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Source text - English Avalanche testing
Avalanche testing was first proposed as a method for evaluating powder flow behaviour in the mid- 1990s and commercial instruments became available soon after. The technique can be used to quantify flow properties under low stress conditions.
Principle of operation
When rotated in a drum, powders roll, fall or avalanche in a way that can be related to their flow properties. Avalanche testers record images of the powder in motion and from these determine parameters such as avalanching frequency which can be used as an assessment of flowability. Short, times between avalanches indicate good flowability. The speed of rotation of the drum has a major impact on avalanching behaviour and is varied to create optimum conditions for testing a given powder. Beyond this, avalanche testing offers limited opportunity to vary the flow regime in order to more closely simulate processing conditions.
Disadvantages
• The sample cannot be subjected to controlled consolidation or aeration to simulate specific process conditions
• An absence of sample preparation can introduce variability associated with the operator or packing history
• Interactions between the surface of the drum, from the outset of test, or as a result of progressive powder coating, can significantly impact the results
• Repeatability can be an issue
In summary
Avalanche testing can be a useful technique for the assessment of flow under low stress conditions. However, the sample is subjected to a single flow regime and, other than varying drum rotation speed, there is limited capacity to tailor test conditions to reflect in-process conditions. The repeatability of some avalanching devices can be relatively low, limiting their ability to differentiate samples that have subtle but important differences.
Uniaxial shear testing
Principle of operation
A uniaxial shear tester measures the stress required to break or fail a consolidated column of powder. The construction of a homogeneously consolidated powder column is essential for accurate and repeatable measurement and modern instruments achieve this via double ended compression of the powder sample within a confining sleeve. Removal of the sleeve produces a free-standing column that is subjected to compressive stress, up to the point of fracture, to determine the uniaxial UYS (uUYS) of the powder.
Biaxial and uniaxial shear testing both determine UYS, and by extension FF. In biaxial testing UYS is generated by extrapolation from measured data, while in uniaxial testing it is measured directly. However, because the methodologies associated with the two techniques subject the powder to different consolidation and failure protocols, the reported values are not identical. The term uUYS is used to highlight this differentiation.
In summary
Uniaxial testing offers a practical, low cost solution for high productivity flowability assessment and generates familiar parameters which have become well-established via the widespread adoption of biaxial shear cell testing. Compared with other simple techniques it offers high repeatability and reproducibility and while it may be less suitable for very free-flowing powders, it can be used to assess a wide range of materials. The data generated is particularly relevant to performance in moderate to high stress environments.
FT4 Powder Rheometer® User Manual
Register on our website for more information
www.freemantech.co.uk
COMPANY PROFILE
Freeman Technology specialises in systems for measuring the flow properties of powders and has over a decade of experience in powder flow and powder characterisation. The company invests significantly in R&D and applications development, and provides detailed know-how alongside its universal powder tester, the FT4 Powder Rheometer®. Expert teams guide and support users around the world in addressing their individual powder challenges, focusing on delivering the most relevant information for the process. The result is world-leading solutions for understanding powder behaviour - in development, formulation, scale-up, processing, quality control, or anywhere that powders have a role.
The FT4 Powder Rheometer uses patented dynamic methodology, a fully automated shear cell (in accordance with ASTM Standard D7891) and several bulk property tests, including density, compressibility and permeability, to quantify powder properties in terms of flow and processability. Systems are installed around the world in the chemical, pharmaceutical, toners, foods, powder coatings, metals, ceramics, cosmetics, and many other, industries. They deliver data that maximise process and product understanding, accelerating R&D and formulation towards successful commercialisation, and supporting the long term optimisation of powder processes.
Freeman Technology was founded in 1989 as a developer of automated testing systems for materials characterisation, and has focused exclusively on powders since the late 1990s. The company’s R&D, manufacturing and commercial headquarters are in Gloucestershire, UK, with subsidiaries and distribution partners located around the world.
In 2007 the company received the Queen’s Award for Enterprise in Innovation and in 2012 the Queen’s Award for Enterprise in International Trade.
Freeman Technology and Powder Rheometer are registered trademarks of Freeman Technology Ltd.
PRECAUTIONS
Please note that the FT4 is supplied without anti-virus software pre-installed. Every effort is made to ensure the instrument is free from viruses at the point of delivery but it is highly recommended that your organisation’s virus protection procedures are implemented prior to connecting the FT4 to your network or using electronic storage devices.
Please also be aware that this instrument contains moving parts. Bodily injury may occur if you attempt to handle the blade assembly when in operation. A safety door is in place and the interlocking system prevents movement should the door be left open.
We strongly recommend you read this manual thoroughly prior to operating the instrument.
If you require any further guidance please contact Freeman Technology or one of our approved partners.
FT4 USER MANUAL CONTENTS
Section 1 – Getting Started
• Installation
• Powering up the FT4
• Running the Software Applications
• Logging On
• Directory Structure
Section 2 – Running a Test
• Preparing the Sample
• Selecting the appropriate Vessel and Blade
• Protecting the Blade
• Fitting the Blade and other Accessories to the Instrument
• Fitting the Vessel to the Rheometer Table
• Use of the Safety Door
• The Menu Structure
• Starting a Test
• Running a Test
• Naming and Saving a Test File
• What happens if a Force or Torque Overload occurs during a Test?
Section 3 – The Test Program
• Test Program Structure
• Definition of Blocks and their Variables
• How to Create or Edit an Existing Test Program
• Setting and using Autoturn
Section 4 – Data Analysis
• Importing Test Files
• Reviewing Test Data
• Working with the Main Graph
• Creating Index Graphs
• Reviewing Raw Data
Section 5 – Calibration
• Calibration of the Rheometer
• System Calibration (Force and Torque)
• System Calibration (Height)
• System Calibration (Speed)
• Audit Calibration (Force, Torque & Height)
• Specification
FT4 USER MANUAL CONTENTS
Section 6 – User Administration
• Add User
• Edit User
• Delete User
• Reset Password
• Report
• Edit Options
Section 7 – System Backup & Restore
• System Backup
• System Restore
Section 8 – Upgrading Software
• Installing New Software
Section 9 – Specification
Appendix 1 – Electrical Connections
SECTION 1 – GETTING STARTED
INSTALLATION
• Electrical connections are as indicated in Appendix 1. Mains AC supply may be in the range 90V to 264V, 1.6A max.
• The FT4 Powder Rheometer should be set up on a stable work surface with access to a wash basin with hot and cold water for cleaning vessels, blades, etc.
• All usual safety procedures need to be implemented when handling and testing powders. The instrument may be set up in a fume cupboard if necessary.
• When the vessels and blades are not in use, store in their respective compartments in the cases provided.
POWERING UP THE FT4
• Switch on the power using the keypad at the top of the instrument.
• The green LED should illuminate and the FT4 will boot into the Windows environment.
Hard disk activity is indicated by the red LED.
• The blue ‘stop’ button at the bottom of the instrument should also become illuminated if not depressed.
RUNNING THE SOFTWARE APPLICATIONS
• Two icons should be present on the Windows desktop. Double clicking on either of these will run that application.
LOGGING ON
• After double clicking on the Powder Rheometer icon the log on screen should appear, please see Figure 1 on following page.
• The default administrator logon details are: -
User Name: admin
Password: admin
Note that this password can be changed at any time, however the User Name for this account is fixed.
• An authorised user must enter their user name and password correctly to gain access.
• An authorised operator may change their password by first logging on and then selecting ‘Edit User' from the
'Create / Edit Users' menu.
• The system administrator is required to create new user accounts (see Section 6).
SECTION 1 – GETTING STARTED
Figure 1 - Log on Screen
DIRECTORY STRUCTURE
• The Powder Rheometer and Data Analysis programs are installed into C:\Program Files\Powder Rheometer and C:\ Program Files\Freeman Technology\Data Analysis folders respectively.
• The directory structure of all the folders used by the programs is shown below in Figure 2, the Rheometer directory can be found in C:\. The structure should not be modified.
Figure 2 - Directory Structure
SECTION 2 – RUNNING A TEST
PREPARING THE SAMPLE
The instrument is very sensitive and will detect small variations in sample preparation. It is strongly suggested that a set of procedures are defined and used consistently. Some things to be considered are:
• The need for rigorous cleanliness of blades and vessels.
• Cross contamination from previous test samples.
• Condition of sample prior to test, e.g. moisture levels.
SELECTING THE APPROPRIATE VESSEL AND BLADE
• Various sizes of blade and vessel are available.
• The 50mm borosilicate glass vessel and 48mm blade is the standard combination.
PROTECTING THE BLADE
The blade and spindle (blade assembly), are precision engineered and must be protected from damage. The blade geometry is critically important. It is made from a high tensile strength stainless steel and is therefore not easily damaged. However every precaution should be taken to avoid dropping, bending or marking the blade. The repeatability of the test results is very dependent upon this.
It is recommended that the blade case should be kept adjacent to the rheometer and used to store the blade when not fitted to the instrument.
FITTING THE BLADE AND OTHER ACCESSORIES TO THE INSTRUMENT
• Insert the spindle into the hub as shown in Figure 3 below. Note that there are only two rotational positions in which the spindle can be correctly inserted.
• Ensure that the spindle is fully inserted, i.e. the circlip is in contact with the hub as shown in the drawing below.
• Tighten the nut by hand. Note that it is not possible to damage the instrument when tightening by hand.
• WARNING – the blade assembly should be handled by the spindle only.
Figure 3 - Spindle Hub
SECTION 2 – RUNNING A TEST
FITTING THE VESSEL TO THE RHEOMETER TABLE
• Firstly, assemble the appropriate vessel following help files W7020, W7021 or W7022.
• Please note that it is necessary to remove the 50mm & 62mm Vessel Clamping Assembly, if fitted. To attach the 25mm vessel, insert the 25mm Vessel Clamping Assembly into the side of the table and then place the vessel centrally on the table. Ensuring that the thumb screw is loose, locate the fingers of the clamping assembly into the slots on the clamp ring. Tighten the thumb screw to secure the vessel to the table.
• Please note it is necessary to remove the 25mm Vessel Clamping Assembly, if fitted. The mechanism for the 50mm and 62mm vessels consists of a table bar and two thumb screws. If these are not already installed on the FT4, remove one of the thumb screws and insert the table bar into the side of the table. Reinstall the second thumb screw and then place the assembled vessel on the table before equally tightening the thumb screws.
USE OF THE SAFETY DOOR
• This is interlocked to prevent movement of the FT4 carriage / spindle whilst the door is open. Close the door before attempting to begin a test.
• Opening the door during a test will stop the instrument immediately. To restart, close the door and click 'OK' in the 'Door Open' message box.
THE MENU STRUCTURE
All features are accessed through the buttons on the main screen. The options available are:
• Standard Test Programs – run standard tests as supplied with the FT4 Powder Rheometer.
• Advanced Test Programs – provides access to less commonly used and user modified test programs.
• Create / Edit Users – Administer Powder Rheometer users including password management and access rights.
• Calibration / Settings Menu – allows users to carry out audit calibrations of the FT4 and ACU, back up, modify and restore system settings.
SECTION 2 – RUNNING A TEST
STARTING A TEST USING STANDARD TEST PROGRAMS
Click on Standard Test Programs and select a Standard Methodology from the following screen. Then proceed to the steps outlined on the next page.
Figure 4 –Standard Methodology Selection
STARTING A TEST USING ADVANCED TEST PROGRAMS
Click on Advanced Test Programs, select a program from the program library and click ‘Run’. Then proceed to the steps outlined on the next page.
Figure 5 – Advanced Program Selection
SECTION 2 – RUNNING A TEST
RUNNING A TEST
After selecting a Standard Test Program or an Advanced Test Program proceed with the following steps:
1. Click on the required vessel size.
2. Insert the recommend accessory into the FT4 hub and click the ‘Confirm Blade’ box.
3. Assemble the recommended vessel and tick the ‘Confirm Vessel’ box.
4. Place the assembled vessel on to the FT4 table and when the balance has stabilised, click ‘Tare Empty Vessel’.
5. Fill the vessel with the sample, return the filled vessel to the FT4 table and when the balance has stabilised, click ‘Record Sample Mass’.
6. Record optional information about the test sample in the Material, Batch Code and Reference No. fields. Additional fields can be added by clicking ‘Modify Test Label Options’.
7. Click ‘Start Test’.
8. Real time measurements can be viewed during the test procedures.
9. The y-axis scale is automatically adjusted to display all recorded information. This feature can be disabled by deselecting the tick box at the bottom-left corner of each graph as necessary using the up and down arrows on the left of the plotting window.
10. Total Energy values are plotted in real time at the bottom right corner of the screen.
11. Test information is displayed in the right-hand column. Variables available to the operator, such as enable/disable ‘Shake Blade’ can be accessed via the Test Options tab.
12. 'Pause' can be selected during the test to temporarily halt the test procedure.
13. Selecting 'End Test' will immediately terminate the test procedure and the carriage will return to the parked position. Any data measured up until this point can be saved.
14. If the test program is not terminated prematurely by the operator, it will finish automatically and the operator will be required to save the test file.
SECTION 2 – RUNNING A TEST
NAMING AND SAVING A TEST FILE
At the end of the test, the data can be saved and the following options are available:
• Location – the directory where the test file will be saved. Click ‘Change’ to select an alternative location.
• File Name – the name to be assigned to the test file. This is generated automatically using the name of the test program and details entered at the start of the test. The information used in the automated naming process can be modified by clicking ‘Options’.
• Run – allows the operator to allocate a run number to the file in the event that repeat tests are being performed.
• Notes – a free text box allowing any observations to be recorded.
Figure 6 – Save Test Data Screen
The file is given a PRB extension and is saved as a read only file. The raw data can be viewed in Excel but must be converted into a CSV file in Data Analysis (see Section 4).
WHAT HAPPENS IF A FORCE OR TORQUE OVERLOAD OCCURS DURING A TEST?
• In the event of force or torque levels exceeding the set maximum levels, the system will stop and alert the user with a message box. Should this occur the program is terminated and a more suitable program for the material should be selected. Please contact Freeman Technology for assistance if required.
• The data recorded up to the point of overload is available and can be saved and analysed.
SECTION 3 - THE TEST PROGRAM
TEST PROGRAM STRUCTURE
• A sequence of Blocks that define the Test Program – see below for further details.
• A program description that summarises what the Test Program does.
• The starting accessories (vessels, blades, pistons, shear cells, etc.) compatible with the Test Program.
• Autoturn settings.
• All equations that have been defined for the Test Program.
DEFINITION OF BLOCKS AND THEIR VARIABLES
Block Function Variable
Conditioning Cycle Used to condition the powder prior to a Test Cycle or other process step (consolidation via tapping, etc.) Uses the standard blade to establish a homogenised, low stress packing in the powder. Helix angle – angle of helical path that blade moves along on down/up traverse.
Tip speed – speed in mm/s at the end of the blade tip. Note that this is not simply rotational speed, but the speed along the helical path.
Height – the position in mm to which the blade will move to. Once the blade reaches this point, the test program moves on to the next step.
Up Levelling – this allows the blade to adopt the settings defined here in order to produce a level powder surface once the blade has exited the powder bed. Used mainly when a Conditioning Cycle precedes a compaction step.
Test Cycle Used to measure the Flow Energy of the powder, either after conditioning, aeration or consolidation. Variables as Conditioning Cycle.
Also includes an ‘Associate Test Variable’ option which allows information to be assigned to that individual test cycle (for example, air velocity during an Aeration test).
User Defined Cycle Can be configured either as a Conditioning or a Test Cycle.
Variables as Conditioning Cycle.
Main difference is that each variable can be set with finer resolution, compared to the limited standard options available with Conditioning or Test Cycles.
Traverse Zone List A single movement or sequence of movements within one Block.
Variables as Conditioning Cycle.
Provides the ability to move the blade in different flow modes during specific parts of a traverse. A traverse can therefore be made up of multiple zones, each with different variables if required.
Park Returns the carriage to the Park position.
Vessel to be split – tells the software to recalculate the mass of powder in the vessel after the ‘OK’ button is clicked.
Funnel to be removed – inserts a message box requesting that the funnel is removed. This step precedes the ‘Vessel to be split’ function in the actual program sequence and ensures that the mass calculation during the split does not include the mass of the funnel also.
Change – Tells the software that the spindle accessory needs to be changed (for example after conditioning with the blade and before consolidation with the piston).
Create Automatic Message – selecting this button automatically creates the message that appears in the message box during the test, based on the status of the other Park variables. If required, a message may be manually typed into this area and will overwrite any automatically created message.
Restart at the following height inside the vessel – defines the height at which the spindle accessory moves to after the Park step and before starting the next Block.
Move Moves the spindle accessory to a specific height. Distance – moves the spindle accessory either to a specific height or by a defined amount, either upwards or downwards.
Helix Angle – the angle at which the spindle accessory moves during the Move Block. Normally set to 90 degrees.
Tip Speed – the speed at which the tip of the blade or outside edge of the piston moves at during the Move Block. When the Helix Angle is set to 90 degrees, this Tip Speed defines the vertical speed.
Rotate at Height Allows the spindle assembly to be rotated at a fixed height. Speed – can be set as Tip Speed or spindle revolutions per minute.
Duration – can be set to duration of rotations, number of rotations or number of degrees.
Apply Force Used to apply a force or normal stress to the powder. Typically uses the compaction piston. Compact to Normal Force – sets the target force, in Newton. This can also be defined as a normal stress, in kPa, by changing the Options at the bottom of the screen.
Hold – allows the target force to be held for a precise time. Alternatively, once the target force has been reached, the position is held for a precise time (this position control allows for potential force decay as the powder relaxes). The final option is to simply move to the next Block.
Helix Angle – the angle at which the piston moves during the Apply Force Block. Normally set to 90 degrees.
Carriage Speed – the maximum vertical speed at which the piston moves during force control. This value is automatically attenuated as the measured force reaches the target force.
Do not compact below – a safety limit, which prevents the piston moving below a certain height in the event that the target force is not reached.
Shear Cell Used to measure shear properties under a controlled normal stress (ASTM D7891). Normal Stress – the consolidation stress imposed during the pre-shearing or shear step. This can also be defined as a normal force, in Newton, by changing the Options at the bottom of the screen.
Shear for – number of degrees of rotation during the pre-shear or shear step.
Control Speed - the maximum vertical speed at which the piston moves during force control. This value is automatically attenuated as the measured force reaches the target force.
Shear Rate – the angular speed of shearing during the pre-shear or shear step.
Auto Analyse – defines which data is automatically displayed when the test file is imported into Data Analysis.
Wall Friction Used to measure wall friction properties under a controlled normal stress (ASTM D7891). See Shear Cell.
Display Message Box Inserts a message box and requires the operator to click ‘OK’ to continue. Message – any text information can be typed here and will be presented during the test program. The program will not continue until the operator clicks ‘OK’. Could be used to advise the operator to measure the temperature or electrostatic charge for example.
Time Delay Inserts a time delay. Pause – defines the period at which the instrument pauses and halts motion of the blade or accessory. During this time a message can be displayed, if entered in the Display Message box. This feature could be used if waiting for X seconds whilst the powder de-aerates, for example.
Tare Table Weight Re-tares the Force measurement. Used during a test program if it is necessary to re-tare the force. For example, after liquid or powder addition.
Aeration Control Sets the air velocity provided by the Aeration Control Unit (ACU). Turn Air Off – instructs the ACU to set the air supply to zero mm/s.
Turn Air On – when enabled, allows a required air velocity to be set.
