal operation all
the valves on the left hand side of the operator console are down including the Isolation
Valve, Figure 8.
Figure 7 Hand Wheel to Operate Valve V15

Figure 8 Valve Position for Normal Operation
2.1.1 Start Eductor
The eductor is run during normal operation for mixing gel. The Eductor C-pump pulls
water from the same suction piping as C-1. The suction piping needs to be primed up in
order for the Eductor C-pump to work properly. Follow these steps to start the eductor:
Step 1 Prime with C-1: Start C-1 with the dial in position 3. Open the suction valve V15
with the hand-wheel to allow some water to come out of the chimney into compartment
1.
Step 2 Close V15: Close valve V15 with the hand-wheel then stop C-1.
Step 3 Start eductor: Start the eductor by pressing the Eductor “Start” button on the
computer screen, Figure 9. Pressing this button actuates three valves. First, the Eductor
Supply Valve Opens. This butterfly valve installs at the exit of the Eductor C-pump under
the front hydration tank, Figure 10. The valve is actuated pneumatically from the top
section of the eductor stack valve on the gooseneck of the trailer, Figure 11. Three
seconds after the Eductor Supply Valve opens, the Eductor C-pump starts, Figure 12,
pumping water through the eductor. The Eductor C-pump runs with a hydraulic valve
and motor. The front most section of the mixer Apitech hydraulic valve bank, which
installs on the trailer in between the front and rear hydration tanks, powers the motor.
Three seconds after the Eductor C-pump starts, the Vacuum Valve opens, allowing
powder to be suctioned from the Transfer Can. The Vacuum Valve installs at the eductor

in compartment 4 of the front hydration tank, Figure 13. The Vacuum Valve is actuated
pneumatically from the middle section of the eductor stack valve on the gooseneck of
the trailer, Figure 11. It is important for the valves to open in this order and with this
timing for proper eductor pressure to build and to prevent water from flowing back to the
Transfer Can through the powder suction hose. The new gel-gun PCM computer
program controls the timing of these valves. The previous PCM program does not
include the coding to run these valves. The new gel-gun PCM program needs o be
installed on the computer running the gel-gun PCM. The PCM program will say “PCM:
GEL GUN” on the title bar in the upper left of the screen when it is set up to run the gel-
gun mixing system. If this is not shown the gel-gun option of the PCM software can be
activated by going to Calibrate -> Advanced -> Enable Dry Guar -> Enable Gel –gun
Eductor. If the option for “Enable Gel-gun Eductor” is not available the latest PCM
software needs to be downloaded from InTouch 4233507.
Figure 9 PCM Computer Screen: Eductor and Guar Control

Figure 10 Eductor Supply Valve Underneath Front Hydration Tank
Figure 11 Eductor Air Stack Valve at Front of Hydration Tanks

Figure 12 Eductor C-pump Underneath Front Hydration Tank (Not Installed Here)
Figure 13 Vacuum Valve on Gel-gun Eductor Powder Inlet

2.1.2 Mixing Gel
Before and during mixing gel consider the state of the Gel-gun Eductor Pressure and
Flow Rate, Blow-down Valve, Eductor Monitor, Transfer Can, and valve V17 as
described below. This PCM meters the same amount of powder as the previous version
of the PCM, up to a maximum of 125 lb/min.
Gel-gun Eductor Pressure and Flow Rate: Ensure that the eductor pressure shown on
the mechanical gauge by the hand-wheel is at least 65 PSI, Figure 14. The pressure
could range from 65 to 75 PSI. Note that the Eductor Pressure shown on the computer
screen, Figure 16, is generally 5-10 PSI higher than that shown on the mechanical
gauge. This is because the electrical sensor for the Eductor Pressure reported on the
screen is right at the outlet of the Eductor C-pump. The pressure on the mechanical
gauge should not be higher than 80.0 PSI. This signals that something could be plugging
the pipe to the eductor or eductor itself, see notes below about the Blow-down Valve.
The suction flow rate with only the eductor running and not C-1 should be 8.0 +/- 1.0
BPM. These conditions of 65 to 75 PSI and 8.0 +/- 1.0 BPM need to be met for the
eductor to create enough vacuum to suction powder from the Transfer Can and to have
enough flow rate to mix the water and powder properly. The suction caused by the
eductor can be felt by putting a hand on the hose connection inside the Transfer Can,
Figure 22.
Figure 14 Eductor Pressure Mechanical Gauge

