INSTALLATION, OPERATION

& MAINTENANCE SPECIFICATIONS

FOR

SIDEWINDER MIXER

MODEL SW-800 Swaco, A Business Unit of M-I L.L.C. A Smith/Schlumberger Company 5950 North Course Drive Houston, Texas 77072 Tel: 281-988-1868 Fax: 281-988-1888

MANUAL PART #90-90-773 (Rev. A)

TABLE OF CONTENTS

SECTION

I. INTRODUCTION…………………………………………………….1 II. PIPING AND PUMP SIZING….………………………………….....1

A. LINE SIZES………………….……………………………………1 B. MAXIMUM LIFT…………….…………………………………..1 C. TOTAL BACK PRESSURE…..………………………………….1 D. DISCHARGE PIPING………….………………………………...1 E. PUMP SIZING………………….…………………………………2

III. INSTALLATION……………………………………………………..2

A. HEAD GAUGE………………….………………………………..2 B. VALVE……………………………………………………………2

IV. OPERATING INSTRUCTIONS…………………………………….2 A. STARTING THE MIXER……………………………………….2 B. STOPPING THE MIXER……………………………………….3

V. MAINTENANCE……………………………………………………..3 A. SOLIDS FEED VALVE…………….…………………………....3 B. TAKING THE MIXER OUT OF LINE…….………….……….3

VI. TROUBLESHOOTING…………………………...……….………...3 A. INSUFFICIENT HEAD………………………………………….3 B. VORTEX INSIDE THROAT OF MIXER….…………..………4 C. SOLIDS FEED VALVE FAILS TO SEAL….………………….4

VII. RECOMMENDED SPARE PARTS LIST………………………….4 FIGURE 1 – DIMENSION DRAWING AND PARTS LIST.……………..5 FIGURE 2 – MAXIMUM DISCHARGE PIPE LENGTH CHART….......6 FIGURE 3 – FEED HEAD VERSUS FLOW RATE……………….….…..6 APPENDIX – SIZING LINES AND CALCULATING REQUIRED PUMP

HEAD

SECTION 1 INTRODUCTION The Sidewinder Mixer solves the one problem that has plagued the oil industry for decades how to quickly and effectively add and blend mud additives. Consisting of a conveniently positioned hopper, 8” feed throat, double stage mixing chamber, and hydraulically matched tangential inlet and outlet, the Sidewinder mixer allows heretofore unobtainable mud additive acceptance rates. The unique patented design exposes added material to the high shear forces developed by the two-stage cyclonic action ensures that each particle of material introduced into the mixer is thoroughly hydrated, mixed and blended to uniformity before being discharged into the active mud system. The natural vortex created within the mixer results in non-plugging, inherently self-cleaning piece of equipment. As with all Swaco products, durability and ease of maintenance are keynotes of the design. Areas of possible wear within the three-piece body are lined with polyurethane. Bolted, all steel construction means long life and easy internal access. SECTION II PIPING AND PUMP SIZING To ensure effective and reliable operation of the Sidewinder In-Line Mixer, considerable attention must be given to proper line sizes, piping arrangement and pump selection.

A. LINE SIZING Using 6” pipe or larger for the Sidewinder Mixer feed and discharge piping. Smaller pipe will cause excessive head loss. B. MAXIMUM LIFT The discharge piping from the Sidewinder Mixer must not be elevated more than 8 feet higher than the discharge outlet of the mixer. More lift than this will reduce the diameter of the mixing vortex and may cause mud to back flow into the hopper throat. For lift greater than 8 feet, consult the Engineering Department of Swaco in Houston, Texas.

C. BACK PRESSURE Back pressure in the Sidewinder Mixer discharge piping has a considerable effect on the mixer performance. If this back pressure is too great, the vortex diameter will become too small and mud may back flow into the hopper throat. D. DISCHARGE PIPING Refer to Figure 2 for the maximum length of straight 6” pipe in the discharge line. The discharge height is measured from the center line of the mixer outlet to the center line of the highest point in the discharge piping. E. PUMP SIZING The correct pump and pump driver is extremely important for reliable operation of the Sidewinder Mixer. The pumping unit must produce a minimum of 65 feet of head at the feed inlet of the mixer. The recommended operating head is 70 + - 5 feet. CAUTION: Do not operate the mixer with over 80 feet of feed head. Figure 3 on page ? can be used as an estimate of the flow rate at various feed head. The amount of head loss due to piping must be taken into account when sizing the pump and motor. If unfamiliar with pump curves, the Swaco Engineering Department in Houston will check and recommend pump specifications at your request. Refer to the Appendix for an example pump sizing.