Permeability Used to supply an air velocity through the powder whilst applying a consolidating normal stress with a compaction piston. Measure – defines whether to measure air pressure as a function of normal force and air velocity, or air velocity as a function of normal force and air pressure.
Normal Force – sets the target normal force for the measurement. This can also be defined as a normal stress, in kPa, by changing the Options at the bottom of the screen.
Air Velocity / Pressure – sets the air velocity or air pressure (depending on the ‘Measure’ setting above) for the measurement.
Control speed - the maximum vertical speed at which the piston moves during force control. This value is automatically attenuated as the measured force reaches the target force.
Hold Time – the duration for which the force and air velocity are maintained.
Minimum Height – a safety limit, which prevents the piston moving below a certain height in the event that the target force is not reached.
HOW TO CREATE OR EDIT AN EXISTING TEST PROGRAM
• Creating a new program is done by editing an existing program and saving it with a new program name.
• Select ‘Advanced Test Programs’ from the Main Menu.
• Select a program from the program library and click ‘Modify’.
• Using the 'Program Editor' modify the settings as required.
• Block types can be selected from the menu on the left of the screen and inserted into the program using the ‘Add’ button. Using the ‘Change’ button changes the block type (for example, from Conditioning to Test).
• Existing Blocks can be modified by clicking on the Block in the right window and changing the parameters on the left.
• Selecting ‘Copy’ makes a direct copy of the block highlighted on the right hand side and inserts it into the program structure. This function is particularly useful if the program contains several repeated cycles.
• The global parameters are modified using the Test Setup tab on the left of the screen. Variables such as Autoturn and Levelling can be adjusted for the program as a whole.
• Test Setup also allows the Starting Accessories to be defined. These then become the only options available when selecting the test program to run in the ‘Run a Test Program’ screen.
SECTION 3 - THE TEST PROGRAM
• Program type defines the type of test and instructs Data Analysis (DA) on how to present the results.
Dynamic - used for all tests where a flow energy is measured using the blade and where the flow energy is to be plotted in DA against any variables in the test program, e.g. air velocity, tip speed, etc.
Shear - used for Shear Cell or Wall Friction tests, where shear stress is plotted against applied normal stress in DA.
Compressibility – used for all Compressibility tests and ensures percentage volume change (compressibility) is plotted against applied normal stress in DA.
Permeability – used for all Permeability tests and ensures pressure drop across the powder bed is plotted against either applied normal stress or air velocity.
• Equations can be created and defined using the Equations tab on the left of the screen. These will be saved with the program and will automatically appear in Data Analysis.
• Select ‘File’ / ’Save As’ and allocate a new name for the modified program. Then click 'OK' to save to the Test Program directory.
• Close the Program Editor by clicking the cross in the top right corner.
Figure 7 – Program Editor
SETTING AND USING AUTOTURN
• Autoturn allows any preset combination of Helix Angle and Tip Speed to be effective below a predetermined height, irrespective of the settings for the particular downward traverse. It is typically used to avoid the generation of very high stresses that would occur between 10mm and 1mm during a Test Cycle. Adopting the Autoturn settings (similar to a Conditioning Cycle) at 10mm ensures that the powder is still disturbed all the way to the bottom, but the high compaction stresses are avoided.
SECTION 4 – DATA ANALYSIS
OVERVIEW
This guide provides an introduction to the basic operation of Data Analysis v4.0 (DA4) and an overview of the main features. It is not intended to provide a complete description of all of the available functions. The software has been written so that a ‘right mouse click’ in the appropriate area will reveal a context sensitive menu so that users can manipulate and display data as desired.
There are a number of significant improvements over previous versions including:
• A clearer user interface with intuitive, context sensitive menu system
• The ability to analyse results from different test methodologies in a single session
• More display options and greater flexibility
If you have any questions or would like more detailed advice on specific aspects of Data Analysis, please contact Freeman Technology on +44 (0)1684 851551 or via [email protected].
IMPORTING TEST FILES
When starting DA4, the window shown in Figure 8 will appear. If a DA4 session is already running, select ‘Import Files’ from the ‘File’ menu.
Figure 8 - DA4 File Import Screen
Use the left hand column to navigate through the directory structure and find the required folder. Any Powder Rheometer (xxx.prb) files that exist in the selected folder will appear in the upper right-hand window. Several options are then available:
• Right-click on a folder to import all files in that folder and/or sub-folders.
• Right-click in the ‘All Files’ border of the upper right-hand window to select files in groups.
• Select individual files from the list by ticking the associated box in the upper right-hand window. Please note that you can use SHIFT and CTRL to create multiple selections.
Any files that have been selected will appear in the Session Summary. To import these files for analysis, click ‘OK’.
To remove files, go to the File Overview tab in Overview (see Reviewing Test Data) and right-click on the file to be removed.
To remove all files and start a new session, click ‘Clear Session’ from the File menu.
SECTION 4 – DATA ANALYSIS
REVIEWING TEST DATA
The selected test data will be imported and sorted according to test methodology. The default display setting shows an Overview tab alongside a tab for each methodology. Each tab is then broken down into sub-tabs as described below.
OVERVIEW TAB
• Graphs – provides a summary of the type and number of test methodologies used in the imported test files.
• File Overview – provides data on each individual test file including variables entered by the operator and parameters derived from the test.
• Index Overview – shows derived parameters grouped by Material and Batch Code. Includes the option to display error values.
• Hopper Design – allows the user to generate Hopper Half Angle and Outlet Size of an axisymmetric and plane flow hopper if suitable test files have been imported.
• Time Consolidation – allows the user to evaluate the effects of extended storage on the shear behaviour of a sample by comparison to a standard shear test (at the same consolidating stress) once suitable test files have been imported.
KEY FEATURES OF THE OVERVIEW TAB
• In File Overview and Index Overview, right-click on the table to open the data in Microsoft Excel or to export the data to the clipboard to paste into other applications.
• In Index Overview, right-clicking on the data will allow you to show the Standard Deviation and select how this is displayed.
TEST METHODOLOGY TABS
• Main Graph – shows the test points plotted in their familiar format as described in the various methodology help files. For further information see Working with the Main Graph.
• Index Graphs – provides a flexible method for plotting information derived from the test files. Graphs can be configured to a user’s specific requirements. See Creating Index Graphs for more detail.
• Report – allows the user to create a report for printing purposes which contains all of the information relevant to a group of tests.
• Raw Data – provides a method of further analysing the raw measurements made during a test. See Reviewing Raw Data for additional information.
• Series Value Table – displays the parameters derived from a test. Right-clicking on the table allows you to select the desired parameters and export data.
SECTION 4 – DATA ANALYSIS
WORKING WITH THE MAIN GRAPH
Figure 9 - DA4 Main Graph
When reviewing data on the Main Graph, holding the mouse cursor over a data point will generate a window containing detailed information. Simultaneously pressing the ‘D’ key will also display the raw data plots for those data points. Holding the cursor between two data points and simultaneously pressing the ‘D’ key will display both the raw data plots allow direct comparison of the data. If the cursor is held on a specific data point, pressing the ‘M’ key will reveal additional information that was collected during the test.
As with most areas of DA4, context sensitive menus are available by clicking with the right mouse button. In the Main Graph, the key features can be accessed by right-clicking the main body of the chart, (shown in white in Figure 9). The main features are described below.
• Manage Graph – this is a key feature of the Main Graph and allows users to describe how the test data is displayed.
Variables – select the values to be displayed on the x- and y-axes.
Data / Groupings – define how the test data is grouped and displayed. Also allows features such as error bars, data cluster and Mohr Circles to be toggled.
Legends – provides the option for user defined legends and colour schemes.
• Add or Remove Data – this feature allows the user to show files generated from different test methodologies on the same graph by ticking the box next to the required file name. By expanding the information (click on the plus sign) specific data points or groups of data points can also be included or removed.
• Add New Object – select this option to add a text label, a line or arrow or a data table. The data table can be configured by the user to show the required data. Once in place, right-click on the table to amend or to remove it.
• Export Image or Data – provides options for exporting data to other applications.
SECTION 4 – DATA ANALYSIS
CREATING INDEX GRAPHS
By following the steps below, the Index Graphs feature allows users to create a customisable series of graphs displaying a range of application relevant test parameters.
• Select the relevant test methodology tab and click on the Index Graphs tab.
• Click the ‘Create Index Graphs’ button to display the window shown below.
Figure 10 - Index Graphs Menu
• Tick the indices that are to be displayed in graphical format.
• Use the ‘Groups defined by’ box to select if the indices are grouped by parameter or by series name.
Figure 11 - Example of Index Graphs
Each individual graph can then be maximised by clicking the ‘Max’ button that appears in the top right-hand corner. Right-clicking on a graph in its maximised or minimised state will bring up a menu of relevant operations.
The Menu button in the top left-hand corner provides overall management of the Index Graphs.
SECTION 4 – DATA ANALYSIS
REVIEWING RAW DATA
Figure 12 - Raw Data Display
Options for reviewing and analysing raw data are mostly available via location specific menus which are accessed by right-clicking on the relevant area of the screen. Some of the key functions are highlighted below.
• Managing the Display – the main graph area is managed by clicking the ‘Menu’ button in the top left-hand corner. This menu allows users to select how many graphs are displayed and how. There is also the option to export the raw data graph as a range of image files.
• Changing X and Y Axes – right-clicking on the axis variable name, e.g. Force, Torque, Height, etc. brings up a list of other variables available to display.
• Viewing Detailed Information – hovering the mouse cursor over a specific trace will highlight that data set and display any relevant information. Double-clicking on the trace will zoom into that data set.
• Zoom Function – to zoom in on a specific area of the graph, drag the mouse cursor to create a rectangle over the area of interest and select the required option from the list that appears.
• Selecting Data – the list below the graphs allows users to select which data sets are displayed. Simply toggle the corresponding tick box to add or remove a data set. The tick box above the list allows additional data sets to be selected, e.g. conditioning cycles or upward traverses. Further options are available by right-clicking on a data set.
SECTION 4 – DATA ANALYSIS
SESSION FILES
DA4 Sessions (xxx.da4) can be saved to prevent the user having to manipulate the data each time the same files are imported for analysis. Please note that Session files only record information on which files were used and how data was displayed and not raw test data. Subsequently moving the original test files (xxx.prb) to a different location will prevent the Session File from loading. The Save Session and Open Session functions are available from the File menu.
OPTIONS
Figure 13: DA4 Options Menu
DA4 Options can be accessed via the Tools menu and allows the user to define preferences for features such as the start-up screen, how units are displayed, default colours and error calculations.
CREATE NEW MAIN GRAPH
Figure 14: Create New Main Graph Menu
The Create New Main Graph function in the Graphs menu provides another method of creating a user defined graph. By ticking the relevant box, the results of different test methodologies can be displayed and analysed together.
HELP
The Help menu provides quick access to this user guide and allows the preferred language to be selected. Information is also provided on the current installed version and allows the user to check for and download updates.
SECTION 5 – CALIBRATION
CALIBRATION OF THE RHEOMETER
Regular calibration of the measured and controlled parameters is recommended. A calibration kit is supplied for this purpose. The calibration procedures are fully supported by the software and are accessed via the Calibration / Settings Menu.
The calibration process is split into two groups, as follows: -
System Calibration – to provide the control software with the necessary calibration coefficients. Completed at the factory and should only be run after consultation with Freeman Technology.
Audit Calibration – a procedure that may be carried out in order to verify the accuracy of coefficients derived during a System Calibration. This procedure should be run at least once every 90 days.
On screen instructions are provided for each stage of each calibration procedure and it is important that these are followed precisely. A comprehensive help file is also available which can be followed during the calibration sequence. This is available from the FT4 Support Documents.
The following comments provide background information relating to calibration.
SYSTEM CALIBRATION (FORCE AND TORQUE)
• Two load cells are used in the instrument to measure the force and torque required to move the spindle accessory (blade, shear cell, etc.) through the material under test.
• Calibration requires known forces and torques to be applied accurately whilst electronic measurements are taken. Calibration coefficients are derived from this and used during normal testing.
• A calibration kit is supplied for this purpose and it must be assembled and used as described on the user screen and in the calibration help file.
• Important things to note are: -
The small pulleys attached to the pulley assembly need to be carefully handled to avoid damage. It is important that the pulleys are free running. When not attached to the instrument, keep in the calibration case.
Correct insertion of the drum spindle into the instrument is essential. Ensure that the spindle is fully inserted by checking that the circlip is against the spindle housing (see Section 2).
After fitting the drum and the pulley support, check that the drum rotates freely and does not contact the pulleys in any way.
• The nylon cord that supports the weight carrier must be undamaged and installed around the pulleys so as to run freely. In all cases the cords should hang vertically. If they do not then check and correct.
SECTION 5 – CALIBRATION
SYSTEM CALIBRATION (HEIGHT)
• This refers to the measurement of spindle accessory height in mm above the table. The zero position is defined as the position when the head of the blade assembly touches the surface of the vessel base.
• Two cylindrical height gauges are provided in the calibration kit. These are placed on the table in turn, when calibrating. The gauges have a difference in height of 100mm.
• The height calibration procedure takes two measurements, one near zero and another at a position precisely 100mm above this zero. The slope coefficient is calculated from these readings and used by the software to determine height.
SYSTEM CALIBRATION (SPEED)
• The spindle rotational speeds and the carriage vertical speeds are controlled by software in response to parameters defined in the Test Program. Both are driven by servo systems comprising motors and gearboxes and use encoder feedback to enable the control of speeds during testing.
• The encoders provide 500 pulses per revolution of the motor and speeds are calibrated by measuring the pulse rate of each servo system at the calibration speeds. (For example, one revolution of the blade produces 33000 pulses, with a 66:1 gearbox).
• Tip speed and helix angle setting and control accuracy are dependent directly upon the accuracy figures of the above servo speeds.
AUDIT CALIBRATION (FORCE, TORQUE & HEIGHT)
• The Audit Calibration is required to be run at least once every 90 days.
• The Audit Calibration procedures are identical to those of the System Calibrations, however the main difference is that the coefficients measured in the Audit Calibration are just compared to the existing, master coefficients on the FT4 (derived during the initial System Calibration). Therefore the Audit Calibrations are simply a verification that the FT4 is within calibration. They do not reset or overwrite anything.
• At the end of an Audit Calibration procedure, an Excel document is created and the results are presented alongside the acceptable pass / fail criteria. This Audit Log should be saved and retained as a record of calibration.
• In the event that an Audit Calibration results in one or more points outside acceptable limits, reported as a ‘Fail’ in the Audit Log, then it is recommended that the Audit Calibration is repeated. If two consecutive Audits result in failure, please contact Freeman Technology and do NOT complete a System Calibration.
• If the Audit Calibration confirms the FT4 is within calibration, denoted by a ‘Pass’ in all rows of the Audit Log, then that part of the calibration is compete and does not need repeating for 90 days. The date is recorded into the Admin form and a tick indicates it is within calibration.
• After three months have elapsed since the last Audit Calibration, a warning message is displayed reminding the operator that the Audit Calibrations need completing.
• Height Audit Calibration is also an identical procedure to the Height System Calibration, but again is solely for verification.
SECTION 5 – CALIBRATION
• Servo velocity audit requires external and independent instrumentation to measure the carriage displacement and blade rotations during an accurately timed interval. Most methods used will be less sensitive and accurate than the built in pulse counting system used for system calibration.
SPECIFICATION
• A specification for the FT4 Powder Rheometer is available in Section 9.
• The accuracy of measurement of all parameters is as follows: -
Better than 1% of reading or 0.25% of full scale, whichever is greater.
SECTION 6 – USER ADMINISTRATION
ADD USER
New users can be added by selecting the ‘Administer Users’ option in the ‘Admin’ then ‘Users’ screen. The following screen then appears enabling the ‘Add User’ button to be selected.
Figure 15: User Administration
When creating a new user, the Administrator is required to enter certain details describing the user to be added. As a minimum, they must define the User ID, Name and Password, as well as the level of permission the user will have.
Figure 16: Add User
SECTION 6 – USER ADMINISTRATION
• Once saved, the new user can logon using their User ID and assigned Password.
• A user can be configured with various permissions. Default rights for System Calibrators and Users are defined, although a Custom user can be configured with any combination of permissions.
• De-selecting ‘Run all Test Programs’ allows the Administrator to configure which Test Programs are available for the User to run.
EDIT USER
The Administrator can edit user properties after they have been created. Everything except the User ID and the user’s Password can be re-configured in this way. This option is also used to unlock previously locked accounts, arising from failed logon attempts.
DELETE USER
A user account can be deleted using this option. The account is made inactive and unavailable to the user, although a record of its existence is available in the Report (see below). If the Administrator tries to create a new account with the same User ID as a deleted account, the account will be reactivated allowing changes to be made to the user properties.
RESET PASSWORD
This option allows a system Administrator to reset the password of any of the accounts contained in the system.
REPORT
Produces a text report defining the attributes of all the accounts in the system.
EDIT OPTIONS
This allows the Administrator to define the Password Policy that will be employed by the system.
Figure 17: Define User Password Policy
SECTION 6 – USER ADMINISTRATION
The following attributes can be defined:
• Minimum and Maximum Password Length.
• Whether the password is required to contain both Alpha and Numeric characters.
• How many times the account can be unsuccessfully logged onto before it is locked out (this does not apply to the Administrator account – this account is never locked).
• How frequently the users are required to change their passwords.
• If the user is required to have a different password from previous passwords.
• How many previous passwords are remembered.
SECTION 7 – SYSTEM BACKUP & RESTORE
SYSTEM BACKUP
The Powder Rheometer system files can be backed up in case there is a computer failure resulting in the computer’s operating system needing to be reinstalled. This option can be found on the Calibration / Settings Menu.
Clicking Backup System opens the following screen:
Figure 18: System Backup
The default location for this file to be saved will appear in the ‘Backup Location’ dialog box. If required, this can be changed to a different location enabling storage directly to a network drive for example. The backup procedure produces a single file with all the necessary information to restore the Powder Rheometer system files. The following information is backed up:
• System Registry (containing calibration information).
• User Account details.
• Blades and Vessels Settings.
• All Test Programs contained in the ‘C:\Rheometer\Test\Test Programs’ folder, including all sub folders.
• Powder Rheometer system INI file.
It is recommended that the backed up file is stored on durable media separate from the FT4 for future restoration if needed. This procedure should be run on a monthly basis as a minimum.
Test Files are NOT backed up during this procedure and should be stored on a secure network drive on a regular basis.
SECTION 7 – SYSTEM BACKUP & RESTORE
SYSTEM RESTORE
From the Calibration / Settings Menu, it is possible to run the Restore System procedure.
Selecting this option allows the user to choose the directory of the backup file and begin restoration of the system files by clicking ‘Start Restore’.
Figure 19: System Restore
Information contained in the selected restore file, such as date, user and instrument serial number is displayed at the bottom of the screen and can be used to confirm whether the file selected is the required one.
The restore process begins by backing up all existing parameters before the new files are installed. These are saved to the directory listed in the ‘Restore Backup Location’ box.
Once the restore process has successfully completed, the application will automatically shut down to allow the restored settings to take effect.
The Administrator (Admin) password is always reset to ‘admin’ after a restore to prevent system lockout. It should be changed by the Administrator immediately after the restore process.
SECTION 8 – UPGRADING SOFTWARE
INSTALLING NEW SOFTWARE
• Copy the installation file to a memory stick or similar device.
• In Windows, select the 'Start' button at the bottom left corner of the screen.
• Select 'Run' then 'Browse', to open Windows Explorer.