Figure 15 Eductor Pressure on Computer Screen (From Electrical sensor)
Blow-down Valve: If the eductor flow rate of 8.0 +/- 1.0 BPM cannot be achieved or the
eductor pressure is higher than 80.0 PSI on the mechanical gauge, the eductor piping or
eductor may be plugged. A cylinder style strainer installs at the base of the eductor,
Figure 16 and Figure 17. This strainer catches any debris before it reaches the eductor.
A blow-down valve purges any content out of this strainer into compartment 4, Figure 16.
Open this valve by using the green handle by the operator’s console, Figure 18, to
clean-out the strainer. If the eductor cannot build at least 65 PSI of pressure it may be
that this blow-down valve is open. Close the blow-down valve after cleaning the strainer.
During mixing powder the blow-down valve must always be closed.

Figure 16 Eductor Strainer Housing and Blow-down Valve
Figure 17 Eductor Cylinder-style Strainer

Figure 18 Blow-down Valve to Clean Eductor Strainer
Eductor Monitor: Ensure that the Eductor Monitor is turned on. This can be checked on
the Diagnostics screen on the computer, Figure 19. The Eductor Monitor stops the
eductor if the pressure is not above 25 PSI three seconds after the Eductor C-pump
starts. This prevents the Eductor C-pump from running dry. The Eductor C-pump has
mechanical seals that should not be run dry. Stopping the eductor also prevents the
Vacuum Valve from opening and water from flowing back through the powder suction
hose if there is not enough water pressure through the eductor. An electronic pressure
sensor that installs at the exit of the Eductor C-pump measures the eductor pressure
reported on the computer screen and used by the Eductor Monitor. The Eductor Monitor
should always be turned on during regular PCM operation. However, if the pressure
sensor fails the Eductor Monitor can be turned off to finish the stage by going to
Calibrate Æ Advanced Æ Eductor Monitor. Pick “No” so that the eductor monitor is not
enabled. The Eductor Monitor change will be reflected in the Diagnostics screen.

Figure 19 Eductor Monitor of PCM Program
Clean Transfer Can: Ensure that the gate on the Transfer Can is pinned open to allow
powder to fall from the feeder, Figure 20. Check that the Transfer Can is clean of any
clumps of gel or debris. Turn the manual wheel if needed to remove clumps, Figure 21. It
is normal for some powder to accumulate at the bottom of the Transfer Can. But, the
clean-out door on the side of the Transfer Can can be opened to clean it if there is
clumped gel or debris clogging the opening of the suction hose, Figure 22. After
cleaning, ensure the clean-out door is fully closed for powder to be suctioned properly.
The screw on the latch may need to be adjusted, Figure 23. If the powder bin was filled
or the bin shakers run while the Transfer Can gate is open the Transfer Can may fill with
powder, Figure 24. This is not a problem. Once the eductor is running the powder will be
suctioned right up. The small volume of powder in the Transfer Can will not hurt the gel
mixture.

Figure 20 Transfer Can Gate Open
Figure 21 Transfer Can Manual Wheel to Catch and Remove Clumps

Figure 22 Transfer Can Clean-Out Door and Hose Connection
Figure 23 Transfer Can Clean-out Door Latch Screw

Figure 24 Transfer Can Filled with Powder
Valve V17 Closed: Ensure valve V17 is in the closed position, Figure 25. This valve
only needs to be open when mixing gel-into-gel or if C-1 fails completely. If valve V17 is
open during regular mixing, C-1 and the Eductor C-pump will pull water from the rear
hydration tank of the PCM. This can lead to suction problems, potentially making fish-
eyes, and plugging of the eductor strainer.

Figure 25 Hand Wheel for Valve V17
Start Mixing: With the eductor running, enter the desired set point for the Dry Guar on
the computer screen and press Guar “On”, Figure 9. The screw in the feeder will start
metering powder.
Speedup C-1 and Open V15: Increase the speed to C-1 to dial position 3 and then
open valve V15 with the hand-wheel. Increase the speed of C-1 more as needed to
reach the desired suction flow rate. The PCM is rated up to 80.0BPM.
Stop Mixing: Once ready to stop mixing, press the Guar “Off” button on the computer
screen.
Open Blow-down Valve Momentarily: After stopping mixing powder for the stage, and
with the eductor still running, open the Blow-down valve, Figure 18, for about 15
seconds to help clean out any debris that may have accumulated inside the eductor
strainer screen. Then, close the Blow-down valve again.