SECTION III INSTALLATION The Sidewinder Mixer is completely assembled when shipped, ready to be installed. The proper sizing with pump and motor selection should already have been determined from previous calculations. Do not weld on the mixer.

A. HEAD GAUGE A Pioneer Head Gauge should be installed just before the entrance into the mixer. The recommended feed head at the mixer is 70 +-5 feet. When operating, if mud splashes inside the solids feed throat, a higher feed head is necessary. CAUTION: Do not operate mixer over 80 feet of feed head. B. VALVE Butterfly valves should be installed on the suction line to the pump, on the feed line to the mixer, and on the discharge line from the mixer. The valves are not necessary for operation of the mixer. However, they make possible the isolation of the pump or the mixer if either must be taken out the line for maintenance reasons. All valves except the solids feed valve must be open before the mixer feed pump is started.

SECTION IV OPERATING INSTRUCTIONS If the proper procedure is followed for operating the Sidewinder Mixer, clean, safe and efficient solids addition will result.

A. STARTING THE MIXER (REFER TO FIGURE 1 FOR IDENTIFICATION OF MIXER COMPONENTS)

1. Open all valves, EXCEPT the solids feed valve, in the line from the suction pit through the pump and mixer to the discharge. DO NOT OPEN THE SOLIDS FEED VALVE WHEN THE MIXER IS NOT AT FULL OPERATING HEAD. If an electric motor drives the centrifugal pump, the mud flow should be started slowly to prevent undue pressure and hydraulic surges. Before starting the pump, partially close the butterfly valve on the suction side. Start the electric motor, and then gradually open this valve to fully open position.

2. Start the pump and allow it to reach full operating head. The head gauge at the entrance to the mixer should read 70+-5 feet of head. CAUTION: Do not operate the mixer over 80 feet of feed head. If the gauge reads below 65 feet of head, the vortex may be inside the solids feed throat. DO NOT PEN THE SOLIDS FEED VALVE SINCE THE MUD MAY FLOW OUT OF THE TOP OF THE MIXER. (See section VI, TROUBLESHOOTING).

3. Open the solids feed valve. A vortex of swirling mud will be seen outside of the solids feed throat. WARNING: Keep hands and tools away from the feed throat while the mixer is in operation.

B. STOPPING THE MIXER 1. Securely CLOSE the solids feed valve. DO NOT STOP THE MIXER IF THIS

VALVE IS OPEN OR MUD WILL POUR OUT OF THE TOP OF THE MIXER. Clean the valve if necessary.

2. Shut off the pump. 3. Close the valves in the flow line.

SECTION V MAINTENANCE The sidewinder Mixer is practically maintenance free. The inside of the mixer has no moving parts and requires no maintenance. The solids feed valve and the pumping unit feeding the mixer do require periodic upkeep.

A. SOLIDS FEED VALVE The Sidewinder mixer has a butterfly valve on the hopper used to feed the mixer. Periodically clean the hopper valve to allow easy opening and closing.

B. TAKING THE MIXER OUT OF LINE With the mixer stopped, close the valves in the line before and after the mixer. Remove the Victaulic couplings from the feed and discharge connections. Allow mixer to drain and remove from line. It may be necessary to drain the mixer in cold weather to prevent cracking of the mixer due to freezing.

SECTION VI TROUBLESHOOTING The Sidewinder Mixer, which utilizes no moving parts for mixing, should run trouble-free. If problems occur, the pumping unit-not the mixer may be the problem. A. INSUFFICIENT HEAD If the head gauge at the entrance to the mixer reads less than 65 feet of head, the pumping unit is not large enough, or is running improperly. Check the pump and pump driver as recommended by the manufacturer for correct operation. If the pump is working as it should and there is still insufficient head, the pump is undersized. Go through the pump sizing again, or consult with our Engineering Department regarding pump sizing. B. VORTEX INSIDE THROAT OF THE MIXER If there is mud swirling up inside the solids feed throat of the mixer when no solids are being added, there is either too little feed head or too much back pressure. Check the head gauge at the entrance to the mixer for at least 65 feet of head, 70+-5 feet of head for normal operation. If there is less than 65 feet of head, see the previous paragraph for insufficient head. If the recommended head is produced at the entrance to the mixer, but the vortex is inside the throat, too much back pressure is being produced by the discharge piping from the mixer. Re-piping will be necessary with a reduction in lift usually helping the most. Sometimes, an increase in feed head needed rapidly becomes prohibitively large. If the vortex is outside the throat while the mixer is running, but becomes swirling inside the throat when solids are being added, the total back pressure is too high. An increase in feed head or a decrease in discharge piping and lift to reduce back pressure is required. A reduction in lift will usually help the most. C. SOLIDS FEED VALVE FAILS TO SEAL If the butterfly valve leaks when the mixer is being stopped, re-start the mixer immediately. Open the butterfly valve, wash the seal and pivot points with water, and re-close firmly. The valve will hold pressure if the seal is intact. If the seal is damaged, the butterfly valve must be replaced.