• Select the relevant drive to view the contents of the memory device and follow the instructions below:
• Installing Powder Rheometer
o Double click on 'Setup_PR*_v**.exe' where * represents version numbers.
o Follow on screen instructions
• Installing Data Analysis
o Double click on 'Setup_DA*_v**.exe' where * represents version numbers.
o Follow on screen instructions
SECTION 9 – SPECIFICATION
SYSTEM: -
FT4 Powder Rheometer intended for use in a laboratory environment for measuring the rheological properties of powders, pastes and semi-solids.
Complies with the following EMC specifications and ASTM International standards:
EN61000-3-2:2001
EN61000-3-3: 1995
EN61326: 1997 + A2:2001
ASTM D7891
Certificates of conformity available on request.
PERFORMANCE: -
Force +/- 50N maximum
0.0001N resolution
Torque +/- 900mNm maximum
0.002mNm resolution
Vertical travel 185mm
Rotor speed 120 rpm maximum
Axial speed 30 mm/sec maximum
Residual energy level in air < 2mJ
COMPUTER SPECIFICATION: -
The instrument incorporates an integrated high specification processor and operates on a Microsoft Windows Embedded operating system. It has built in networking capability and a universal serial bus to provide serial daisy chaining of all automated accessories.
CONSTRUCTION: -
Working zone: 316 stainless steel
Contact parts: 316 stainless steel
Borosilicate glass
Delrin and Peek plastics
DIMENSIONS: -
Main instrument 306 x 306 x 760mm high
WEIGHTS: -
Main instrument 22kg net
POWER REQUIREMENTS: -
Supply voltage range: 90 to 264VAC
Input current range: 1.6A at 120VAC
0.8A at 230VAC
Input frequency range: 47Hz to 63Hz
Minimum fault protection limit: 30mA
ENVIRONMENTAL CONDITIONS: -
Humidity range 20-80% non-condensing
Temperature range (operating) 10˚C to 40˚C
Temperature range (storage) 0˚C to 50˚C
VESSELS: -
Precision bore, borosilicate glass tube.
Standard sizes:-
25mm x 10ml Split Vessel
25mm x 25ml Split Vessel
25mm x 35ml Vessel
50mm x 85ml Split Vessel
50mm x 160ml Split Vessel
50mm x 260ml Vessel
62mm x 137ml Split Vessel
62mm x 240ml Split Vessel
62mm x 400ml Vessel
BLADES: -
Hardened stainless steel.
Standard sizes:-
23.5mm diameter x 6mm wide
48.0mm diameter x 10mm wide
60.0mm diameter x 10mm wide
CALIBRATION KIT: -
Force, torque, height, carriage velocity and spindle speed are configured for calibration.
Calibration fixtures, weights and height gauges are supplied as part of the calibration kit.
A calibration log is automatically kept of the current and all previous calibrations.
ACCESSORIES: -
25mm Accessories Kit
50mm Accessories Kit
62mm Accessories Kit
Aeration Control Kit
1ml Shear Cell
SOFTWARE: -
All Control and Data Acquisition Software is supplied and configured with the instrument and includes Microsoft Office.
APPENDIX 1 – ELECTRICAL CONNECTIONS
POWER
Supply voltage range: 90VAC to 264VAC
Input current range: 1.6A at 120VAC
0.8A at 230VAC
Input frequency range: 47Hz to 63Hz
REAR OF FT4
Key
1 Mains Power Cable
2 USB (Dual)
3 USB (Dual)
4 Ethernet (RJ45)
5 VGA
WARNING
The FT4 must be shut down and power removed before connecting / disconnecting cables.
English to Chinese: TECHNICAL SPECIFICATION (53830 words) General field: Tech/Engineering Detailed field: Electronics / Elect Eng
Source text - English TITLE: TECHNICAL SPECIFICATION
GS 7
01 2002-01-22 FOR REVISION
REV DATE REVISION DETAILS E&I Manger INST. MAINT. SUPT PROJ. SMELT INST. CONC. INST.
1
INTRODUCTION
This GS-7 document deals with standards for Instrumentation at Palabora Mining Company. It aims to provide a standard for the equipment used, and installations done on site. Technical specifications are provided for reference with respect to engineering, rating, procurement and documentation.
The specifications contained within this document will be used as of 2002-02-01, and changes on existing equipment or plant will be made (where applicable) to adhere to these specifications.
2 GENERAL TECHNICAL CONDITIONS AND REGULATIONS
2.1 General
2.1.1 Instrument Description
The equipment must be suitable for the operational duty as detailed in the data sheets.
The equipment shall accept the input/output and power supply ranges specified on the Data Sheet.
It is the responsibility of both the Instrument Supplier and the requestor to verify the selection of instrument size; type and materials of construction for each application, based on the information provided on the data sheets.
2.1.2 Notes to Tenderer
The equipment to be furnished shall essentially be the standard product of a manufacturer regularly engaged in the production of the required type of equipment, and shall be the manufacturer's latest approved design/technology. Where later technology within the near future, (but which is not yet available) may supersede equipment, this must be stated in the tender.
The Seller's recommendations (such as new materials of construction, new developments or special equipment features, special application recommendations etc.) must be attached to the tender as a separate item. Complete technical details shall be submitted, including comparative unit costs, to enable proper assessment of merits.
2.1.3 Mounting
All instruments shall be provided with the necessary mounting accessories i.e. clamps, mounting brackets etc. Such accessories shall be of the appropriate materials for the instrument and area application.
2.1.4 Functional Requirements
Equipment shall confirm to the requirements of the Data Sheet. The supplier must submit his calculation sheets with the tender to enable evaluation of the tender. Where the specified requirements cannot be met, the Vendor may offer the range that most closely approximates the specified one. This must be clearly stated in the tender.
2.1.5 Repeatability
Repeatability shall be ± 0.5% span minimum (As per data sheet).
2.1.6 Inspection and Testing
The Supplier shall submit a request in writing for “Acceptance of Inspection and Testing”, and this will be submitted at least 5 days prior to the activities.
The minimum requirement for inspection and testing of the contract works, is as follows:
Inspection: To carry out a visual examination, including a dimensional check of the equipment at the Seller's works.
Testing: To witness functional testing of selected equipment prior to delivery. Test certificates will be required for all items. Material certification will be required for any special materials used.
2.1.7 Recommended Spares
The Seller shall recommend the stock level of the spares for the equipment offered. This recommendation should be based on a minimum of a 10% stock level, taking into consideration a 24 month operation period, unless the Seller from his past experience believes it necessary to hold either more or less equipment. Where individual parts are offered, they have to be itemised with part numbers, descriptions and prices at the time of tender.
2.1.8 Instrument Documentation
The Supplier shall provide instrument documentation comprising of the following:
Specifications
Mechanical dimensions
Process connection details
Installation and calibration procedures
Connection details
Note: No submissions or payments will be considered without the receipt of the above documentation.
2.2 Design Standards
Electrical installations shall be done according to the SABS.
Instrumentation installations shall comply with the following codes:
USA ASME
ISA
ANSI
API
NFPA
RSA Minerals Act
SABS-0108-1974
(Classification of Hazardous Areas)
SABS 089 part II 1965 as amended
SABS-549
GERMANY VDE Standard and PTB
Deviations from the above applicable codes or standards are acceptable only on written approval from Palabora Mining Company.
2.3 Official Regulations
Engineering, design and installation shall comply with the South African Minerals Act as amended, as well as with the various Safety Standards at Palabora Mining Company.
2.4 Geographical Data
The general environmental conditions can be regarded as typical central Lowveld conditions. The principal conditions are summarised as follows:
Site location: Adjacent to the town of Phalaborwa, Northern Province approximately 400 km Northeast of Johannesburg
Site elevation 400m above m.s.l.
Highest (maximum) summer temperature 42°C
Average summer temperature 32°C
Lowest winter temperature 10°C
Average winter temperature 14°C
Ave. rainfall per annum 480.6 mm
Maximum Humidity 87%
Average number of thunderstorm days per annum 36 days
Maximum wind-speed* gusts - 56.6 m/sec
Hourly - 15,0 m/sec
*Prevailing winds rise southeast
Temperatures, rainfall and humidity are measured at the recording station at Phalaborwa.
2.5 Special Palabora Mining Company Requirements
2.5.1 Noise Limits
Noise limits will be 85 dBA. Emergency services such as relief valves, safety valves, alarms, firewater pumps etceteras are excluded from meeting any noise limit when operating outdoors.
Control valve vendors shall utilise their standard calculation or measurement procedures to determine control valve noise.
2.5.2 Accessibility of Instruments
All instruments must be accessible for maintenance purposes. Where applicable, platforms or extended grating must be provided.
3 DESIGN CRITERIA AND SPECIFICATIONS FOR INSTRUMENTS
3.1 General Design
3.1.1 Pre-assembly:
Equipment shall be pre-assembled to the standard technique in the sub-contractor's workshop.
3.1.2 Climatic, process and technical requirements:
All circuitry and wiring shall have a temperature rating which exceeds the operating conditions indicated on the data sheets. (E.g. Military Specifications for components and cards.)
The Radio Frequency Interference Effect from a portable 5-watt output transceiver at 1 metre from an instrument shall not exceed ± ½% of the full scale of the instrument, with the instrument enclosures in the normal operating position.
The process wetted material of that control and supervisory equipment in contact with the process media shall be able to withstand the conditions and influences of the respective media. They shall also be compatible with the piping and embodying material and be resistant to corrosion at the operating conditions as specified.
The instruments shall withstand the different local chemical ambient influences and plant conditions (such as steam pipes).
3.1.3 Electronic/Pneumatic Control Systems
The preference is for electronic control and for equipment with no moving parts. Pneumatic control may be used for all local mounted indicating and recording systems.
Self-actuated regulators shall only be used for instrument air supplies, and pilot gas in the case of combustion control.
All other control systems for temperature, pressure, flow or level shall consist of a separate pneumatic controller and control valve.
All control systems shall be designed for fail-safe operation of the plant.
3.1.4 Safety/Relief/Control Valves and Orifice Plates
All safety-, relief- and control-valves and orifice plates shall be adequately sized to enable the instruments to cope with the normal operational conditions that exist during start-up and shutdown.
3.1.5 Alarm circuits
All alarm circuits shall have field- or panel-mounted contacts that are closed during normal conditions and open during fault conditions.
Where Analogue inputs are used, alarms of absolute values (Trip-alarms) shall be derived from monitor switches.
The complete logic/interlocking system shall be energised permanently.
Where an alarm is a deviation from a controller set point, it may be derived from the controller directly.
Electrical shutdown systems shall be energised for normal operation and de-energised for shutdown where possible.
Adjustable switching of analogue signals from temperature-, pressure-, flow- or level-transmitters is allowed to actuate alarms. Where this is not practical, suitable switches may be connected directly to the process lines.
Separate switches connected to the process (where possible) shall operate Pneumatic or electrical shutdown systems. (Especially where gasses are concerned).
For no-flow trips, directly connected switches shall be used.
In the case of orifice plates: a second differential pressure transmitter shall be used.
3.1.6 Deviation to Specifications
Any deviation to any specification must be pointed out in writing, and approval obtained from Palabora Mining Company.
3.1.7 Instrument Name Plate/Packing
Name Plate
Instruments shall bear the original manufacturer's name, model and type number, except in the case of a specially ordered construction. The permanently attached manufacturer’s nameplate should show the following information regarding the instrument:
Manufacturers name or trademark
Model number or type
Input range/units
Output range/units
Power supply
Electrical classification
Nema classification
Packing
Each individual carton or box shall be marked with the Order Number on the top and the side of the carton. If individual cartons are grouped in a larger box for ease of shipment, then the larger box must be marked on the top with the Order Number for all the instruments inside the box. A shipment list must be provided, listing all instruments ordered and delivered.
It is the responsibility of the Seller to ensure that the equipment is adequately protected and packed to meet the shipping and delivery requirements.
3.1.8 Marking of Wires and Cables
Electrical wiring shall have all terminals marked and terminal blocks identified as indicated in the individual panel packages.
Each wire shall be marked at both ends with suitable wire markers, and the following information shall be available on each wire tag: the instrument tag number, local terminal block termination number, and the destination.
See Palabora Mining Company drawing number PMC-GS7-DWG 5 (P2) for details on wire tags and cable tags.
Cable markers must be attached at both ends of the cable and at 15m intervals, or where a cable changes direction. Cable markers shall be applied with strap-on marker tags, in compliance with the cable schedule.
Where a cable exits a cable tray, it is only required to mark that particular cable if it is within the 15m intervals.
3.1.9 Analyzers
Analysers must be defined and engineered in conjunction with the Asset Management – E&I Instruments Department at Palabora Mining Company.
These items are considered as Speciality Items and shall be engineered separately.
3.2 Measuring units, Ranges and Scales
3.2.1 Measuring units
All instruments shall be calibrated and inscribed with SI units. No measuring units other than the following shall be used for the indicated measured variables:
KPa or mm H2O - Pressure and Differential Pressure
°C - Temperature
% - Position and Level
m³/h or l/h - Liquid flow
T/h or kg/h - Steam flow
nm³/h or nl/h - Gas flow (Normal = 0 °C; 101,325 kPa)
mm - Differential and absolute Expansions
Hz - Frequency
mA or A or kA - Current
mV or V or kV - Voltage
W or kW or MW - Active power
Wh or kWh - Active energy
T or kg - Weighing
µs/cm - Conductivity
3.2.2 Measuring ranges and scales
Where possible, measuring ranges shall be as follows:
Flow: Measuring ranges for differential pressure transmitters - 0 - 600 mm H2O
0 - 1600 mm H2O
0 - 2500 mm H2O
Orifice plate and annubar sizes should be calculated to provide 0 - 25 kPa differential pressure ranges.
Flow instruments shall have either square root (0-10) or linear (0-100) scales and charts based on process requirements. Square root extraction for dedicated recorders must be economically justified.
Scale and chart multipliers shall be based on the following flow units:
Gas flow - normal cubic meter per hour (m³/h dry) where normal conditions are 0 °C, 101,325 kPa abs and dry.
Steam, condensate and boiler feed water flow - kilogram per hour (kg/h)
Liquid flow: -liter per minute (l/min) (small)
-cubic meter per hour (m³/h) (large)
Exception: Measuring ranges for rotameter scales shall be the manufacturers standard.
Level (Tank flange and DP transmitter) - Ranges shall have smooth values calibrated in mm H2O or kPa, with normal scales from 0 - 100%.
Pressure - Scales must be calibrated in kPa. Absolute pressure and vacuum instruments shall have scales in kPa abs or kPa vac.
Temperature - Scales must be in °C.
3.3 Instrument Accuracy and admissible external influences
The measuring instruments that are provided for the evaluation of the consumption and production figures shall have the following accuracy's, where tolerances refer to the indicated full-scale reading at constant temperature:
3.3.1 Primary elements:
Standard orifice plate - ±5.0 %
Venturi tube - ±1,0 %
Rotameter - ±2,5 %
Magnetic flow meter - ±0,75 %
RTD - ±0,6 %
Thermocouple (up to 400 °C) - ±3,0 °C
Thermocouple (up to 1200 °C) - ±0,75 %
3.3.2 Transmitters:
Temperature for RTD's - ±0,6 %
Temperature for thermocouples - ±1,0 %
Pressure transmitters - ±0,5 %
Flow transmitters (differential press.) - ±0,5 %
Level transmitters (displacer) - ±1,0 %
3.3.3 Panel Instruments:
The admissible temperature influence may be 0,3 % per 10-°C change.
The admissible voltage fluctuation influence may be 0,2 % per 10 % voltage change.
The ambient temperature influence must be within the range -20°C to +60°C for field instruments, and 0°C to +50°C for panel instruments or control room instruments.
Voltage fluctuation for power supplies shall be within ±10% of the nominal voltage, with frequency variation between 48 and 52 Hz only. All instruments must be able to operate within these limits.
3.4 Graphic Symbols, Loop and Instrument Designation
Each measuring- or control-circuit, including control equipment, shall have an identification number that consists of an alphabetical part followed by a numerical part.
The ISA standard shall apply as specifically modified for Palabora Mining Company.
Refer to diagram PMC-GS 7 sheets P0 and P1 for details.
3.5 Numbering system for Instrument Loops
Numbering of all points on Process and Instrumentation Flow Diagrams or Instrumentation Loop Diagrams shall be done according to the extended ISA format, which is as follows:
02-FC-123A (example)
Digit 1 and 2 - Area code
Digit 3 - Primary loop Type
Digit 4 - Function of Instrument
Digit 5 - Train, streams or section number
Digit 6 and 7 - Serial number of instrument
Digit 8 - Indicates a duplication (standby or redundant unit)
3.6 Signal Transmission
Electronic instruments shall have preference over pneumatic instruments. Pneumatic instruments may be used in areas where power is not available and where the air signals are not transmitted over long distances.
The pneumatic signal standard range shall be 20 - 100 kPa.
The electronic signal standard range shall be 4 to 20 mA DC.
RTD's shall be used for temperatures up to 100°C (i.e. bearing temperatures).
Thermocouples will be used for higher temperatures, with type N for temperatures above 1000°C.
Electronic bus signal transmission shall be via Profibus or AS-I bus.
3.7 Utility Data
3.7.1 Instrument Air Supply
System air supply in the field must be 600 to 700 kPa, oil free and water free.
3.7.2 Electrical Power
All electrical power circuits inside main- or field-mounted Control Panels shall operate at a maximum of 24 V DC or 110 V AC at 50 Hz. No voltage exceeding these specifications shall be brought into any instrument panel, rack or cabinet, with the exception of 220 V AC lighting, rotating beacons and utility outlet circuits.
Note: it is permitted to install instruments that require a 220V AC supply, but only if no substitute for 110V AC operation is found.
The Electrical cable connection must be able to accept a 20mm gland, or adapters must be provided to convert non-standard fittings or holes to accept a 20mm gland.
AC power shall be 110V, 50 Hz, single phase with neutral connected to earth. Voltage fluctuation for power supplies shall be within ±10% of the nominal voltage, with frequency variation between 48 and 52 Hz only. For non-critical applications this supply shall not be fail-safe. For critical applications, this supply shall be fail safe and free from interruption by means of back-up batteries and power inverters or Uninterruptible Power Supply units (UPS’s).
DC power shall be 24V with drift less than 5%. Slope voltage variation shall be less than 2V/ms.
3.8 Other utilities
As applicable to the particular plant area.
4 CONNECTIONS AT INSTRUMENTS
4.1 Air Pipes, Pipe Fittings and Air Headers
All instrument air pipes and pipefittings shall be galvanised or stainless steel (e.g. acid plant) and shall be sized in metric units (e.g. half-inch).
Air headers shall be manufactured as stipulated on Palabora Mining Company drawing number PMC-0-8057, revision 1, and shall be connected to the air pipes as an interface between instrument air pipes and air tubes.
4.2 Air Tubes and Fittings
4.2.1 Metric Sizing
All instrument air tubes and tube fittings shall be sized in Metric units.
4.2.2 Fittings
All air tube fittings shall be of the cutting ring type, such as Swagelock or an approved equivalent.
4.2.3 Tube material and Tube size
The tube size between the air header and the instrument shall be 10 mm, and shall be fabricated from materials as specified for instrument signal air tubes (below).
For instrument signal air tubes, single runs of 6 mm OD, fully bonded, fused black polyethylene/aluminium (dekabon) tubes shall be used.
Where mechanical abuse may take place or high temperatures or corrosive conditions exist, stainless steel may be used.
Copper tubes may be used, provided it is approved for the particular application.