2.1.3 Stop Eductor
Follow the steps listed below to stop the eductor. It is important to follow these steps
because if the water in the frac tanks is low and Valve V15 is open the eductor could
suck air back up the piping through V15.
Step 1: Slow down C-1 to position 3.
Step 2: Close hand-wheel Valve V15.
Step 3: Stop C-1.
Step 4: Press the Eductor “Stop” button.
2.2 Staging
Follow the steps below to finish pumping the stage. Staging works the same on the gel-
gun PCM, except for the added “Isolation Valve”. The pneumatic Isolation Valve opens
and closes only the suction valve 13A, decoupling its operation from valve 13B. See
Figure 5, Table 2, and Table 2 for the valves actuated during each stage.
2.2.1 Stage 1
During Stage 1 the PCM suction valve 13A is closed and C-1 pumps water from the
bottom of compartments 1 & 2 into compartments 3 & 4 through valve V16 as before. To
start Stage 1 the first and second valves on the left side of the operator console should
be put up, Figure 26. Continue with Stage 1 until water stops spilling over the weir from
compartment 4 to 5 and compartments 1 and 2 are empty.

Figure 26 Valve Position for Stage 1 Operation
2.2.2 Stage 2
During Stage 2 C-1 pumps water from the front tanks of the PCM to compartment 5 in
the rear tank as before. Start Stage 2 by lifting the third valve on the left side of the
operator console, Figure 27. Note that for Stage 2 to work properly, the first and second
valves, for Stage 1, should already have been in the up position. Continue with Stage 2
until all of the water has been moved from the front tanks to the rear tanks.

2.2.3 Stage 3
During Stage 3 C-1 pumps water from the frac tanks into compartment 5 of the PCM as
before. Start Stage 3 by putting the first valve on the left hand side of the operator
console, the Isolation Valve, down and the fourth valve up, Figure 28. Note that for
Stage 3 to work properly, the second and third valves should already have been up from
Stage 2. Continue with Stage 3 until no more water is needed for flush.

2.3 Mixing Gel-into-gel
The gel-gun PCM has the added capability to mix gel-into-gel if needed. To mix gel-into-
gel C-1 and the Eductor C-pump pull water from the rear tanks of the PCM into the front
tank. The additional required powder is added to the water pushed through the eductor.
The gelled water then follows the normal path from compartments 1 through 6, allowing
it to be hydrated properly. Note that the suction flow rate will read zero because the
water being pulled does not pass through the suction flow meter. Follow the steps listed
below to mix gel-into-gel.
Step 1: Put the PCM valves in Normal operation, but with the Isolation Valve closed,
Figure 29. This isolates the PCM from the frac tanks.

Figure 29 Valve Position for Mixing Gel-into-gel
Step 2: Open valve V17 by turning the hand wheel located in between the front and rear
tanks on the curb side, Figure 25. Valve V17 connects the piping in between the front
and rear tanks.
Step 3: Circulate water with C-1 by turning the dial to position 6. Have the hand wheel
for V15 fully open.
Step 4: Press the Eductor “Start” button on the computer screen. The valve sequence
explained above ensues to start the eductor.
Step 5: Enter a set point for the amount of powder to be added to the gel. It is
recommended to mix at 25 lbs/min. Must use auto rate for the powder, not auto
concentration, because the suction flow meter will read zero. Press Guar “On” from the
computer screen to start mixing.
Step 6: Once the needed amount of powder has been added, stop mixing by turning off
the powder first, then the eductor and C-1.