SECTION VII RECOMMENDED SPARE PARTS LIST The following spare parts or components are recommended for one year of normal operation. They can be identified below and on the drawing on the next page of this manual. DESCRIPTION PART NUMBER QTY Middle Section 13319 1 Bottom (Lower) Section 13320 1 Gasket 13387 2 Butterfly Valve 31095 1 Head indicator Assy 30838 (English) 1 Or 30837 (SI Metric) 1

APPENDIX

SIZING LINES AND CALCULATING REQUIRED PUMP HEAD

INSTRUCTIONS

(Use with “Work Sheet” Form C-42A, Chart EN10-27A, & Table EN07-04A)

To calculate line size and choose a pump, the proper impeller size and an adequate motor or engine to run it, it is necessary that you know where the pump skid is to be located relative to the tank from which it will take mud, and also where the mixer is to be located relative to the pump. A mud centrifugal pump should always be installed below the mud level in its suction tank to prevent priming problems, to reduce cavitations and to keep down maintenance costs. On the other hand, the mixer should be located so that mixer discharge piping will be short. Once the decision has been made on the location of the equipment, proceed to fill out the “work sheet” form C-42A provided, using the following instructions and charts. If you wish to Swaco Engineering to do the sizing and advice on matching the pump and motor or engine, fill out only the following parts of the “work sheet” and mail it to Swaco Headquarters Engineering 5950 North Course Drive Houston, TX 77072.

- Line 1: (See instructions, Step 1) - Line 6: Columns under “No. of fittings in Line” for Suction Line and for

Line to Mixer (See instructions, Step 6). - Line 11: (See instructions, Step 11). Discharge piping lengths and fittings.

If you wish to work out the sizing problems for yourself, follow these instructions closely. STEP 1: Under “Pump Suction Line: write the Sidewinder Mixer feed capacity at 65’ head. Refer to Figure 3 for flow rate. Write in Line 1 and the feed capacity of the mixer, to be fed by the one pump under the column “Pump Suction Line.” STEP 2: Use the upper (velocity) and lower (friction) portion of Chart EN10-27A to select line sizes. Work separately with the pump suction and discharge lines if the GPM is different in Line 1. using the GPM’s from step 1, try to pick line sizes tat will give a liquid velocity in the line of not less than four feet per second (upper chart). Five feet per

second is better, especially in the large lines, but also try to stay under 5 psi friction drops per 100 feet (lower chart) on the “T” curves. If the velocity is too low, due too large a line, solids will settle out on the bottom of the lines in horizontal runs. As the solids settle, the line will close up until the velocity us up to four feet per second, or higher. The velocity necessary to keep a line clean can be called the “minimum scour velocity.” If the pump discharge piping to the mixer is extremely short, and there are not many fittings, a drop of 5 psi per 100 ft. may not be too much. An excess drop in the pump suction line, however, will be paid for in maintenance dollars and poor pump performance, resulting in poor mixer performance. No calculations for it are needed, but for the mud discharge from the mixer to the pits, use the same size line as the feed mud line to the mixer, unless there is an upward lift of more than eight feet. In this case, contact our Engineering Department and give the engineers all the details you can. STEP 3: Using the minimum GPM figures from Line 1 of the “Work sheet,” and the line size from Step 2, read on the upper part of Chart EN 10-27A the mud velocity and record it in Line 3 of the “Work Sheet.” STEP 4: Write down in Line 4 the GPM from Line 1 plus 10%. STEP 5: Again using the upper part of Chart EN 10-27A, and using the GPM from Line 4 and the pipe size from Line 2, write in Line 5 the velocities at the maximum pumping rate. STEP 6: Before filling in the lines under 6, you obviously must first figure out how to run the lines with the least number of turns to keep pressure losses down. Then,

- First, add up the estimated total length of straight line in the suction line and enter this figure in both the L (Laminar Flow) and the T (Turbulent Flow) columns under “Pump Suction Line.”