4.2.4 Seamless Precision Tubes
Seamless precision tubes with suitable tube strengths and materials shall be used in plant areas where particularly high corrosive conditions exist.
4.2.5 Other
Blue, plastic Festo piping may be used for specific applications, such as sample lines.
5 ELECTRONIC SIGNAL AND SUPPLY CABLES
5.1 General
5.1.1 Tagging of Cable Reel
A permanently attached (with drive pins or equal) metal tag stamped with the following information shall be provided on each side of the reel:
Order Number
Rated Voltage, Conductor Area and Number of Cores/Pairs
Manufacturers Name or Trademark
Serial Number
Length of Cable on Reel
Gross Mass
Year of Manufacture
In the case of thermocouple extension cable: the thermocouple type, i.e. "T", "K" or "S".
5.1.2 Packing of Cable
Cables shall be supplied on wooden drums of substantial construction, having the centre hole reinforced with a steel plate to prevent damage during the unwinding. The reels shall be wood lagged and strapped to protect the cable during transit.
Each end of the cable shall be provided with a watertight seal to prevent entrance of moisture during outdoors storage. Each end of the cable shall be firmly and properly secured to the reel to prevent damage during handling. Care must be taken to ensure that the cable is wound up firmly on the reel. The inner end of the cable shall be allowed to protrude through the reel in order that the cable may be tested while still on the reel.
Each cable reel shall be furnished with one continuous length of cable. Each cable reel shall have an arrow on either side of the reel showing the direction in which it must be rolled to prevent loosening of cable on the reel.
5.1.3 Signal Cable Specification
5.1.3.1 Conductor Specification:
Twisted pair
Seven strands un-tinned copper
PVC insulated
Insulation test voltage: 3kV AC
Single pair 1.0mm²
Multi pair 1.0mm²
Insulation colours: black and white
Multi pair conductors to be numbered (alphanumeric)
Lay of twist to be 40 - 60mm (i.e. 16 - 25 twists/m)
5.1.3.2 Individual and Overall Screen Specification:
Extruded black PVC with rip cord for jacket removal
Minimum thickness: 1.2mm for up to 8 pair, and 1.5mm for 12 pair
5.1.3.4 Outer Sheath and Armouring Specification:
Overall weatherproof thermoplastic jacket of minimum thickness 1.5mm for up to 8 pair, and 2mm for 12 pair
An insulated communication wire shall be provided in all multi-pair cables.
The outer cable protection shall be steel wire armoured where necessary.
Sheath colour: black.
Fire retardant plastics must be used.
Dekaron cable must be used where applicable.
Note: Cables shall comply with the latest editions and amendments of SABS 150 and shall bear the SABS mark.
5.1.4 Thermocouple Extension Cable Specification
5.1.4.1 Conductor Specification:
Twisted pairs
Solid alloy - single pair - 16 gauge (1.3mm²)
Solid alloy - multi pair - 20 gauge (0.518mm²)
PVC insulated
Insulation test voltage: 3kV AC
Insulation colours to ANSI MC96-1
Multi-pairs to be numbered (alphanumeric)
Lay of twist to be 40 - 60mm (i.e. 16 - 25 twists/m)
Wire matched and calibrated to ANSI C96.1 - 1969
5.1.4.2 Individual and Overall Screen Specification:
Extruded black PVC with ripcord for jacket removal: minimum thickness 1.2mm.
5.1.4.4 Outer Sheath and Armouring Specification:
Overall weatherproof thermoplastic jacket of minimum thickness 1.5mm for up to 8 pair, and 2mm for 12 pair and above.
An insulated communication wire shall be provided in all multi-pair cables.
The outer cable protection shall be steel wire armoured.
Sheath colour: black
Fire retardant plastics must be used.
Twisted triad
Seven strands un-tinned copper
PVC insulated
Insulation test voltage: 3kV AC
Single triad 1.0mm²
Multi triad 1.0mm²
Insulation colours black, red and white
Multi triad conductors to be numbered (alphanumeric)
Lay of twist to be 40 - 60mm (i.e. 16 - 25 twists/m)
5.1.5.2 Individual and Overall Screen Specification:
Extruded black PVC with ripcord for jacket removal.
Minimum thickness 1.2mm.
5.1.5.4 Outer Sheath and Armouring Specification:
Outer weatherproof thermoplastic jacket of minimum thickness1.5mm
An insulated communication wire shall be provided in all multi-pair cables.
The outer cable protection shall be steel wire armoured.
Sheath colour: black.
Fire retardant plastics must be used.
5.1.6 Earth wire Specification
Conductor Specification:
Multi-strand un-tinned copper wire
PVC insulated
Conductor size: 6.0mm², 15mm²
Insulation test voltage 3kV AC
Outer Sheath Specification:
Overall weatherproof thermoplastic jacket of minimum thickness 1.5mm.
Sheath colour: Blue or Green
Fire retardant plastics must be used.
5.1.7 Panel Wire Specification
Seven strands un-tinned copper
PVC insulated
Insulation test voltage 3kV AC
Conductor 1,0mm²
Insulation colour: black, red and grey
5.2 Electronic Signal Cable
5.2.1 1/2/6/12 -pair Cable
The preferred cable is the single/two/six/twelve pair type with multi-strand copper cores, with cable pairs individually twisted and screened. The screening shall be of the aluminium twisted foil type, or equivalent. The cable shall be fitted with an overall aluminium twisted foil shield.
For classified areas the outer cable protection shall be to SWAPVC standard at least.
The core size shall be 1 mm² and the preferred colour coding of the cores is black and white. Multi-pair cables shall have number markings of the cores for ease of identification.
5.2.2 Profibus Cable
Only Siemens Profibus cables shall be used, and it shall be of the shielded, twisted pair type.
5.2.3 AS-I bus Cable
Only Siemens AS-Interface cables shall be used, and it shall be of the unshielded, single pair type with IP 65 rating.
5.3 Intercom Cable
The preferred cable is the Telkom two-pair twisted type (Indoor wire, unshielded, 600 ohm).
Each external unit must be connected to the main unit with its own individual cable.
5.4 Power Supply Cable
The preferred cable is 2,5 mm² three core multi-strand copper cable, with a black outer SWAPVC protection. The colour coding of the cores must be Blue, Red and White (Yellow).
5.4.1 Power Supply Cable Specification
5.4.1.1 Conductor Specification:
Multi-strand un-tinned copper wire
PVC insulated
Conductor size: 1.5mm², 2.5mm², and 4.0mm²
Insulation test voltage: 3kV AC
5.4.1.2 Conductor colour coding:
2 cores: black and red
3 cores: blue, red and white (yellow)
5.4.1.3 Screen:
Not required.
5.4.1.4 Inner Jacket Specification:
Extruded PVC with ripcord for jacket removal
Minimum thickness 1.2mm
5.4.1.5 Outer Sheath and Armouring Specification:
Overall weatherproof thermoplastic jacket of minimum thickness 1.5mm.
The outer cable protection shall be steel wire armoured.
Sheath colour: black
Fire retardant plastics must be used.
5.5 Coaxial Cable
5.5.1 Electronic Data
The preferred coaxial cable for electronic data (such as Ethernet) is type RG 62.
5.5.2 TDC3000 UCN Network
For the TDC3000 UCN network, RG 11 coaxial cable shall be used for the trunk lines, and high quality RG 6 shall be used for drop lines.
The coaxial connectors specified by Honeywell shall be used.
5.5.3 Radio Communication
RG 58 or RG 213 coaxial cable shall be used for radio equipment.
The specific type shall depend on the application/installation (E.g. RG 213 coaxial cable is used where there is quite a long distance between the radio and the antenna/repeater).
5.5.4 Video Cameras and Monitors
For video cameras and video monitors, either RG 58 or RG 59 coaxial cable shall be used.
5.6 Optical Fibre Cable
The preferred cable is the 4, 8 or 12 graded index multi-mode type. The cable must be of non-metallic Kevlar strengthened construction, and of the rural aerial self-support type, and must be bright orange in colour. The fibre core diameter must be 50 µm and the cladding diameter 125 µm (e.g. multi-mode fiber 50/125).
Attenuation at 850 nm should be better than 2.8 dB/km. The minimum bandwidth at 850 nm should be better than 400 MHz/km.
The maximum free-hanging distance without a catenary wire shall be 70 m. The minimum-bending diameter should be 300 mm.
Ethanol should be used as cleaning agent to clean the optical fiber tips.
Meter indications by the manufacturer should be available on the cable.
5.7 Other
All other cables shall be subject to approval by Palabora Mining Company and shall be with due consideration to current and voltage loading, distance, heat dissipation and all other factors, which is applicable to cabling.
6 SIGNAL AND AUXILIARY ENERGY DISTRIBUTION
6.1 General
All electronic signal cables terminated on field instruments shall be routed to junction boxes or protection boxes in the field. Splicing of the cables is not allowed (where individual cables are joined to form multiple cables that are then routed to the rack room).
The multiple cables routed from the junction boxes to the rack room are terminated at the respective panel sections or cabinets used as distributors (marshalling racks). The purpose of the marshalling racks is to connect the various signal cables to the appropriate equipment in the rack room.
Power supply to the electronic field instruments shall be by directly routed single cables from the fuse cabinet in the rack room to the instrument.
All signals connected to Analogue and Digital input cards, and Digital output cards, shall be fused.
Note that where there are fused terminals inside the junction boxes, dual power feed is required for Honeywell systems.
6.1.1 Fuse ratings
The fuse rating for the Siemens S7 and Honeywell TDC3000 systems is 500mA.
6.2 Distribution of Electronic Signals
6.2.1 Control room
Multiple cables from the field (incoming electronic signals) are routed to different marshalling racks as required, or directly to the input/output terminal strips of the panel sections or cabinets.
Multiple cables from solenoid valves or initiators are connected directly to the terminal strips of the alarm and interlocking cabinets.
To interconnect control room equipment, connections shall be made with single-, multiple-, Profibus-, or AS-I bus cables.
See section 11 for extended detail regarding control rooms.
6.2.2 Cable installation on cable trays/racks
All instrument cables must be separated from power cables with a minimum distance of 250 to 300 mm.
It is acceptable practise to run 110V AC power cables and Instrument Signal Cables on the same cable rack.
6.2.3 Cable Racks
Refer to PMC Electrical Specification E17 for cable rack specifications.
7 PROTECTION, MOUNTING AND COOLING FACILITIES
7.1 Protection and Mounting Facilities
All field instruments that are not installed onto lines, vessels or field equipment shall be accommodated in protection boxes.
Equipment shall be protected to at least IP 65.
Enclosures shall be the Sarel type, with back plane fitted. The box size shall depend on the application.
Instruments installed inside protected rooms with clean atmosphere, shall be wall-mounted.
Where conductors have to pass through a wall, it shall be laid in plastic conduits that have open bends.
Where physical damage may occur to instruments, protection must be provided.
7.2 Protective Cooling Facilities
Instruments shall be protected by suitable means when their functions are jeopardised by high ambient temperatures. This includes:
• Direct protection by providing thermal shielding walls or roofs.
• Indirect protection by means of a coolant that dissipates excessive heat via cooling fins or cooling jackets.
• Direct cooling by installation of Vortex coolers.
7.3 Marking of Instruments, Racks and Panels
All instruments shall be marked as to the location (i.e. 37-LT-401) with a permanent tag attached to a column, the back plane of the protection box or any other suitable position, which will remain in place even in the event where the instrument is removed for repairs.
Instrument racks and panels shall be marked with a permanent tag, showing the equipment number clearly on the centre (front) of the equipment.
Lettering size shall be at least 20 mm.
Trafolite labels are allowed.
8 DOCUMENTATION
Documentation shall include the following, which shall also apply to package unit suppliers:
8.1 General Specifications, Codes and Standards
Index of documentation
Index of drawings
Specifications, regulations, standards, codes and symbols.
8.2 Instrument Loop Summaries, Specifications and Calculations
Instrumentation index
Data sheet index
Data sheets
Data sheets for centralised process control systems
Installation material specification
8.3 Functional Diagrams, Lists and Descriptions
Signal function summary
Logic diagrams
Loop function diagrams
8.4 Drawings
Layout of Control panel and central facilities
Frontal views of Control panels and boards
Mimic or graphic diagrams
Analyser room layout
Plot plans, location and cable tray routing
Manufacturer drawings
Drawings must conform to Palabora Mining Company Specifications GS-14 with the following additions:
• Drawings must be done on AutoCAD ® as standard where computer aided draught is used.
• Diskettes, containing the relevant drawings and libraries used, must be handed over together with the actual drawings, and must be considered as part of the documentation package.
8.5 Pen sizes and colours
• 0.1mm pen (black – pen 1):
Dimension lines
Text
• 0.25mm pen (magenta – pen 2):
Battery Limit Lines
Instruments (including all instrument symbols on flow diagram legend; speciality items; instrument vent and drain lines)
• 0.30mm pen (dark blue – pen 3):
Auxiliary or utility lines such as air, steam, water, fuel (gas or oil), etc.
Note: in the event where the single purpose of a drawing is to show the auxiliary process, then it will be drawn as normal process lines.
• 0.40mm pen (red – pen 4):
Secondary Process lines (generally shown on the process flow diagram)
Primary Process lines on utility system flow diagrams, such as instrument air, etc.
• 0.25mm pen (green – pen 5):
Equipment
• 0.70mm pen (cyan – pen 6)
Primary process lines (generally shown on the process flow diagram)
• 0.25mm pen (yellow – pen 7):
Instrumentation and instrument communication lines
• 0.25mm pen (gray – pen 8):
Viewports and Drawing borderlines
8.6 Flow diagram layout
See attached examples of Flow Sheet Diagrams and P&ID’s for more details.
8.6.1 In order to establish and maintain a degree of clarity and order, the flow diagram shall be divided into the following areas/sections: the draught area, the note section, the title block section, and the equipment list section.
8.6.2 Any process lines entering or leaving the flow diagram must be connected to an on/off page connector. Arrows must be inserted to show the direction of flow of the lines.
8.6.3 All valves at pumps shall be drawn lined up.
8.6.4 All pump- and equipment identification numbers must appear either inside the relevant symbol, or directly below the symbol.
8.6.5 Where possible, place any valve manifold assemblies on a vertical line.
8.6.6 For the standard symbols, see Palabora Mining Company systems diagram PMC – 0 – 8191 Rev B; this is based on ANSI/ISA standard S 5.1 as revised (1989). Note that the non-abbreviated form of the tag number is used, where the area code is part of the tag number, and not just mentioned in the note section.
8.6.7 For standard type layouts, drawings either exist, or will be developed, and these will be referred to where such standard layouts should appear.
8.6.8 The equipment list must appear in the upper right hand corner of the title block frame, indicating the equipment number and the frame in which it appears.
8.6.9 Any notes relevant to the diagram shall appear above the title block.
8.6.10 Where horizontal and vertical lines cross on the diagram do not break the horizontal line; use half-loops on the vertical line to show where they cross the horizontal line.
8.7 P&ID preparation
The standard sheets provided by the drawing office shall be used.
8.8 Installation Technology
Local instrument arrangement lists
Local instrument installation diagrams
Principal installation diagram for fastening, cooling and insulation
Cable and connection lists
8.9 Operation and maintenance instructions
Operating manuals
Maintenance instructions
Spare parts lists
8.10 General
To ensure uniformity of the P&ID’s, the following general rules apply:
• Where possible, let all lines enter and leave on the left- and right- hand side of the drawing.
• All pumps, motors, drive units etc. must be shown on the P&ID.
• All equipment numbers and instrumentation must be shown on the P&ID.
• All changes must be updated on the loop drawings and P&ID’s.
• All equipment should be drawn in the same geometrical order as in the plant (where possible).
• P&ID’s and flow diagrams must correlate with quantitative flow diagrams
9 CONTROL VALVES
9.1 Body Size
Control valves shall be sized according to flow, pipe size and control valve flow coefficients (C.v.).
9.2 Body and Flange Rating
The minimum body rating and flange rating for all flanged control valves shall be 300 pounds as per ANSI code B16.1 or BS 4504. Wafer type bodies may be 150 pounds rating.
Control valves with cage trim shall be used for both single ported and balanced double ported configurations. Control valves of this type shall have 300-pound minimum ANSI code B16.1 or BS 4504 flanged connections or as required by the relevant piping specifications.
The valve body material and the pressure- and temperature ratings shall meet the requirements of the piping specifications.
9.3 Butterfly or Ball-type Control Valve
Palabora Mining Company may consider butterfly or ball-type control valves for specific applications, subject to approval.
Control valves of any of these types shall have flanged process connections for installation between flanges. The valve body and flanges shall meet the requirements of the piping specification as put down in part 4 and part 9.2.
9.4 Control valve material
All control valves shall have carbon steel, stainless steel or alloy bodies as required by the piping specifications.
Split body control valves may be used when high-cost-alloy alloy bodies are required to meet process requirements.
9.5 Control valve Actuators
All control valves shall have pneumatic spring and diaphragm, or cylinder actuators designed for an operating signal range of 20 to 100 kPa. Supply pressure shall be a maximum of 800 kPa and a minimum of 560 kPa.
Where applicable, electrical motorised valves may be used.
9.6 Positioners
Positioners shall be specified for all control valves with exception of valves for on/off service (i.e. shutdown isolation valves).
9.7 Isolating/bypass valves
Control valves (Except three-way valves) shall be provided with isolating block valves and/or a bypass valve for hand control as indicated below. A local process variable indicator shall be provided where necessary, but must be requested by Palabora Mining Company Operations during Process and Instrumentation flow diagram reviews.
Fluids containing abrasive solids or fluids which may plug, shall have block valves.
Corrosive and erosive services, toxic fluids and flushing services, shall have block valves.
Wherever a bypass is required to reduce the risk of process shutdowns and where manual control is impractical, block- and bypass valves shall be installed.
Steam with an upstream pressure of 350 kPa or above (except when separate control valves are supplied for a turbine driver and a standby) shall have block- and bypass valves.
Boiler feed water service shall have block- and bypass valves.
9.8 Hand- or wheel operation
Control valves which are not provided with isolating block valves and/or bypass valves shall be fitted with a hand wheel or other means of hand operation.
Control valves in on/off service, such as solenoid-operated trips, shall not be supplied with hand wheels or other means of hand operation.
All control valves with hand wheels shall be capable of opening and closing under full differential pressure.
9.9 Control valve characteristic
The control valve characteristic shall be the standard characteristic of the selected valve for most applications.
9.10 Linear trim
Linear trim shall be used only for split range services or where the control valve pressure drop remains constant over the range of 10% to 100% of flow capacity.
9.11 Control valve flow coefficients
Calculated values of control valve flow coefficients (C.v.) shall be based on either normal flow multiplied by 1,3 or maximum design flow multiplied by 1,1; whichever is the greater.
All calculated flow coefficients should be corrected for the effects of pipe reducers, cavitations and/or critical velocity.
9.12 Control valve body design and trim requirements
The body designs and trims for control valves shall meet the following requirements:
• Control valves shall meet the requirements for noise limits as specified in this document. Any estimated additional expenditure required to meet this specification shall be pointed out to Palabora Mining Company for prior approval before procurement of the equipment.
• If noise calculations are not available for liquids other than water, the valve shall be designed so that the following velocities are not exceeded:
• Standard Control Valves: 15m/s at the valve outlet
• Controlled Velocity Valves: 30m/s anywhere within the valve at any position of the valve stroke.
9.13 Line size control valves
Line size control valves for throttling service may be used only with reduced trim. Line size control valves with line size trim may be used for on/off service.