2.4 Bin Shakers
The gel-gun PCM has shakers added to the sides of the powder bin to help loosen the
powder when it gets compacted. (The blower that was installed in previous dry powder
PCM’s has been removed.) One shaker installs on each side of the bin, Figure 30, for a
total of 4. The shakers actuate from the computer screen by pressing the “Bin Shaker”
button, Figure 31. Each time the “Bin Shaker” button is pressed the shakers run for 10
seconds. The shakers are very loud. The shakers are supplied air from a small
dedicated air tank, Figure 32, so that they do not drain the air from the primary PCM air
tanks. A pressure protection valve allows air into the tank only when the main system air
is above 80 PSI. The main system air is usually 100 PSI. A pressure regulator takes the
air down to 60 PSI for the shakers because they should not be operated with higher air
pressure. The shakers use a lot of air. The small air tank only has capacity to run them 2
to 3 times consecutively. But, they only need to be run every few minutes to loosen the
powder in the bin. Additionally, there are two manual valves, Figure 32, to blow a little bit
of air into the bottom of the powder feeder. These valves spring close so they do not
stay open for a long time. These valves supply air to fluidizers at the bottom of the
feeder. They help loosen powder around the metering screw if the powder is compacted
and the screw does not turn. The bin hatch should be open when running air through
these fluidizers to prevent the bin from over pressurizing.
Figure 30 Bin Shaker (1 of 4)

Figure 31 PCM Computer Screen: "Bin Shaker" Button
Figure 32 Air Tank for Bin Shakers and Feeder Fluidizer Manual Valves

2.5 Unloader Auger
The gel-gun PCM has an Unloader Auger installed to help unload powder from the
powder bin if needed. This Unloading Auger installs on the side of the bin on the curb
side of the PCM, Figure 33. The Unloader consists of a screw similar to the metering
screw used in the feeder. A hose and flange connect to the Unloader Auger housing to
facilitate transfer of the powder into a bag. This hose and flange should be located with
the loose equipment in on the tote tank platform and distribution box. The Unloader
Auger actuates by turning the knob all the way in the Auxiliary Apitech valve bank
section labeled “Unloader Auger”, Figure 34.
Figure 33 Unloader Auger

Figure 34 Unloader Auger Actuates from Auxiliary Apitech Valve Bank
3 Parts & Service
The following are some new parts on the gel-gun PCM that may require service.
3.1 Eductor Strainer
The cylinder-style strainer that installs prior to the eductor for the Blow-down Valve may
need to be cleaned or changed, Figure 16 and Figure 17, if opening and closing the
Blow-down Valve did not make the eductor gauge pressure go under 80.0 PSI. Remove
the four bolts from the square plate with the hose connection to access the strainer.
Replacement strainers can be ordered through SWPS by using SLB P/N 100962295,
see Table 3.

SLB P/N Description Manufacturer Mfg P/N Order

100962295 SCREEN,4.0" O.C. 1/4P34-41FFY- SWPS
DIAMETER, 1/4" KECKLEY BC-A
PERFORATED, COMPANY
304SS FOR
STYLE A
STRAINER
Table 3 Eductor Strainer Ordering
3.2 Eductor Orifice Plate
The eductor orifice plate, Figure 35, Figure 36, and Figure 37, that installs inside the
eductor may need to be cleaned if cleaning or replacing the strainer did not make the
eductor gauge pressure go under 80.0 PSI. Remove the two clamps, hammer union,
pneumatic connections shown on Figure 38 to pull out the eductor. Be careful not to
drop the clamps or O-rings inside them into the tank. A rope and at least two people are
needed to take the eductor out. Care must be taken that after cleaning the beveled side
of the orifice plate installs facing up, Figure 37. Make sure all the O-rings are in place
and in good condition, see section below on Eductor O-rings. Also, the eductor orifice
plate and powder tube should be flush with each other as shown and described in the
eductor alignment procedure, Figure 39. Align the eductor orifice plate and powder tube
if needed. The eductor needs to be aligned as described to obtain the correct flow rate
and vacuum suction for mixing.
Figure 35 Gel-gun Eductor: Orifice Plate Inside

Figure 36 Eductor Assembly

Figure 37 Eductor Orifice Plate and O-ring
Figure 38 Items to Disconnect to Remove Eductor

Figure 39 Eductor Alignment Procedure

3.3 Eductor O-rings
The O-rings in the eductor, Figure 36, Figure 37, Figure 40, and Figure 41, may need to
be replaced if the eductor leaks or if they get damaged. Care should be taken that the
seals are installed correctly and do not get damaged during installation. The seals are
listed in Table 4. They can be ordered as a kit through SWPS or obtained commercially.
Figure 40 Eductor Exit O-rings