- Second, do the same for the line from the pump to the Sidewinder Mixer and enter this figure in the “L” and the “T” columns under “Pump Discharge Line.”

- Third, in the proper space under “No.” for “Pump suction Line,” put the number of tees, ells, etc.

- Fourth, do the same as above for “Pump Discharge Line” piping, in the “No.” column.

- Fifth, using Table EN-07-04A, “Friction Loss in Fittings,” find each fitting at the left hand side and read across to the proper pipe size. Under “L” and “T” you will find figures representing the approximate length of straight pipe that would have the same friction drop as that particular fitting in either Laminar or Turbulent flow. Multiply the number of these

fittings in the “No.” column by the proper figure under “L” in the Table EN07-04A and write this product under “L” in the proper space on the “Work Sheet.” Do the same with the figure “T” and enter in the proper “T” column. Do this for both the pump suction and discharge piping.

STEP 7: Add up the “L” and “T” columns of Line 6 and write in Line 7. These are the total equivalent straight lines for suction and for discharge in both Laminar and Turbulent flow. The effect of too many fittings will show up here. STEP 8: Using the lower part of the Chart EN10-27A and using the GPM’s from Line 1 and Line Size from Line 2, read off the chart pressure drop per 100 feet for the suction piping in Laminar flow and in Turbulent flow. As each is read off, write it in the appropriate column in line 8. STEP 9: Multiply each number (ft. per 100 ft) in Line 8, times the number (equivalent length of pipe) in the corresponding column in Line 7 (Laminar drop time Laminar equivalent length, etc.), and divide each result by 100. These resulting numbers represent the approximate friction drop in feet for the pump suction piping and for the pump discharge piping, in Laminar and Turbulent flow. Enter these results in the proper columns of Line 9. STEP 10: Since we do not know whether the mud will be in Turbulent flow or Laminar Flow, we must play it safe and assume it will be in the type flow that results in the most friction drop (head loss). Usually this is true. For Line 10, take the largest of the two feet figures for the pump suction piping from Line 9, and add it to the largest of the two feet figures for the pump discharge piping. This will give the approximate total friction drop in the piping in feet for a 9.5 ppg mud. STEP 11: Measure or estimate the vertical height from the average mud level in the suction tank down to the centrifugal pump suction line. (Using maximum mud operating level will give a safer or more conservative result). Write this figure in Line 11 in feet. This is the head gain due to the fall of the mud, exclusive of all other losses and pressures. STEP 12: The total required head increase which the centrifugal pump must furnish will be the piping lines losses minus the mud level gain you have already calculated plus the required feed head at the mixer feet inlet. It is best to figure for 65 feet at the mixer. Total necessary head rise in feet = 65 + (friction drop, line 10)-(Mud level gain, Line 11) STEP 13: You are now ready to select a centrifugal pump and a motor engine. If an AC electric motor is to be used, the speed of the motor can be assumed at 1750 rpm loaded, or sometimes at 1150 rpm for very large centrifugal pumps.

Using the centrifugal pumps curves of RPM, impeller size, capacity and horsepower corrected for muds heavier than water, the information you have worked out through Step 13 is sufficient to select a pump and impeller size and motor, provided you understand the pump curves. If you do not have mud corrected pump curves, or do not understand pump curves, Swaco Engineers will check and recommend pump specification, provided you furnish the brand of pump and type of engine or motor the customer wishes to use. Pump representatives usually have information to aid in pump sizing. Engine representatives can help in checking the best speed for the engine and available continuous horsepower at those speeds. Swaco will be pleased to quote skid-unitized pump-engine and pump-motor skids using the brands of the customer’s choice. Our units are matched in that no V-belts are used from engine to pump. We have specially developed Mission pump curves from which we can match the pump and impeller size direct to the engine for maximum efficiency of the overall unit with minimum maintenance costs. REMARKS If two or more centrifugal pumps are used with cross-manifolds, they should not discharge into a common line at the same time. If one pump is in better condition than the other, or has a lower suction head drop, it will tend to hog the load from the other pump and overload the engine or motor. A centrifugal pump will also tend to overload if it is operated with the suction closed or pinched. The horsepower load on a constant speed centrifugal pump also increases almost directly as the weight of the mud being pumped increases. If information is needed in an emergency, please contact SWACO HEADQUARTERS Engineering 5950 North Course Drive Houston, TX 77072.