Three-way control valves shall be avoided where possible. Dual control valves, one reverse- and one direct acting, are preferred for these applications.
10 PREFERRED VENDOR LIST
10.1 Actuators
10.1.1 Electrical
10.23 Radio Transmitters/Transceivers
10.23.1 Portable
• IRC
• Kenwood
10.23.2 Mobile
• IRC
• Kenwood
10.23.3 Radio Telemetry
• Televonic
• Alpha-numerical Systems
10.23.4 Power supplies (radio)
• Base station: Gale 6
• Rubber tyres: 24 V/15 A Converter from Webb
10.23.5 Chargers (radio)
• Rapid desktop chargers
10.24 Hydraulic solenoids
• Vickers
• Bosch
10.25 Solenoid valves
• Burkert
• Asco
• Festo
10.26 Safety/Relief valves
• Consolidated
• Masoneilan
10.27 Signal conditioners/isolators
• Control Logic
• Acromac
• R.I.S.
• Knick
• Inor
10.28 Temperature
10.28.1 Local Indicators
• Control Instruments
10.28.2 Switches
• Burka (Thermostat)
• Honeywell (Thermostat)
10.28.3 Radiation Pyrometer
• Land
• Williamson
10.28.4 Thermocouples/RTD’s
• C.G.S. Thermodynamics
• Temperature Controls (mineral insulated)
10.28.5 Transmitters
• I.M.C.
• Hockeypuck
• Inor
10.29 Distributed control system
• Honeywell TDC3000
10.30 Programmable Logic Controllers
• Siemens PCS 7 (Preferred)
• Allen Bradley (on special arrangement)
10.31 Turbidity
• Yokogawa
10.32 Uninterruptible Power Supply (UPS)
• Meissner
• Omnitech
10.33 Weighing equipment
10.33.1 Nuclear belt weigher
• Process Automation
10.33.2 Load Cell Belt Weigher
• Process Automation
• Ramsey
(In all cases the preferred load cells are those supplied by SA Load Cell Services).
10.33.3 Load cells
• SA Load Cell Services
10.33.4 Road/Rail
• SA Automation
• Avery
• Process Automation
10.34 Water Trap
• Festo self dumping
• Capacitive type – Bekomat
• Hakkonen
• High flow
11 CONTROL ROOMS
11.1 Layout
Control rooms will be designed in such a way that dual entry cabinets/racks are avoided as far as possible. Cabinets must be installed against the walls. Passages of at least 1200mm must be provided in front of the cabinets or equipment. Units must be grouped together logically, and installed with numbering in the sequence of north - south, east - west, top to bottom, left to right.
Operating panels or other operator interfaces must be installed with good ergonomics in mind. Operating areas must be separated from equipment areas to control access of unauthorised personnel. Access to hygiene facilities must be provided for operating personnel.
Cable trays or ducting must be allowed to enter from the bottom of cabinets. For this reason a load-bearing computer floor is preferred with a space of at least 400mm to allow two cable trays to cross.
The high quality earth system may be connected to the electrical safety earth, but the intend to do so must be brought to the attention of all parties involved before any connections are made. This will only be done when difficulties arise in finding/providing a high quality earth system.
Drainage must be provided for water that may puddle under the floor. Sloped floors with several drain points are preferred.
Air conditioning must be provided with an entry ducting underneath the computer floor, and an exit or re-circulating ducting at roof height, and above suspended ceilings (non-preferred) if fitted.
Walls, roofs and floors must be finished in such a way so as to prevent cement (or any other) breakdown of material that may become suspended in the air and circulate in the air-conditioning system.
Such items will be trapped on the electronic equipment and cause short circuits.
11.2 Power distribution
Power must be fed from the electrical feeder system from two alternative sources: one of which will be the same as the emergency supply, or standby. The power will be transformed down to 380/220V AC, and used to power two individual uninterruptible power supplies (UPS’s) of which the output will be regulated in terms of frequency and voltage. The battery backup system must have at least 40 minutes capacity and they shall be fitted with batteries of the gas- and leakage free type. One UPS shall monitor the other and take over full demand should it fail. Full maintenance capability must be provided, without any disturbance or loss of function.
Power from the UPS shall feed an instrument distribution panel at 110V AC. This distribution panel shall be fitted with breakers allowing isolation of individual instruments, and with particular attention to fault levels where fuse ratings and time to trip or blow should be calculated.
For 24V DC it is preferred to use power supplies that transforms and rectifies 110V AC to 24V DC.
Additional information is available in section 3.7.2.
11.3 Marshalling Cabinets
The internal dimensions of the Marshalling cabinets must be: 800 wide by 800 deep by 2000 high (mm).
See section 16 for details.
11.4 Equipment Cabinets
The internal dimensions of the Equipment cabinets must be: 800 wide by 800 deep by 2000 high (mm).
See section 16 for details.
11.5 Earthing System
The earthing system shall have three parts, namely a High Quality Earth, a Safety Earth and a Power Signal Common. These three together shall form the earthing system.
11.5.1 High quality Earth
The High Quality Earth system shall consist of an earth mat with a total ground resistance of less than 1 ohm. The earth mat is an isolated ground electrode array with the following requirements:
• A distance of not less than 3m to any grounded metal.
• The earth mat must be situated within 127 cable meters of any portion of the Distributed Control System.
• An earth electrode is typically 3m long and made of 25mm diameter stainless steel rod, driven into the earth. For a single electrode, reference rod sections are welded together as the hammering progresses, until the water table is reached. Alternatively an array of rods can be used, with 3m rods inserted into the ground with 3m spacing in between, forming either a circular pattern or a straight line. The rods are then interconnected using cadmium welding and 11.8mm blue insulated copper wiring.
• All electrode ends and all connections must be placed inside re-enforced concrete pipe ends, with steel cover 18mm thick.
• Instead of hammering the electrodes into the ground, holes of 100mm diameter can be drilled. After insertion of the electrode, the hole must be filled with coke breeze or any other ash, which will improve earthing over time.
11.5.2 High quality earth distribution bar
Inside the Equipment Rack Room a distribution bar must be fitted. The High Quality Earth mat will be connected to this bar with a single 11mm blue insulated cable. All the marshalling racks and local High Quality Earth bars will be tied to this bar with a 5,3mm minimum blue insulated cable. The radial method of connection must be used, rather than the daisy-chain method of connection.
The bar must be connected to the Safety Earth system through a 90V, 150kA Spark gap.
Where local High Quality Earth bars are fitted to the top of cabinets, the local bars can be linked together using two redundant 5,3mm cables, with two redundant 5,3mm cables connected to the main High Quality Earth bar.
11.5.3 Safety earth system
Each marshalling cabinet, junction box and Equipment cabinet must be connected to the Safety Earth. The High Quality Earth and the Safety Earth must physically be separated through the use of isolation washers or spacers.
Power supplies must have their ground input terminals connected to Safety Earth.
11.5.4 Power signal common
All power supplies shall have the neutral of the electrical feed connected to the proper input terminal. The output Power Signal Common shall not be connected to either the Safety Earth, or the High Quality Earth. However, since the common is used throughout the system, it can be distributed in the same manner as the earthing system, using bus bars or preferably terminals daisy chained.
11.6 Lightning protection
11.6.1 Spark-Gap
A 90V, 150kA spark gap shall be installed between the High Quality Earth system and the Safety Earth.
11.6.2 Metal Oxide Varistors (MOV’s)
For additional protection against lightning or static energy, the use of MOV’s is approved. They shall be installed on the control room side of control loops only, since the floating earth system is generally considered better protection.
The shields of all cabling shall be terminated at the furthest point, e.g. at the field instrument, but NOT earthed there.
All MOV's shall be taken to the High Quality Earth. Under no circumstances shall the MOV's be connected directly to the Safety Earth System, since this will result in earth current loops between the two systems.
12 DATA/VOICE COMMUNICATION LINES
Signal transmission via fibre optic is the preferred means of connecting remote areas.
As an alternative, the use of coaxial cable is approved. Multi-core electronic cable then follows. Radio links may be installed when there is a technical and/or economic advantage.
The use of dual redundancy is the minimum requirement where downtime cannot be tolerated, and multiple redundancies may be provided on highly exposed highway backbone routes.
Cables should be routed in areas where the risk of damage is the least. In buildings, cables must be run within ducting or panduit for mechanical protection. The use of conduit must be confined to plant areas. Cables, other than fibre optic, must be installed in such a way that crossing of electrical cables is done at 90 degrees angle. Parallel runs should have the electrical and electronic signal cables separated by 250 to 300mm at least; or else adequate barriers must be installed.
Cables should not be installed where they carry strain. Carrier steel cable, such as catenary wire, should be used as well as the correct hanger, where required. Hangers shall be constructed in such a way that the minimum-bending radius is not exceeded, nor should the clamping action physically distort the cable. Proper care should be taken for protection against any mechanical damage, which may be caused by ambient conditions or inclement weather.
Cables should be tested twice before a system is placed in service. The first test is performed with the cable still on the drum; loss per unit length should be within specification. The second test is performed after installation, to determine whether the sum of losses is within the tolerable limit.
Ease of maintenance must be provided to facilitate periodic testing, as well as repair of cables with minimum downtime.
13 QUALITY ASSURANCE AND COMMISSIONING
The Quality Assurance and Commissioning Flow diagram - as attached - must be used in conjunction with this section.
13.1 Contractor's Own Quality Control Responsibility
The contractor or vendor must do quality control on his own performance (on the individual scope of work items).
13.2 Supervisory Quality Control
The contractor and Palabora Mining Company must do supervisory quality control during the execution of the individual scope of work items. Certification must be done on the approved documentation in the format as specified by Palabora Mining Company procedures.
13.3 Shop And Field Calibration
13.3.1 Shop Calibration:
This is the preferred calibration method; all instruments must be calibrated prior to installation or mounting inside their protection boxes. Calibrations must be done in accordance with the applicable data sheets, using approved and certified test equipment. Every calibration must be witnessed and certified by Palabora Mining Company.
13.3.2 Field Calibration:
This must be carried out on installed equipment in the field, and only when shop calibrations cannot be done. Permission must be obtained from Palabora Mining Company before field calibration commences. Although calibration is done in the field, the same standards apply as for the shop calibration above.
13.3.3 Test Equipment:
Only test equipment approved by Palabora Mining Company, for specific use on the required application, may be used for calibration and loop checking. The contractor must obtain approval from Palabora Mining Company before work commences.
13.4 Pre-Delivery Inspection
All equipment and fabrication pieces are subject to pre-delivery inspection. The supplier or fabricator must request permission to deliver with adequate notification (at least 5 workdays). Palabora Mining Company will inspect and provide written clearance for the equipment that is prepared for shipment.
Control Panel, Instrument Racks or Systems:
These will be inspected at the vendor's/manufacturer's premises prior to shipment. They will be wired and/or piped complete (with tubing) and will be inspected in accordance with the purchasing specification and the design documentation.
13.5 Receiving, Checking And Warehousing After Shipment
All equipment and fabrication pieces are subject to inspection and acceptance after shipment and arrival at Palabora Mining Company. They will be checked for complete compliance with the purchase specification in relation to type, range, and materials of construction, appropriate scales, tags, etc. They will also be checked for damage or shortage of parts. This will be reported immediately for replacement or repair.
After checking, instruments will be clearly marked with tag numbers, and stored in a separate instrument portion of the warehouse. If the items are stored in the export boxing, then the packing shall be carefully re-sealed. Control valves, positive displacement meters, meter provers and in-line instruments may be stored outside, but the preference is warehousing until installation.
Note: The warehouse must contact the person who ordered the items, and that person shall either check the items himself, or send a competent person to do it.
13.6 Cable Meggering/Continuity Checks
All cables shall be meggered, except for electronic and thermocouple cables: continuity checks shall be done on electronic and thermocouple cables, using a volt/ohm meter. Meggerring and continuity checks shall be done between conductors, and conductor-to-earth. This will be done once cabling is complete, and prior to cable termination. The contractor must complete the proper certification on the approved documentation. The contractor and Palabora Mining Company shall witness Meggering/continuity checks. The minimum reading should be 1 MΩ.
13.7 Pressure Testing
Pressure testing up to the first block valve shall be in accordance with Palabora Mining Company procedures. Extreme caution should be taken to avoid damage to instruments. The permissible leak rate shall be less than 7 kPa per 30m of 6mm OD tubing for a 5 second duration, and a rate of 7 kPa per 60m of 6mm OD tubing for a 10 second duration.
13.7.1 Instrumentation tubing exclusions:
Tubing which is an integral part of a tubing system, or an integral part of the equipment.
The instruments and/or the permanently sealed, fluid filled systems, furnished with the instruments.
13.7.2 Pressure test exclusions:
• Design pressure at or above 0 kPa, but less than 35 kPa, regardless of temperature.
• Design pressure at or above 35 kPa, but less than 100 kPa, if the design temperature is below 343 °C.
• Non-metallic systems shall be tested according to their manufacturer's recommendations.
13.7.3 Leak tests/detection
Piping and tubing shall be air tested, and all leaks eliminated. A soap solution must be used, together with a sight feed bubbler, to detect leaks.
13.7.4 Pressure used for testing
Pressure for the Pressure Test must be the same as the maximum safe working pressure of that component in a system where this pressure is the highest working pressure.
Normally tests shall be executed with instrument and control connections open. Instrument air headers shall be tested individually to 1,5 times their working pressure, up to the air regulator station shut off valves.
13.7.5 Preparation for pressure testing
Before the piping contractor does pressure testing of the process lines, close the block valves at the instrument lines, and open the bypass valves at the instruments.
Review the maximum pressure rating of the instruments installed in the process lines. Should their rating be less than 1,5 times the process line rating or the process line pressure test requirement, remove the instruments from the line during the pressure test.
13.7.6 Vacuum pressure test
Instrument lines for vacuum service shall be pressure tested to a minimum of 100 kPa, unless limited to a lower pressure rating by the line design pressure.
13.7.7 Analyser sample line test
Analyser sample lines shall be tested up to the instrument. Disconnect the line at the analyser before testing. The pressure reducing regulator and sample vaporisers should be removed and a jump line installed during the test.
13.7.8 Orifice Plates, Turbine Meters etc.
Orifice plates, turbine meters etc. shall be removed from the process lines during pre-start-up flushing and or/testing operations. Orifice meter runs will arrive in the field with a carbon steel full-bore spacer bolted between the flanges by undersized carbon steel stove bolts and nuts. The carbon-steel nuts and bolts shall be removed and replaced with the correct line specification studs and nuts by the contractor. Line specification gaskets shall be installed on either side of the spacer plate. Spacer plates shall be left in place during flushing and testing operations.
13.8 Installation of control panels, Instruments, Analysers and Other Systems
See section 15 for full details regarding Instrumentation Installation Specifications.
Control panels
Control panels shall arrive in the field wired and/or piped and completely checked. They will be carefully unloaded by the contractor and set in place to avoid damage to sensitive instrumentation. Storage, if required, shall be indoors. Hook-up and tagging of cables shall be done in accordance with the installation details.
Field Instruments and Supports
This must be installed in accordance with the relevant installation and design details. Instruments have to be calibrated before installation and must be checked for zero shift at time of loop checking.
13.9 Preliminary/Final Punch list
Preliminary punch lists can be drawn up on larger work items. It is considered an aid to assist the contractor with his work to speed up completion. Signing off the completion is not required, but it is still the intention of Palabora Mining Company to show the contractor that it will not approve/accept the relevant items by placing it on record.
A final punch list shall be compiled on all work items. This will be done in the following way:
• When the individual work item is mechanically complete, the contractor/vendor shall notify Palabora Mining Company in writing that Punch out may commence.
• This action must be executed within two working days after receipt of the notification. A group that consists of the contractor, Palabora Mining Company, and maintenance personnel must compile the punch list through inspection.
• The list drawn up shall be agreed upon, and signed by all parties present.
• The list shall contain the items that were not to satisfaction, and shall include the required completion dates as well as the responsible parties.
13.10 Working Off Final Punch List
All items on the punch list have to be worked off by the responsible parties within the required time. The items have to be inspected by the various parties and signed off when completed to satisfaction.
13.11 Mechanical Completion
Notice of Mechanical Completion
When the Contractor has worked off all the items on the Preliminary Punch lists, and has deemed the work complete, the contractor shall give written notification to Palabora Mining Company that the installation has been mechanically com
Machine and Occupational Safety Act (Act No. 6 of 1983)（机器与职业安全法（1983年第6号））
S.A. Bureau of Standards Codes of Practice and Standard specifications（S.A.标准局实施规范和标准规范）
Mine Health and Safety Act（矿山健康与安全法）
Standards and Practices for Instrumentation by the Instrument Society of America（美国仪器仪表学会仪器标准与规范）
English to Chinese: Petroleum（NIDC South Parse Project - Iran & China）- 30000 word General field: Tech/Engineering Detailed field: Petroleum Eng/Sci
Source text - English 5.2 Mud Programme
5.2.1. INTRODUCTION
The South Pars Gas Field is located in the middle of the Persian Gulf in South West of the Iranian coast, and adjacent to the international boundary with Qatar. The South Pars Gas Field is the northern part of a super-giant structure extending from Qatari waters into the Iranian waters in the Persian Gulf. The distance of this Field to the Iranian shore is about 100 km and the average water depth over the field is about 70 meters. The southern extension of South Pars gas bearing structure into Qatari waters is known as North Field. North Field has been discovered in eighties and has been put into production during 1991. Subsequent to a 2D seismic survey during 1988-1989, the South Pars gas field was discovered by the NIOC in 1991 via drilling the first exploratory well SP-1 in the central location of the structure and near the borderline. In South Pars Phases 17&18 will be drilling done with two drilling jack up rigs but not limited to providing two jack up rigs, Two (2) vertical APPRAISAL wells and Twenty five (25) deviated DEVELOPMENT wells from two separate platforms, each with eleven slots. Each drilling rig shall drill eleven directional wells and five (5) wells are on third platform, all wells must be perforated through all reservoir layers.
INTERVAL DISCUSION
The 32-inch section will be drilled with sea water and hi-viscous mud sweeps.
Offset well analysis shows no drilling fluid related issues whilst drilling this section.
This section will be drilled from Seabed at 70 m using seawater and HI VIS pill. BENTONITE will be pre – hydrated in fresh at the concentration of 100kg/m³. Fars Group is the main formation which will be drilled with slow pump rate to 26”casing point.
This is a large diameter hole and the hole cuttings removal mechanism will be a combination of high annular velocities and hi-viscous sweeps. The viscous sweeps are composed of Guar gum and Pre- hydrated Gel (PHG).
Soft dispersive clays and unconsolidated sands can be expected whilst drilling this interval. The formation is mainly composed of unconsolidated sands with some mudstone, shale beds and possibly
lime stone. The hole is to be displaced to weighted viscous mud at the section TD in order to plaster off the sands, enhancing bore hole stability and minimizing fill while running the conductor.
This hole is to be cleaned as required but as a minimum the following should be adhered to:
• Every single a 6-m³Guar Gum hi-viscous slug should be pumped to clean the hole and to sweep the cuttings to loss zone.
• At connections, the 10 m³ Guar Gum hi-viscous slug should be followed by a 10 m³ PHG viscous slug in order to build filter-cake on the bore-hole wall and enhance the stability of the hole.
The well is to spud with a low pump rate of 1.5 m³/min for the first 10 meters as not to washout the seabed.