Figure 41 Eductor Powder Tube O-rings
Figure 42 Eductor2 IN Sanitary Clamps

Order SLB P/N Description

SWPS 100968105 SEALS,KIT FOR GEL-GUN EDUCTOR INSTALLATION
This kit includes the seals listed below, which could also be obtained commercially.
Reference Quantity Description
Figure 41 4 O-RING BLACK BUNA 039, FOR C3 POWDER TUBE
Figure 40 1 O-RING BLACK BUNA 252, FOR C-DISCHARGE FLANGE
Figure 42 3 GASKET 2 IN SANITARY CLAMP BLACK BUNA
Figure 37 1 O-RING BLACK BUNA 155, FOR B/C3 HOUSING SEAL
Figure 40 1 O-RING BLACK BUNA 147, B/C3 INSERT DICHARGE SEAL
Table 4 Eductor Seals
3.4 Eductor C-pump & Seals
The 3X4 Mission Sandmaster Eductor C-Pump should turn at 1630 +/-10 RPM. It has
mechanical seals. Mechanical seals generally last a very long time, but they could get
damaged if the pump runs dry. The pumped fluid cools the mechanical seals as the
pump turns. Replacement mechanical seals can be ordered through SWPS or from
Master Pumps & Equipment in Oklahoma City, OK 405-670-5214,
[email protected]. An entire replacement Eductor C-pump can also be
ordered through SWPS. See Table 5.

100841192 C-PUMP, 4 X 3 X National 4313SM SWPS
13 SANDMASTER Oilwell Varco
100962305 SEALS,KIT FOR National 648414308 SWPS
C-PUMP 4 X 3 X Oilwell Varco Mission No
13 MISSION
SANDMASTER
Table 5 Eductor C-pump & Seals

3.5 Eductor Hydraulic Motor
A Rexroth hydraulic motor runs the Eductor C-pump. The hydraulic motor is run from the
forward most section of the Mixer Apitech valve bank located in between the hydration
tanks. See Mixer hydraulic piping and schematic per InTouch 5507921. The Mixer
hydraulic pump should be set at 3500 PSI. The mixer hydraulic pumps on previous
PCM’s were set at 3000 PSI. A 12V pulsar actuates the hydraulic valve section to turn
on the motor. The pulsar is controlled from the Guar DCU board. See electrical wiring
diagrams per InTouch 4994632. If a replacement motor is required it can be ordered
through SWPS, see Table 6. Due to long lead times a similar motor from a different
manufacturer may be used.

100841198 MOTOR, HYD, REXROTH AA2FM45/61W- SWPS
AA2FM45/61W- VSD510
VSD510
Table 6 Hydraulic Motor for Eductor C-Pump
3.6 Bin Shaker Parts & Air Lubrication
See Figure 43 and Table 7 for parts used in the bin shaker installation. The bin shakers
are actuated from the computer screen through the Guar DCU board. The Guar DCU
board sends a 12V signal to a relay in the distribution box, Figure 44. When closed this
relay sends a 24V signal to a pneumatic solenoid to allow air to pass to the bin shakers,
Figure 43. Two N14007 diodes install inside the conduit connecting the solenoid. These
diodes need to be installed to prevent electromagnetic interference with optical encoder
signal for the powder RPM when the solenoid discharges.
An 80.0 PSI protection valve allows the bin shaker supply air tank to fill, Figure 43. This
80.0 PSI protection valve should be installed to prevent the air for the bin shakers to
drain the main PCM air tanks. Downstream of the solenoid a 60.0 PSI regulator supplies
air through a lubricator to the bin shakers. The shakers should not be actuated by air at
higher pressure than 60.0 PSI. The air going to the bin shakers should be lubricated.
The air lubricator should be filled with transmission fluid.

CONDUIT WITH DIODES PNEUMATIC SOLENOID
80 PSI PROTECTION VALVE
60 PSI REGULATOR AIR LUBRICATOR
Figure 43 Parts for Bin Shakers Installation