Availability of drill water might be a logistical issue and shortage of drill water is to be expected. A large volume of fluid will have to be turned over in both this section and next section and emphasis will be placed on pit management and drill water logistics. The engineer should endeavor to have all the pits full with gel based hi-viscous mud in order to avoid ending up in a “catching up” situation.
At section TD the following procedure shall be adhered to:
• Before pulling out drill string of the hole to run casing the hole shall be swept with a 20 m³PGH viscous pill and spot 100 m of bottom in the Open Hole volume with 1.3 S.G. weighted PHG viscous pill.
General Practices to help avoiding hole to pack off during connection:
• Spot 20 m³ PHG prior to any Totco run.
• Prior to POOH for any BHA change spot 20 m³ PHG on bottom.
• Prior to connection spot 20 m³ PHG.
Displace the cement and related float equipment with treated seawater. Take returns to seabed.
No lime is to be used in the displacement volume as its effect on viscosifying – flocculation – of gel is only of short duration.
There has been no need for Kill mud identified.
POTENTIAL MUD RELATED PROBLEMS AND HAZARDS.
Hole cleaning:
Pump hi-viscous mud more frequently and of greater volume.
Increase pump rate.
No drill water:
Ensure gel is pre-hydrated at high concentrations. Use guar gum to alternate the gel based viscous sweeps.
Hole instability:
Displace to a weighted hi-viscous gel mud.
Mud composition
A - Mud Composition: PHG sweeps
PreHydrated Gel Viscous sweeps
Drill water: Less than 200 mg/l Cl- for gel hydration.
Caustic soda: Alkalinity control
Soda Ash: Hardness control / Alkalinity control.
Bentonite: Viscosifier.
Mixing Procedure:
1. Fill the tanks with the required volume of drill water.
2. Raise the pH to 9.0 with additions of caustic soda.
3. Treat out any hardness greater than 200 PPM with soda ash.
4. Add 100 kg/m³ of Bentonite and allow hydrating for as long as possible (at least 6 hours).
Processing with a shearing device will improve yield.
Properties
Funnel Viscosity : ± 120 sec/qt.
B - Mud Composition: Guar gum viscous sweeps.
Sea water :
Guar gum : (Viscosifier)
Safecide : Biocide
Mixing Procedure:
1. Ensure mixing tank and mixing lines are free of any caustic soda residue (or any other alkaline material)
2. Fill the tanks with the required volume of sea water.
3. Add Biocide at 0.1 Lit/m³.
4. Add 8 – 10 kg/m³ of Guar gum and allow hydrating for as long as possible. Processing with a shearing device will improve yield.
5. Pills should not be kept for more than 6 hours in the surface tanks. These will lose viscosity rapidly over time.
Properties
Funnel Viscosity : ± 120 sec/qt.
C - Mud Composition: Displacement mud.
Drill water : Less than 200 mg/l Cl- for gel hydration.
Caustic soda : Alkalinity control
Soda Ash : Hardness control & Alkalinity control.
Bentonite : Viscosifier
Mixing Procedure:
1. Fill the tanks with the required volume of drill water.
2. Raise the pH to 9.0 with additions of caustic soda.
3. Treat out any hardness greater than 200 PPM with soda ash.
4. Add 35 - 45 kg/m³ of Bentonite and allow hydrating for as long as possible (at least 6 hours).
Processing with a shearing device will improve yield.
5. Add barite to weight 1.30 S.G.
Properties:
Funnel Viscosity : ± 100 sec/qt.
Weight : 1.30 S.G.
ENGINEERING COMMENTS
Slugs: should be a minimum of 10-m³ per single. The frequency or volume may be increased dependent open hole conditions.
Connections: the 10 m³ Guar gum hi-viscous slug should be followed by a 10 m³ PHG viscous slug in order to build filter-cake on the bore-hole wall and enhance the stability of the hole.
Section TD: The following procedure shall be adhered to:
o The hole shall be swept with a 20 m³ PHG viscous pill and spot in Open Hole with 1.3 S.G. weighted PHG viscous pill 100 m of bottom.
o Before pulling out of the hole to run casing the same procedure will be adhered to sweep the hole with 20 m³ PHG viscous pill and spot 100 m of bottom in the Open Hole with 1.3 S.G. weighted PHG viscous pill.
Diluting: The pre-hydrated gel with more than 35% sea-water may result in rapid decrease of yield point and thus prove less cost effective.
Drillers: General Practices to help avoiding hole to pack off during connection:
o Spot 10 m³ PHG prior to any Totco run.
o Prior to POOH for any BHA change spot 20 m³ PHG on bottom.
o Prior to connection spot 20 m³ PHG.
INTERVAL DISCUSSION
The 24-inch interval will be drilled with sea water and hi-viscous mud sweeps.
As this is a large diameter hole and the hole cuttings removal mechanism will be a combination of high annular velocities and hi-viscous sweeps. The viscous sweeps are composed of Guar Gum and Pre-hydrated Gel (PHG).
This section will be drilled through the ASMARI, JAHRUM, ILAM and LAFFAN formations. Each of these, have their own particular problems to be dealt with and the engineers are to be aware of these prior to drilling these.
From offset well analysis it is proven that the major problem is the down-hole losses and its consequent loss of hydrostatic. This loss of hydrostatic will result in bore-hole failure, poor hole cleaning, pack off and stuck pipe.
In order to minimize the chances on the above problems, the hole is to be cleaned.
As required but as a minimum the following should be adhered to:
During kick off stage, pump 6-10 m³ Guar Gum pill after drilling first of 5 m.
Every single a 10-m³ Guar Gum hi-viscous slug should be pumped to clean the hole.
At connections, the 10 m³ Guar Gum hi-viscous slug should be followed by a 10 m³ PHG viscous slug in order to build filter-cake on the bore-hole wall and enhance the stability of the hole.
In JAHRUM, pump a 10 m³ Guar Gum every ½ single if ROP is more than 15m/hr and a 5 m³ if it is less than 15m/hr.
Due to logistical constraints, it is possible that drill water might be in short supply. The engineers however are to ensure that sufficient drill water is kept on location in order to prepare pre-hydrated gel (PHG) for at least the final displacement. A large volume of fluid will have to be turned over in this section and emphasis will be placed on pit management and drill water logistics. The engineer should endeavor to have all the pits full with gel based hi-viscous mud in order to avoid ending up in a “catching up” situation.
All hole-cleaning pills are to be formulated with H2S scavenger to neutralize H2S and minimize corrosion. Offset wells recorded a maximum of 18 PPM H2S.
For the protection of drill string, Corrosion inhibitor shall be used as a filming agent. This can be used in slugs, sprayed or mopped when tripping out of hole. Concentration is between 5.6- 7.5l/305 m.
At section TD the following procedure shall be adhered to:
Prior to wiper trip, sweep hole with a 20 m³ PHG viscous pill and spot open hole volume with 1.3 S.G. PHG viscous pill till 100 m into JAHRUM, PAC R is to be added to provide extra fluid loss control to the fluid.
Before pulling out of the hole to run casing, sweep hole with a 20 m³ PGH viscous pill and 1.3 S.G. weighted PHG viscous pill shall be spotted till 100 m into JAHRUM, PAC R is to be added to provide extra fluid loss control to the fluid.
General Practices to help avoiding hole to pack off during connection:
Spot 10 m³ PHG prior to any TOTCO run.
Prior to POOH for any BHA change, spot 20 m³ PHG on bottom.
Prior to connection spot 10 m³ PHG.
Avoid pump stop when switching between pills and Sea Water.
There is no requirement to treat losses, continue drilling with Sea Water and Viscous Sweeps.
If severe losses occur, drill with floating mud cap to prevent under balanced conditions in the well and prevention of H2S migration. If it is applicable, Sea Water should be maintained at high alkalinity and pre-treated with H2S Scavenger to neutralize H2S.
In case bit and BHA balling occur, pump surfactant pills such as Drilling Detergent to reduce balling. Concentration is between 11.4 – 17.1 kg/m³.
There has been no need for Kill mud identified.
POTENTIAL MUD RELATED PROBLEMS AND HAZARDS.
Well bore and formation related problems are identified as follows:
Complete losses in JAHRUM and SACHUN formations.
Stuck pipe in JAHRUM and ASMARI.
Sulfurous water flow from JAHRUM.
Stuck casing.
Hole cleaning
Pump hi-viscous mud more frequently and of greater volume.
Increase pump rate.
The use of SUPERSWEEP pills should be considered in this section as hole cleaning is detrimental to hole stability.
Shortage of drill water: Ensure gel is pre-hydrated at high concentrations. Use Guar Gum to alternate the gel based viscous sweeps.
Hole Instability
Displace to weighted hi-viscous gel mud .
Mud composition
A - Mud Composition: Prehydrated Gel Viscous sweeps
Drill water: Less than 200 mg/l Cl- for gel hydration.
Caustic soda: Alkalinity control
Soda Ash: Hardness control / Alkalinity control.
Bentonite: Viscosifier.
H2S Scavenger
Mixing Procedure:
1. Fill the tanks with the required volume of drill water.
2. Raise the pH to 9.0 with additions of caustic soda.
3. Treat out any hardness greater than 200 PPM with soda ash.
4. Add 100 kg/m³ of Bentonite and allow hydrating for as long as possible (at least 6 hours). Processing with a shearing device will improve yield.
5. Add: H2S Scavenger at 0.3 ltr/m³
Properties
Funnel Viscosity: ± 120 sec/qt.
B - Mud Composition: Guar gum viscous sweeps
Sea water : Less than 200 mg/l Cl- for gel hydration.
Guar Gum : Viscosifier
Biocide
H2S Scavenger
Mixing Procedure:
1. Ensure mixing tank and mixing lines are free of any caustic soda residue (or any other alkaline material)
2. Fill the tanks with the required volume of sea water.
3. Add Biocide
4. Add 8 – 10 kg/m³ of Guar Gum and allow hydrating for as long as possible (at least 6 hours). Processing with a shearing device will improve yield.
5. Pills should not be kept for more than 6 hours in the surface tanks. These will lose viscosity rapidly over time.
6. Add H2S Scavenger at 0.3 ltr/m³
Properties
Funnel Viscosity : ± 120 sec/qt.
C - Mud Composition: Displacement mud.
• Drill water : Less than 200 mg/l Cl- for gel hydration.
• Caustic soda : Alkalinity control
• Soda Ash : Hardness control & Alkalinity control.
• Bentonite : Viscosifier.
• PAC R : Viscosity &Fluid loss control
• H2S Scavenger
Mixing Procedure
1. Fill the tanks with the required volume of drill water.
2. Raise the pH to 9.0 with additions of caustic soda.
3. Treat out any hardness greater than 200 PPM with soda ash.
4. Add 35 - 45 kg/m³ of Bentonite and allow hydrating for as long as possible (at least 6 hours). Processing with a shearing device will improve yield.
5. Add PAC R.
6. Add H2S Scavenger.
7. Add barite to weight 1.30 S.G.
No lime is to be used in the displacement volume as its effect on viscosifying – flocculation – of gel is only of short duration.
Engineering Comments
Slugs: should be a minimum of 10-m³ per single. The frequency or volume may be increased dependent upon hole conditions.
Connections: the 10 m³ Guar Gum hi-viscous slug should be followed by a 10 m³ PHG viscous slug in order to build filter-cake on the bore-hole wall and enhance the stability of the hole.
Section TD: the following procedure shall be adhered to:
Prior to wiper trip, sweep hole with a 20 m³ PHG viscous pill and 1.2 S.G. and spot PHG viscous pill till 100 m into JAHRUM. PAC R is to be added to provide extra fluid loss control to the fluid.
Before pulling out of the hole to run casing, sweep hole with a 20 m³ PGH viscous pill and 1.3 S.G. weighted PHG viscous pill shall be spotted till 100 m into JAHRUM. PAC R is to be added to provide extra fluid loss control to the fluid.
Diluting: The pre-hydrated gel with more than 35% sea-water may result in rapid decrease of yield point and thus prove less cost effective.
Drillers: General Practices to help avoiding hole to pack off during connection:
Spot 10 m³ PHG prior to any Totco run.
Prior to POOH for any BHA change spot 20 m³ PHG on bottom.
Prior to connection spot 10 m³ PHG.
In JAHRUM, if ROP is more than 15 m/hr, pump 10 m³ Guar Gum every ½ single, otherwise 5 m³.
Avoid pump stop when switching between pills and Sea Water.
Hole-cleaning pills: to be formulated with H2S scavenger to neutralized H2S and minimize corrosion H2S Scavenger
Corrosion protection: Corrosion inhibitor shall be used as a filming agent. This can be used in slugs, sprayed or mopped on drill String when tripping out of hole. Concentration is between 5.6- 7.5 Liter per 11 stands of Drill Pipe.
Bit & BHA Balling: Use Surfactant pill, such as drilling detergent to reduce surface tension, hence minimize balling. Concentration is between 11.4 – 17.1 kg/m³.
24” INTERVAL VOLUMES AND MATERIALS
Description Units Quantity
Last Casing Size in
Last Casing Setting Depth(MD) m
Last Casing Volume m³
Meters to Drill m
Surface Volume m³
Mud Recovered from Last Section m³
VOLUME ESTIMATES
Description Units Quantity
Hole Wash Out %
Estimated Hole Volume m³
Volume of GG Sweeps m³
Spot mud at TD m³
Volume of PHG Sweeps and Spots on Connections m³
Total Volume m³
Description Concentration
(Kg/m³) unite Required unite
Guar Gum Sweeps
Guar Gum
PHG Sweeps & Spot on Connections
Bentonite
Caustic Soda
Soda Ash
PHG Spot at TD
Bentonite
Caustic Soda
Barite
Soda Ash
5.2.5: Hole 17"
Casing Size: 13 3/8 "(943 to 1714 m) MD
Drilling Fluid System: KCl/Polymer system
Key Products: KCL, Sulfonated Asphalt, PAC R, PAC LV, Caustic, Soda Ash, Xanthan Gum, Starch high quality, Barite,
Solids Control: Rig Shakers, Centrifuges
Potential Problems: Hole instability, Lost Circulation, Shale Swelling, Differentially Sticking
INTERVAL MUD PROPERTIES:
API Fluid Loss(ml/30min) Yield Point (lb/100ft2) Plastic Viscosity (cp) Mud Wt (S.G) Depth TVD(msl)
OBJECTIVE
This section will be drilled into the LAFFAN, SARVAK, KAZHDUMI, DARIYAN, GADVAN and FAHLIYAN formations, and after drilling few meters into HITH formation the 13 3/8” casing will be set at 1405 m TVD.
INTERVAL DISCUSSIONS
This interval consists of limestone, clay, marl, shale, sand stone, siltstone, dolomite and anhydrite.
KCL /Polymer mud to be used to drill this section.
Utilization of a KCl /Polymer mud system should firmly inhibit reactive KAZDHUMI clays and some of the marl/shale sections encountered in the LAFFAN and GADVAN formations. It goes without say though that the KAZDHUMI is the most troublesome reactive shale.
Drill out cement with seawater and high vis. sweeps and before drilling shoe displace the hole to new mud system. This is to avoid cement contamination. Drilling to within a few meters of the shoe and then switching over to mud would save on the cost of treating the cement against cement contamination. If the issue is the possible danger from H2S below the shoe, this can be prevented by treating the sea water with caustic Soda and H2S Scavenger during drilling this interval, the following problems are anticipated:
Well bore and formation related problems are identified as follows:
Oil/Water influx from KAZDHUMI.
Swelling shale and clays in KAZDHUMI.
Partial or Total losses in KAZDHUMI Sands and FAHLIAN.
Possible H2S in DARIYAN& HITH.
The swelling shale encountered in the KAZDHUMI can lead to a plugged flow line and bit balling.
The HITH and DARIYAN contain potentially H2S. Lost circulation material should be prepared in advance and prior to drilling the FAHLIYAN.
In the event of loss of circulation, these should be treated with different grades of LCM such as mica (F/M/C), fiber blend (F/M/C), Wall nut shell (F/M/C).
Hole cleaning to be monitored to ensure that the annulus is kept free of cuttings as much as possible as it is a major contributing factor to hole instability.
It is important to maintain the mud weight as per program and this should be maintained at 1.18- 1.20 S.G. Maintenance of mud weight in this section will be a junction of applying all solids control efficiently as well adapting a dump and dilute strategy.
The KCl and Sulfonated Asphalt concentrations are to be at 70 kg/m³ and 15 kg/m³ respectively. Sulfonated Asphalt will minimize fluid invasion into formation and will stabilize the bore-hole and is an essential additive of this system.
Hole Instability: In addition to the KCL/polymer mud, PHPA and/or Glycol can be added to provide extra inhibition to shale sections. PHPA shale inhibitor acts as encapsulating polymer, minimizing the hydration and dispersion of cuttings. The Concentration of PHPA is between 2 - 4 kg/m³ and the concentration of Glycol is 3-5 V%.
Lost Circulation: The concentration of LCM will vary according to losses. In the event of seepage losses, treat system with a finer grade of LCM at 25 - 30 kg/m³. In the event of moderate to high rate of well bore loss, prepare pills at different graded concentrations and spot over thief zone. The concentration may between 55 kg/m³ to 225 kg/m³.
In order to avoid LCM plugging MWD tools a circulation sub should be installed in the drill string.
The MWD engineer is to advise on the size and concentration of LCM that can be pumped through MWD Tools. Ensure that the drilling displace all the LCM pill out of the string prior to shutting down the mud pumps In the event of severe losses, cross linking pills should be pumped to minimize losses( Please refer to the contingency Manual) .
Bit balling: This can occur due to KAZDHUMI soft formation and is attributed to different factors other than mud chemistry, such as bit hydraulics. At times, hydraulics is not adequate to clean the bit and stabilizer and balling may occur. If hydraulics appears to be adequate, then a strategy of additions of materials such as drilling detergent or walnut can be adapted or pumping caustic Wash pills to be considered in order to minimize bit balling.
MUD COMPOSITION
KCl /Polymer
Sea water …………………… 800 - 1000 mg/l Calcium.
KCl …………………………. Inhibition
Caustic potash………………. pH control.
Soda Ash …………………… Hardness control.
Xanthan Gum………………. Rheological control
Starch high quality…………. Fluid loss control
PAC UL ……………………..Fluid loss controls.
PAC R ………………………Viscosifier / Fluid loss control.
Sulfonated Asphalt …………………….Inhibitor
Barite ………………………..Weighting agent.
Biocide
Defoamer
Mixing Procedure:
1. Fill the tanks with the required volume of sea-water.
2. Add KCl at 7% W/V.
3. Raise the pH to 9.5 – 10.0 with additions of caustic soda.
4. Treat out any hardness greater than 200 mg/l with Soda Ash.
5. Add Starch high quality at 6 – 8 kg/m³
6. Add PAC UL at 4 – 6 kg/m³
7. Add PAC R at 2 – 3 kg/m³
8. Add Xanthan Gum at 1 – 2 kg/m³
9. Add Sulfonated Asphalt at 15 kg/m³
10. Adjust pH
11. Adjust barite to desired weight.
12. Add Biocide
13. Add Defoamer
Properties
Mud weight – SG
Yield Point
3 rpm reading
6 rpm reading
PH
LGS
API fluid loss
Gel, 10’
Gel, 10”
KCl
Sulfonated Asphalt
MBT
ENGINEERING COMMENTS
Inhibition and hole stability:
Shale Inhibition: Potassium chloride at 70 kg/m³ and 15 kg/m³ Sulfonated Asphalt will be the primary and secondary inhibitors for this fluid. It would be an option to start off with a slightly higher concentration of KCl – 80 kg/m³, to avoid catching up when the dilution volume requirements are high. The cuttings need to be monitored for firmness and integrity at the shakers. If these dictate, the concentrations of KCl and/or Sulfonated Asphalt may need to be increased.
PHPA Addition: If the KAZDHUMI exhibits signs of instability then it is recommended to add 2-4 kg/m³ PHPA. PHPA shale inhibitor acts as encapsulating polymer, minimizing the hydration and dispersion of cuttings.
KCl Content: If cuttings dictate, increase KCl content to over 7%
Sulfonated Asphalt content: If hole conditions dictate, increase Sulfonated Asphalt content. Use Sulfonated Asphalt from the beginning of the section, it will lubricate the cake thus reduce torque, and decrease fluid loss. In the event of drag and torque, add a lubricant.
Glycol: Glycol should be added in the range of 3-5 V% in case, hole condition dictates.
Losses: surface and sub surface to be documented on a daily basis.
Mud properties
Density: drilling fluid density will be controlled by addition of barite or light premix fluid. Use available solids control equipment to reduce low gravity solids build-up, thus reducing any dilution requirements for density control. Mud weight to be increased as hole conditions dictate.
Plastic Viscosity: Dependent on 6 rpm value. Note that addition of PAC R will also tend to increase the plastic viscosity.
Yield Point: To be maintained in the 20-25 lb/100ft² range.
3 RPM reading: Additions of Xanthan Gum should be done to increase the low-end shear readings.
6 RPM reading: Additions of Xanthan Gum should be done to increase the low-end shear readings.
Fluid loss control, API: The API fluid loss should be kept within specifications using additions of PAC UL and /or Starch high quality.
MBT: To be controlled with solids control equipment and dilution
Hole cleaning:
Hole cleaning: Prior to tripping pipe, the hole should be circulated clean and, if possible, the drill-pipe rotated. Soft ware of Hydraulics may be used to calculate the sensitivity of various operating
parameters that may have an effect on hole cleaning. For example, higher flow rates and rotary improve hole cleaning, while higher ROP may adversely affect hole cleaning.
Solids control:
Solids control: to be optimized with on board shale shakers, desilter and centrifuge.
Solids control equipment: Use all available solids control equipment efficiently to maintain mud weight. Adapt a dump and dilute strategy, using whole pre-mix mud, to control the weight.
Shale shakers: Ensure shakers are running immediately prior to and during all periods of circulation. Shakers to be dressed initially with 80/100 mesh screens and after the mud is Sheared, finer screens of 150/180/200 mesh should be dressed to avoid making gumbos while drilling through KAZHDUMI.
Drilling / Fluids operations:
Controlled drilling: Strongly recommended for proper hole cleaning. Cuttings should be circulated up above the BHA prior to connections. It should also be considered to ream at each connection. This will minimize the potential of cuttings settling during connections, causing packing off and stuck pipe. Prior to trips the hole should be circulated clean and at least 1 ½ x bottoms-up. This will prevent tight hole on the way out and bridges, fill etc. on the way back in.
Dump and dilute strategy: Dilute active system with premixed fluid to maintain volume and mud properties. The concentration of this fluid should be somewhat higher than in the initial mix to compensate for depletion.
GENERAL REMARKS ON SHALE CONTROL
Shale problems cannot be solved by the drilling fluid alone. Good mud practices along with good drilling practices can do much to alleviate the trouble. This is logical when one considers that shale problems may be physical or mechanical rather than chemical or a combination of both. In a pressured or stressed shale environment, sloughing may occur regardless of the inhibition or type mud used. The sloughing could be caused by localized internal forces within the shale or by invasion of whole mud or filtrate into micro fractures.
The subsequent effect of the fluid on the shale after invasion can become either mechanical or chemical.
The following is a list of recommendations that will aid in alleviating shale problems:
a. Avoid high surge and swab pressures due to raising and lowering the drill pipe too rapidly. (A minimum of 30 seconds per stand is recommended).
b. . Avoid excessive annular velocities resulting in excessive turbulence (particularly along collars). We recommend velocities below 45 m/min. around drill pipe.
c. Minimize occurrences of under gauge hole caused by the wearing down of the faces(s) of stabilizers and reamers.
d. Changing of drill string design, often results in having to ream back through previously conditioned hole. This occurs for instance when new or repositioned stabilizers, reamers, or bent subs are run.
e. Fanning deviated holes at high rotary speeds with stiff string designs usually promote mechanical degradation of already sensitive shale(s).
f. Stuck pipe occurring due to in-gauge hole, With minimum clearances around collars and stabilizing down hole tools, only small settlings of cuttings need occur to cause tight hole on trips or connections. It is not unusual to pump out singles, particularly after long bit runs. Drillers must be educated in the various techniques of averting trouble such as circulating before tripping; never pulling too hard into tight spots and putting the pump on the hole and pumping slowly at the least sign of a snug hole.
17” INTERVAL VOLUMES AND MATERIALS
Description Units Quantity
Global S.C.E. Efficiency
LGS Content
Last Casing Size
Last Casing Setting Depth
Last Casing Volume
Meters to Drill
Surface Volume
Mud Recovered from Last Section
VOLUME ESTIMATES
Description Units Quantity
Hole Wash Out
Estimated Hole Volume
Estimated Dilution Volume
Total Volume
Description Concentration
(Kg/m³) unite Required unite
KCl
Soda Ash
Caustic Soda
Xanthan Gum
High qulity starch
PAC R
PAC UL
Sulfonated Asphalt
Barite
5.2.6: Hole 12 1/4"
Casing Size: 9 5/8''- 10 ¾'' (1714 to 4287m) MD
Drilling Fluid System: KCl/Polymer
Key Products: KCl, PAC,Sulfonated Asphalt, Xanthan Gum, Caustic Soda, Soda Ash
Solids Control: Shakers, Centrifuges
Potential Problems: H2S, Loss Circulation, Differential Sticking, possibility of Salt Water flow in DASHTAK formation
INTERVAL MUD PROPERTIES
Sulfonated Asphalt
(kg/m3) KCL
(%w/v) API Fluid Loss(ml/30min) Yield Point (lb/100ft2) Plastic Viscosity (cp) Mud Wt (S.G) Depth TVD(msl)
OBJECTIVE
This section will be drilled into the HITH, SURMEH, NEYRIZ, DASHTAK, SUDAIR and AGHAR shale formations. After drilling few meters into KANGAN formation the 10 ¾” casing will be set at 2598 m TVD.
KCl /Polymer
KCL /Polymer mud to be used to drill this section.
INTERVAL DISCUSION
This interval consists of limestone, clay, marl, shale, sand stone, siltstone, dolomite and anhydrite.
The 12 ¼ -inch interval will be drilled with a KCl /Polymer mud system. The fluid will be carried over from the previous section at zero cost. The utilization of a KCl /Polymer mud system should firmly inhibit shale(s) and provides excellent properties drilling and inhibition properties.
This section will cross the HITH, SURMEH, DASHTAK, SUDAIR and AGHAR formations and casing will be set into KANGAN. These formations consist of Dolomite, Limestone, Chert, Anhydrites and shale(s). Before drilling the 13 5/8” Casing shoe, the mud should be treated with sodium bicarbonate and citric acid to avoid cement contamination. During drilling this interval KCl and Sulfonated Asphalt are the primary components providing inhibition to the shale sections. Ensure that concentrations are as per program and that these are determined and reported every tour.
Sufficient and adequate stocks of LCM are to be kept on board of the rig as partial to severe losses are expected in SURMEH formations. In case of seepage losses, the system should be treated with finer grade of LCM at 28 kg/m³, for Moderate to large Losses, prepare pills at different F, M, C concentrations and spot across the thief zone, concentration may vary between 57 kg/m³ to 228 kg/m³.
In the event of severe losses, cross linking pills should be pumped to minimize losses (refer to operation manual for more details).
There is the possibility of Salt Water flow in DASHTAK formation .Regarding to Experience in the South Pars Oil Field, the water analysis of the influx in offset wells gave a brine weight of 1.165 S.G. containing high concentrations of Calcium 12800 mg/l, Magnesium 10800 mg/l, Sodium 104000 mg/l and Chloride 163000 mg/l. This had caused severe contamination to the mud, which necessitated a lot of dump and dilution and high products consumptions. Therefore, sufficient stocks of products are to be on board to control flow. Mud weight was increased to 2.0 S.G. to control flow, but well remained flowing between 4 - 7 m³/hr till section TD in one of the offset wells. The possibility of differential sticking is SURMEH formation, to minimize it, tighten fluid loss and introduce Seepage loss control material into the system. Seepage loss control material will bridge and seal formation hence reduces differential sticking. It is important in AGHAR shale to maintain the mud weigh at 1.41 S.G. and reduce the API fluid loss to less than 2 ml and provide sufficient inhibition of KCl and Sulfonated Asphalt. This should provide optimum hole stability and less hole problems. However, as a contingency, if extra inhibition is required in AGHAR consideration should be given to Glycol and PHPA.
12 1/4” Section Run finest possible shaker screens and optimize solids removal equipment at all times in order to reduce dilution volume, thus reducing mud cost.
POTENTIAL MUD RELATED PROBLEMS AND HAZARDS.
Well bore and formation related problems are identified as follows:
o Hole instability in the Upper SUDAIR Shale section.
o Partial to severe loss of circulation in SURMEH formation.
o Sensitive and reactive shale(s) in the AGHAR formation.
o Salt Water influx in the DASHTAK formation.
Hole instability: Maintain MW as per pore pressure curve dictates in the drilling program. The mud weight might be raised up to 1.45 S.G. prior to entering the Upper SUDAIR Shale. Maintain KCl and Sulfonated Asphalt as per program to inhibit the shale sections (70 kg/m³ and 15 kg/m³ respectively).
It is important in AGHAR shale to keep MW at >1.41 S.G., fluid loss < 2 cc's and provide sufficient inhibition of KCl and Sulfonated Asphalt. This should provide optimum hole stability and less hole problems.
In the event extra inhibition is required for stabilizing the AGHAR shale(s), additions of PHPA are to be considered. Glycol is a poly-alkaline Glycol, which will chemically inhibit the swelling of shale(s) by interfering with the buildup of water hydra ionic layers. PHPA is a shale inhibitor and acts as encapsulating polymer, minimizing the hydration and dispersion of cuttings. The Concentration of Glycol and PHPA are, 3 - 5% v/v and 2 - 4 kg/m³; respectively.
Lost circulation: The concentration of LCM will vary according to losses. Partial to severe losses are expected in SURMEH formations and sufficient stocks of graded LCM should be kept on board. In case of seepage losses, the system should be treated with fine grade of LCM at 28 kg/m³, for moderate to severe losses, prepare pills at different graded concentrations and spot across the thief zone.
In order to avoid LCM plugging MWD tools a circulation sub should be installed in the drill string. The MWD engineer is to advise on the size and concentration of LCM that can be pumped through MWD Tools. Ensure that the drilling displace all the LCM pill out of the string prior to shutting down the mud pumps In the event of severe losses, cross linking pills should be pumped to minimize losses (refer to operation manual for more details).
Differential Sticking: The possibility of differential sticking is present after SURMEH formation. In order to reduce and minimize this occurrence tighten fluid loss and introduce 14 kg/m³ Seepage loss control into the system. Seepage loss control will bridge and seal formation hence reduces differential sticking.
MUD COMPOSITION
KCl /Polymer
Sea water ……………………….800 - 1000 mg/l Calcium.
KCl ……………………………..Inhibition
Caustic soda …………………….pH control.
Soda Ash ………………………..Hardness control.
Xanthan Gum …………………...Rheological control
High quality starch………………Fluid loss control
PAC UL …………………………Fluid loss control.
PAC R …………………………...Viscosifier / Fluid loss control.
Sulfonated Asphalt…………………………. Inhibitor
Barite ……………………………..Weighting agent.
Biocide
Defoamer
Mixing Procedure:
Fill the tanks with the required volume of sea-water.
Add KCl at 7% w/v.
Raise the pH to 9.5 – 10.0 with additions of caustic soda.
Treat out any hardness greater than 200 mg/l with Soda Ash.
Add High quality starch at 8– 10 kg/m³.
Add PAC UL at 6 – 8 kg/m³.
Add PAC R at 3 – 5 kg/m³.
Add Xanthan Gum at 1 – 2 kg/m³.
Add Sulfonated Asphalt at 15 kg/m³.
Adjust pH.
Adjust barite to desired weight.
Add Biocide
Add Defoamer.
流体入侵后对页岩的后续影响可以转变成机械或化学层面的影响。
有助于减少页岩问题的建议，见下列内容：
a. 避免由于下钻或提钻速度太快而引起的高浪涌和反冲压力。（建议每次单程操作时间至少30秒）。
b. 。避免旋转速度过高导致过多的湍流（特别是箍环周围）。建议钻杆周围线速度低于45米/分钟。
c. 将由稳定器和铰刀表面磨损导致钻孔质量下降的情况降至最低。
d. 改变钻缆设计后，往往会导致钻杆必须从处理后的钻孔中沿着之前的螺纹钻孔退回。例如，当使用新的或重新定位的稳定器、铰刀或弯接头时会发生这种情况。
e. 在高转速下，采用刚性钻柱设计的范宁斜井通常会促使已经不太稳定的页岩发生机械降解。
f. 由于按规格钻孔从而使管道卡住，由于箍带周围间隙最小并且井下工具稳定，因此只需要很少的切屑沉降就可以在脱管或连接处形成紧凑的钻孔。逐个泵出并不罕见，尤其是使用长钻头钻孔后。钻井作业员必须接受各种相关技能培训，以免出现脱管前循环操作等问题，钻入狭窄位置时切勿用力过猛，此时可将泵放在钻孔上方，然后慢慢泵吸，直到达到合格钻孔所需最低条件为止。
Translation - English The "Westward Movement” is well known in the United States,
through which a dream of a powerful nation has been realized in the United States
The western part of the United States becomes a new cradle for wealth creation
which has inspired a creativity and economic vitality in USA in a period of more than 100 years
and greatly accelerated the fast growth of the overall national economy of the United States
also promoted the integration of the political & economy between the eastern and western part of the United States
The total value of industrial and agricultural production of the United States has exceeded that of Britain, France and Germany to become the top of the world
Meanwhile, the "West Development” is well known in China
which enables the strategic adjustment of economic structure by Chinese government and promote the balanced development of regional economy in China
As an upgraded version of the West Development, the Chengdu-Chongqing-Xi’an-Kunming Rhombus Economic Circle will bring unprecedented opportunities for the development in West China regions.
The regions in West China has already become a new Gold Rush area for all industries and businesses.
Today, let’s work together
to successfully establish a great business plan for automotive downstream market services
in this Gold Rush area of West China......
To Exploit Hand-In-Hand
The Great Gold Ore In China (Western) in Automotive Downstream Market
An Insight On [West] China Automotive Downstream Market Business
and Introduction Of Value Of MOHIGO Service System
An Insight On [West] China Automotive Downstream Market Business
China:
Is Becoming The World’s Top
Downstream Market
Explore The Unlimited Service Value In 1.1 Trillion Chinese Market
It is shown in Research Report of Chinese Automotive Downstream Market In 2016 that:
With a market scale of exceeding RMB 1 trillion, the Chinese automotive downstream market has become a member of the Trillion-Dollar Market Club, and it is expected to exceed 120 million by 2019 with the complex annual growth rate of over 19% in the automotive downstream market.
Meanwhile, as the core of value chain of the automobile industry moving toward the back end, it is expected that there is a chance that the scale of Chinese Automotive Downstream market reach 4-5 trillion in the next decade.
Chinese Automotive Downstream Market Size
Unit: million Yuan
1.2 An ownership of over 200 million vehicles will enable a full release of service requirements
According to statistics from the Traffic Control Bureau of the Ministry of Public Security of China, the vehicle ownership exceeded 200 million in China for the first time, accounting for 66.67% of the total ownership of motor vehicle which is immediately behind that of the United States.
It is expected to exceed the United States within five years in the future to rank the top of the world.
In China, there are 49 cities with more than one million vehicles for each, and 19 cities with more than 2 million vehicles for each, among which there are more than 3 million vehicles in Beijing, Chengdu, Chongqing, Shanghai, Suzhou, and Shenzhen.
With the continuous increase in the number of vehicle ownership, various demands for vehicle maintenance, repair, and replacement of accessories will continue to increase, and it’s clearly concluded that the demand for services will also increase.
Chinese Vehicle Ownership
Unit: million
Attachment:
Comparison Of Passenger Vehicle Ownership (major market)
Unit: million
China will soon exceed the United States
to rank the top in the world
United States
China
Japan
Germany
1.3 An obvious aging trend of Chinese automobile will enable a burst of new potential demand
A total of 160 million motor vehicles were sold in China from 2009 to 2016, among which 24,500,000 were sold in 2015 and 2,800 in 2016.
From above, the sales volume of new vehicles is increasing explosively in China, and with the aging of these vehicles, the demand for maintenance and repair will inevitably increase.
The statistics of the overall number of domestic vehicles shows an aging trend, and the average vehicle usage period is expected to increase from 4.6 years in 2016 to 5.2 years in 2022.
As the usage period a vehicle getting longer and beyond the warranty, the owner will demand more on cost-effectiveness and seeks flexibility and convenience when selecting an after-sales service provider, so it is more likely to have his car checked at an independent repair shop instead of a traditional 4S shop. Therefore, a golden age is coming for independent forecast of automobile downstream market.
Automobile Ownership in China ( by usage period)
Average usage period
2012
2013
2014
0.49
0.51
0.53
0.58
0.31
0.29
0.26
0.25
0.16
0.16
0.14
0.16
0.04
0.04
3
0.03
Attachment: As the usage period getting longer, the demand for services will also increase continuously.
Scrapped vehicle
New vehicle
Basic maintenance
Average usage of passenger vehicle
The United States
Europe
Japan
China
Intermediate frequency
high frequency
Low frequency
Average usage period
Comprehensive maintenance shop/DIY
Comprehensive maintenance shop
Authorized maintenance shop
4S
Current usage distribution
Vehicle usage
Forecast of future distribution of usage
Part replacement rate
Channel
1.4 The ownership of second-hand vehicle in China is increased tremendously and continuously, also there is an extremely urgent demand for independent after-sales services.
In 2016, the trade volume of second-hand vehicle in China exceeded 10 million for the first time, reaching 103.097 million, a year-on-year increase of 10.33%, which again broke through double digits of percentage since 2012.
Since the beginning of this year, the second-hand vehicle market has been thriving on a background of relatively depression in the new vehicle market.
The accumulative trading volume of second-hand vehicles totaled 7,891,500 vehicles from January to August 2017, a year-on-year increase of 20.85%; with an accumulated transaction volume of 529.192 billion yuan, a year-on-year increase of 44.15% .
Meanwhile, the transaction of second-hand vehicles will exponentially increase in the coming years as Chinese government has recently issued regulations to encourage the transaction of second-hand vehicles.
It is worth mentioning that the growing major group of second-hand vehicle owners will have their maintenance services done at independent after-sales stores, which also indicates the prosperity of Chinese automotive downstream market.
Transaction scale of second-hand vehicle in China
Unit: Thousand vehicles
Transaction size
Growth rate
Attachment:
Comparison of the ratio of trading volume between second-hand vehicles and new vehicles (major market)
Second-hand vehicles
New vehicle
China
The United States
Germany
Gapalso means the potential of the second-hand vehicle market
and will further promote the development of the independent downstream market
Japan
Korea
1.5 Chinese users demand keenly and painfully for vehicle services and look forward to the upgrade and evolution of service in this industry
The automotive downstream market is an emerging industry with a bright future, but in general, the automotive downstream market in China is lagging significantly behind the overall vehicle development, products and services are still in the initial construction period of the industry rules which have become the biggest complain from consumers, which, not only unable to catch up with the rapid growth of the vehicle market, but also restrict the development of Chinese auto industry to some certain extent.