100281799 RELAY, TERMINAL PHOENIXCONTACT 2966906 SWPS
BLOCK DIN RAIL
MOUNTED 12VD
100755733 DIODE,AXIAL Any 1N4007 Any
RECTIFIER, 1A, electrical
1000V, PACKAGE = parts
DO-41, P/N = supplier
1N4007, -65 to 150C,
ROHS COMPLIANT
439212000 VALVE,PRESSURE BENDIX AIR 286500 SWPS
REGULATOR
100876274 VALVE,SOLENOID PARKER-FLUID 73212BN4TN SWPS
AIR 1/2 IN NPT 00N0H111C2
24VDC-NC
100874110 REGULATOR,AIR Parker Hannifin 06R213A- SWPS
NON-ADJUSTABLE L060
60PSI 3/8" PORTS
60SCFM
100454009 LUBRICATOR,AIR PARKER-SEALS 07L24B SWPS
SYSTEM 3/8",
SIGHT GAUGE AND
TWIST DRAIN, WITH
FILL PLUG
Table 7 Parts for Bin Shaker Installation

Figure 44 Relay for Bin Shaker Solenoid
3.7 Unloader Auger Parts
The unloader auger, Figure 33, is run by a hydraulic motor from the Auxiliary Apitech
hydraulic valve bank, Figure 34. The motor should be setup to turn at 300 +/- 25 RPM to
push powder out of the bin. A replacement motor can be order through SWPS, see
Table 8.

100573651 MOTOR, AUGER Parker TE0165AS10 SWPS
SCREW Hannifin
CONVEYOR
Table 8 Hydraulic Motor for Unloader Screw

3.8 PCM Program Software
The new gel-gun PCM computer program controls the timing of the eductor valves. The
previous PCM program does not include the coding to run these valves. The new gel-
gun PCM program needs o be installed on the computer running the gel-gun PCM. The
PCM program will say “PCM: GEL GUN” on the title bar in the upper left of the screen
when it is set up to run the gel-gun mixing system. If this is not shown the gel-gun option
of the PCM software can be activated by going to Calibrate -> Advanced -> Enable Dry
Guar -> Enable Gel –gun Eductor. If the option for “Enable Gel-gun Eductor” is not
available the latest PCM software needs to be downloaded from InTouch 4233507.

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SBF-215 GEL-GUN PCM OPERATION AND PARTS

Part 01 - Section 01 – SBF-215 GEL-GUN PCM

Document Type OSP Manual template

Software Microsoft Word 2007

Author Idalia Ovalle Stevenson

Review & approval Kim Hodgson

Last saved 10-Aug-11 13:21

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2.2 Staging................................................................................................................................. 2-20

2.3 Mixing Gel-into-gel ............................................................................................................. 2-23

2.4 Bin Shakers ......................................................................................................................... 2-25

2.5 Unloader Auger ................................................................................................................... 2-27

3 Parts & Service............................................................................................3-28

3.2 Eductor Orifice Plate .......................................................................................................... 3-29

3.3 Eductor O-rings .................................................................................................................. 3-33

3.4 Eductor C-pump & Seals ................................................................................................... 3-35

3.5 Eductor Hydraulic Motor.................................................................................................... 3-36

3.6 Bin Shaker Parts & Air Lubrication .................................................................................. 3-36

3.7 Unloader Auger Parts......................................................................................................... 3-39

3.8 PCM Program Software...................................................................................................... 3-40

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Figure 42 Eductor2 IN Sanitary Clamps ..................................................................................... 3-34

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Figure 1 Gel-gun Eductor in Front Hydration Tank

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Figure 2 Transfer Can for Suctioning Powder

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Figure 3 Isolation Valve for Suction Valve V13A

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Figure 4 Suction Valve V13A

Figure 5 Gel-gun PCM Schematic

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CURB SIDE VIEW

V22 V13A ISOLATION

Figure 6 Gel-gun PCM Process Valves, Curb Side View

Gel‐gun PCM Manual Valve Settings for Operation Stages

Table 1 Gel-gun PCM Manual Valve Settings

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Gel‐gun PCM Valve Response During Operation: X = Closed, O = Open

Table 2 Gel-gun PCM Valve Response

2.1 Normal Operation

Figure 7 Hand Wheel to Operate Valve V15

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Figure 8 Valve Position for Normal Operation

2.1.1 Start Eductor

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Figure 9 PCM Computer Screen: Eductor and Guar Control

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Figure 10 Eductor Supply Valve Underneath Front Hydration Tank

Figure 11 Eductor Air Stack Valve at Front of Hydration Tanks

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Figure 13 Vacuum Valve on Gel-gun Eductor Powder Inlet

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2.1.2 Mixing Gel

Figure 14 Eductor Pressure Mechanical Gauge

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Figure 15 Eductor Pressure on Computer Screen (From Electrical sensor)

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