Lack of standardization • Poor value-perception
Lack of uniform standards in the downstream market, no standardized service procedures exist, and no quality can be examined and tracked.
.
Lack of transparency • Lack of trust
The market is filled with fake and inferior products in addition to an ambiguous pricing mechanism and high service fees.
Unfriendly service manner • low service satisfaction
In general, auto companies are providing after-sale services of low quality at present, and an uneven qualification of relevant employees which, as a result, leads to an uneven levels of services received by users, low satisfaction from the owners, and continuously increasing of the complaints related to auto after-sales services.
Deceptive "Vehicle Zero-Overall Ratio"
“Overhaul Small Issues, Excessive Repairing"
Replace Instead Of Repair
PDI inspection fee, Garage pick-up fee, etc.
.
How many days more than the vehicle should have been reasonably repaired?
Expensive
Thousands yuan of maintenance costs
Store service fee
Frequent change
Chinese users lack trust in existing vehicle service industry
There is an urgent need for the emergence of star enterprises to make consumers to feel confident.
In 4S shops, obligations are regarded as benefits by service personnels who take for granted that customers do not understand
1.6 The lack of industry giants in Chinese downstream automotive services enable a large space for market integration and a high probability of success.
On one hand, it is still a vacancy currently for auto parts retail brands in China's automobile downstream market. The auto parts sales industry is extremely affected by the scale, a brand which can be formed quickly and get the fastest user acceptance will win the most prevailing market share. On the other hand, most auto repair factories are located in a relatively scattered distribution in China with very backward management capabilities in purchase-bargaining power and supply chain.
This provide a huge growth opportunity and development space for China's downstream market. Therefore, there must be a link in which some companies will integrate scatteringly located repair shops to optimize the supply chain and make up for the vacancy in China’s auto downstream market.
Low market centralization
There has not yet a company of which the market share exceeds 1% in the supply chain of Chinese spare parts
However, the total market share of all leading companies accounts for less than 5%
High market centralization • national market
The five largest auto parts suppliers in the United States account for 30% of US market sales, with a total market value of over US$76 billion.
Market centralization
In China, it is much lower than in the United States
Lack of leadership brands
1. Strong regional limitation in the market, lack of qualifications, no national leading company
2. Brand chain stores and special service shops have not settled in second and third-tier cities
About 900,000 terminals (2015)
26,000 4S stores, 440,000 repair shops, and 250,000 accessory shops
There has formed four major brands NAPA, Company, AZO, O’Reilly
About 220,000 terminals (2015)
There are 13,000 4S shops, 170,000 repair shops, and about 36,446 accessory shops
Brand influence
In China, it is much lower than in the United States
Supply Chain System
China lags behind the United States
Lack of necessary supply chain links
1. On-line platform: Internet access, rapid development in O2O, but without enough sediment and a profound background
2. There is not a middle or large scale supply chain system, and lack of large-scale auto parts chain brands, lack of an alliance of repair shops
Mature & complete supply chain
1. Solid development in a profound background
2. Strong supply chain management and high efficiency in large-scale operation
.
History of Supply Chain Development (Comparison between China and USA)
Attachment:
Tradition: Multi-level —— After merge: Chain and alliance —— On-line platform
Vacancy in Chinese market
Chinese Automotive Downstream Market
Current status of the industry chains
2.1 The downstream service market of Chinese automobiles is entering a mature period, and it is an excellent opportunity to enter the industry.
In the next five years (2017-2022), the sales volume of new passenger vehicles is expected to grow at a complex annual growth rate of 3.8%, which is much lower than the average growth rate in the past few years.
With the slowdown in the sales growth of new vehicle, the continued increase in the overall vehicle ownership and the average vehicle usage getting longer, it has been a “New Normal Situation” in Chinese market in which the demand for the downstream market has increased, parts replacement rates has become higher, and more independent after-sales repair stores emerged, all these factors have brought many opportunities for the development of the automotive downstream market.
History map of Chinese automotive market development
Mature period
Infancy period
Starting period
Take-off period
Stable period
Certain period in the future
China
Development stage
Initial purchase in first-and fourth-tier cities
To sell vehicles in the countryside
Certain time point in the future
Family initial purchase in second and third-tier cities
Family initial purchase in first-tier cities
Mainly for official demands
Increase in the stock market
Percentage in market opportunity
Public consumption
Growth in consumption of “Additional, Replacing and Purchase”
Attachment 1: Comparison Between Downstream Market In China & USA And Development Trend of China Automotive Downstream Market
USA
USA
CHN
CHN
ACCESSORIES
The Independent Downstream Market
CHN
CHN
ACCESSORIES
The Independent Downstream Market
Under warranty
Beyond the warranty period (initial vehicle purchase)
Beyond the warranty period (second-hand vehicles)
Attachment 2: Map Of Industry Chain Of Chinese Automotive Downstream Market
Rescue
Parking units
Fuel consumption
Repair
Violation investigation & treatment
Vehicle cleaning & maintenance
Supplies
Supplies logistics & distribution
Wholesale and retail of supplies
Downstream market
Accessories
Accessories logistics & distribution
Wholesale and retail of Accessories
Logistics,
Second-hand vehicle dealers,
Financial institutions,
E-commerce platforms, etc.
Design institutions
College
Manufacturer design department
4S shops,
Repair & maintenance shops
Platforms
OEM financial corporation
Automotive financial corporation
Banks and other automotive financial institutions
Distributors
Agents
4S shops
E-commerce platforms
Clubs
Website
Upstream raw materials,
Parts suppliers
OEM logistics
Parts & accessories manufacture companies
Third-party logistics platform
Financial,
Insurance agency
Parts suppliers
Automobile fitting and assembly plant
Ecosystem
Core participants
Vehicle
Consulting
Vehicle
Modification
Vehicle
lease
Manufacturing
Logistics & distribution
Materials procurement
Wholesale and retail
R&D
Automotive finance
Second-hand vehicles
Repair & maintenance
Insurance
Distribution
After sales links
Sales links
Production process
2.2 Chinese automotive downstream market is undergoing a period of transformation from "Vehicle manufacturing and auto consumption" to "Vehicle service"
Each segment of the market in Chinese auto service industry chain will accelerate, from aspects of profit margin and market share, the maintenances and repairs businesses are the most prominent and most promising, of which more than 60% of the profits are concentrated in the field of automotive after-sales services. The proportion of Chinese automobile after-sales service accounting for the net profit of automobile dealers will also increase gradually over the past few years, and the after-sales service growth is expected to 30%, while the current domestic service accounts for only 12%, which is also a segment among the most intense competition.
Vehicle manufacturer
Vehicle consumption
Vehicle services
Profit margins
Market share
Undergoing a period of transformation
After sales links
2.3 Benefiting from the support by Chinese Internet industry, the B2B mode in Chinese auto parts supply chain is undergoing an initial excellent period of development out of all segments.
Due to the influence of policies, technologies and new entrants,
The old structure has been broken,
And a new pattern is emerging
The tide of entrepreneurship under capital support in the past two years has promoted the chain process.
The Auto 4S groups take the initiative under a condition that insurance companies keep on coveting
Having their own abilities, advantages and resources,competing entities
bring us new ideas for development,
and meanwhile, they are facing huge challenges
Attached:
Layout Of Competition Pattern For Providers Of Chinese Downstream Market Service
Financial
Take "Vehicle Insurance" as an entrance point
“i Service” Alliance including members such as China Ping An Insurance, Pacific Insurance, Land Insurance Easy Cats, and People's Insurance
Insurance agency
Yixin Vhicle Loan, First Vehicle Loan, Lingling Vehicle Purchase
Auto Parts B2C: Tuhu Vehicle Service, Vehicle Superman
Brands of self-operated chains: Che Xiangjia, Vehicle Workshop (Shangqi Group), BMW
On-site service: E-Service
Brands of join-in chains: Diandian Vehicle Service, E-Vehicle Service
Traffic guidance services: LeCheBang, Kuantu Vehicle
Repair & Maintenance Service O2O+
Take the "Weibao" as an entrance point
Comprehensive category: Jingdong, Yihaodian, Ali Auto
Vertical category: Cool Distribution Network
B2C e-supplier
Information platform: Auto Parts Network
E-commerce transactions: Taoqi Stall, Auto Parts Shop (Batulu)
Supply chain service platform: Kangzhong Auto Parts, Yuandun Siji Vehicle Service
B2B e-supplier
Auto parts & supplies manufacturers
Michelin Chijia, Hela (Jingdong), Bosch Automotive
Auto parts & supplies distributors
Pangda Group, Yongda Auto
Brands of 4S shop
4S
Zhixin Jingdian, Hexie Auto
Traditional chains
Huasheng, Aiyihang, Zhongxin Zhibao
Area grouping
Zhihe Huisheng, Jiuyi Auto
Cross-border chains
Jiqun Vehicle Insurance, Changtu Auto Chain
Medium and large-scale auto repair factory
West China
is the perfect entrance point of the world's top automotive
downstream market
3.1 Valuable basin, unlimited business opportunities, great opportunities
After the period of rapid growth in the economy and automobile consumption, the vehicle ownership in major cities such as Beijing, Shanghai and Guangzhou has reached a state of saturation, and as the continuously moving and promotion of the national western development policy, the economic in the southwestern region is moving into the fast lane of development, and the potential of vehicle consumption has also been triggered step by step.
With the promotion of policies such as restricted licensing in first-tier cities, the second and third tier regional markets represented by the western automobile market have become the fastest growing regions in the Chinese auto market.
The southwest region represented by Sichuan, Chongqing, Yunnan, and Guizhou , Provinces which were once considered by the auto manufacturers as second and third-tier, have now become the most competitive markets.
•Second and third-tier cities
First-tier cities
Yunnan, Guizhou, Sichuan, Chongqing
Beijing Shanghai Guangzhou
Saturated
Consumption potential has been released
Enter into the fast lane
Thanks to:
Policy guidance on Chinese West Development
and Chinese economic development
City Ranking List Of Newest Cities With Vehicle Ownership Over 2 Million In 2017 (as of June)
3.2 Misaligned match of supply and demand relationships brings huge business opportunities
Polarization pattern has been formed in Chinese auto market, namely the 4S monopoly groups and ordinary repair shops with low quality and inefficiency which is incompatible with the overall upgrade of western consumer demand.
Maslow's theory of Hierarchy Of Needs
Consumer demands upgraded
Consumption habits upgraded
Requirements on full service
Maintenance needs extended
Consumption concept upgraded
Information Barriers of Internet broken
Consciousness on “Excellent Preferable”
Lower consumption threshold
Lower channel barriers
Increased competitors, increased consumer choices
Self-realization
Current stage
Respect
Love and sense of belonging
Needs on safety
Physiological needs
3.3 Low-latitude competitive pattern in West China: a relatively low threshold of entrance
It is a trend as well as the user's expectation for the transition from price competition to value competition: from primary products and services to full-process system solutions.
Abuse of user subsidies
general subsidy services: replacement of oil, on-board filters, air conditioning filters, air filters; value-added services refer to some of the automotive appearance services, including engine compartment cleaning, air conditioning system cleaning, vehicle inspection and so on.
Vicious cycling
0 yuan vehicle cleaning
1 yuan on-site service
9.9 yuan maintenance
High subsidy costs - low cash flow - service quality declined - consumer attraction reduced - loss of trust
How to get a guest
Value returned to user
Virtuous cycling
Business - to meet the needs of vehicle maintenance and repair
Security - Life and Property Safety for Consumer
Convenience - save user’s time
Transparency - price transparency, service transparency
Quality - user experience (aspects of consumption space, service manner, store decoration, customer visit & maintenance, etc.)
[Closed-loop of off-line services - initial trust establishment] (repeatedly many times) - users accumulation - voluntary advocacy - users group expansion
3.4 Users in West China have a greater tolerance of experience and fault, providing a more tolerant environment for the creation of new brands
Compared with the most economically developed regions in China (such as eastern coasts, etc.), The western region in China is still an economically developing market.
Customers have a more generous tolerance for purchase of service and use experience.
Poor original foundation
Greater opportunity of development
More tolerant environment for development
Introduction of service system value of MOHIGO Company
Introduction of Service Operation System Value
“5+2" Integration, Marketing and Management System of the Company
Brand Management Product Planning Marketing Channels Service Operation Sales Promotion Team + Culture Media Promotion
Introduction of organizations
MOHIGO has always been engaged to providing high-quality services to customers, as a result, MOHIGO Customer Service Management Center was established as early as 1998 for the management of customer services routines in three provinces and one city of the West China: Sichuan, Yunnan, Guizhou and Chongqing;
The Center consists of nine departments, with more than 120 employees merely in management positions, more than 60 sub-centers for regional customer service management and the largest "home appliance accessories storage base" in West China has been established for the Center, with more than 1,000 fast & powerful customers service outlets, a technical team team of 9,000 engineers for the service of nearly 8 million customers.
Organization Chart of MOHIGO Customer Service Center
General Manager
Technical Training Department
Deputy General Manager
Rear-end Support Unit
Front-end Execution Unit
Network Outlet Management Department
Accessories Management Department
New Product Service Department
Business Service Department
Home Service Department
Finance Department
Call Center
Administration & Management Department
Logistics & Distribution Department
Introduction of organizations
A modern enterprise management system has been fully implemented in the Center, with various mobile and interconnected office management systems equipped, it is available for efficiently and accurately mobilizing more than 2,500 service outlets and a large number of engineer teams across the southwest of China to provide customers with 7x24 hours of service and make quickly responds on customer's demand for services, thus minimizes the loss caused by equipment failure or poor use experience.
After 20 years of development and exploration, the Center has established a management system of "Four-Force Drive” and a service concept of "Create A Touched Feeling”.
These continuously proven management modes and concepts have helped MOHIGO Customer Service Management Center in winning the "Advanced Unit of Customer Service” Award, the 3.15 Consumer Protection Protection Honors (Collective) Award in Chongqing issued by Chongqing Consumer Rights Protection Committee for 5 consecutive years; and the "Integrity Service Award" issued by the Chongqing Household Electrical Appliances Association as well as authority-level honors issued by many other industries.
The Customer Service Management Center of MOHIGO has been recognized for its outstanding customer service capability within the same industry in West China based on above-mentioned various types of competitiveness, which has enabled it to win the trust of customers in West China.
Introduction for the "Four-Force Drive” Management System in the Customer Service Center
The “Four-Force Drive” Management System of Customer Service Center of MOHIGO consists of four components: Cultural Appeal, Professional Empowerment, Logistic Equipment, and Resource Linkage.
"Four-Force Drive” Sub-Management System in the Customer Service Center
“5+2" Integration, Marketing and Management System of MOHIGO
Let’s share together the mysteries of above four systems
MOHIGO Customer Service Center firmly believes that “Create A Touched Feeling” is the highest standard of service. MOHIGO’s customer service team transfers this concept internally to guideline for action in the implementation of such services such as “Every small thing of the user is a big event of us”; “Customer First, Profession First, Credit First” to fully arouse the members on their sense of professional honor and sense of mission, and always ensure the quality of services, to provide customers with the best service standards.
A variety of team cultural activities has been launched and countless touching moments and scenes have been created in MOHIGO Customer Center, such as corporate ceremonies and events for internal employees and teams, for example, the selection & appraisal of “Moving Characters” etc. for inspiring employees; and touching service systems such as "Blue Bee Service” for external users has been launched to make users touched by the most intimate services.
A complete employee professional skills training system has been established in MOHIGO Customer Service Center, and through the iterative and adjustment of the existing system, it can quickly adapt to and meet the needs of cross-field services such as auto repair, home appliances, logistics, and traditional industrial manufacturing etc.
We have created a comprehensive service operation management system, including not limited to: Training & Enabling System; Service Capability Rating System; Administrative Operation Management System, After-sales Service Response Process System, Corporate Culture & Ceremonial System;
Attached: Introduction of Service Quality Management System of MOHIGO Customer Service Center (Partial)
Service Capability Rating System
Training & Enabling System
Senior Engineer
Skills Training Department
Organization training\assessment
Mid-level Engineer
Technical Support
Technical Training
Technical Notice
Technical assessment
Technical needs
Training needs
Quality feedback
Complaints
Junior Engineer
65 Regional Customer Centers
150 Signed after-sales service unit
Management System
Needs of technical support units,
Needs for special complaint handling
Technical Support
Complaints
Special Training
Technical needs
Training needs
Quality feedback
Information System
Technical Notice
Technical Support
Organization Training
Management System
Settlement System
Accessories System
Technology System
Over 2000 after-sales service units
Management System
MOHIGO Customer Service Center,
Receive a support and enabling form MOHIGO Company, and you will have a strong logistics equipment system
In MOHIGO, we have designed an overall process of customer service, established a call center which ranks the top in the marketing industry in West China, set up an accessory library which ranks the second largest within Gree Electric Appliance Group of China, and established more than 1,000 customer service stations, a total of 100 million users will receive professional home appliance service from MOHIGO's Customer Service Center in the year.
Call Center
Access of 20 megabits of telecommunications dedicated fiber
A total number of over 300,000 calls received in the year
24-hour customer service hot-line
Accessories Management Library
An accessory management system has been developed
A utilization of accessories of 78%
In MOHIGO Customer Service Center, we manage the efficient and efficient access and tools from MOHIGO for product distribution services
“Chongqing Hongli Logistics Co., Ltd.” was found by MOHIGO Company, and more than one logistics bases in many cities in West China has been established, multi-manner transport in the inland regions of West China has been realized by utilization of its own over 1000 vans, logistics delivery by MOHIGO can be achieved directly to the end-user within 3-28 hours in the vast area in West China, from cities to the villages.
MOHIGO Customer Center serves as the competent authority of the above-mentioned corporate resources.
Self-owned logistics transportation
A comprehensive logistics company engaged in goods transportation, storage management, product distribution, information loading, etc.
A company specialized in third-party logistics services for design and offering of supply chain management services to customers,
Based on offering service to product terminals throughout the long link of the supply chain
Characterized by a variety of environmentally friendly transportation such as railways, highways, and waterways; remarkable advantages in logistics cost
Self-built storage base
Application Innovation System
Logistics Transportation Network
Based in Chongqing, covering the whole country
3 logistics bases have been established in Chongqing, Chengdu, and Guiyang in West China with the storage area exceeds 250,000 square meters.
LIM Logistics Management System
SP Warehouse Management Platform
UOP Urban Distribution Management System
LM
UOP
SP
Equipped with a management office system more advanced than others in the same industry in China, MOHIGO Customer Service Center is able to effectively schedule a large team of engineers to provide customers with 7x24 service.
With the above management system, a quick response is guaranteed to meet the customer's service needs to minimize the losses caused by equipment failure or poor using and experiencing.
After iteration and upgrade, this type of management system and service concept also applies to situations and requirements for on-road rescue of vehicle, emergency rescue & disaster relief, etc.
MOHIGO Customer Service Center Management System
MOHIGO Customer Service Center has a profound understanding of the trend of development of the market in West China regions, and relying on the goodwill and appeal of MOHIGO Company in West China, we have gained a wealth of government public relations and business network resources to help start-up companies achieve better project operations.
With the help of MOHIGO's commercial resources, 8000 strategic cooperation companies formed by large, medium, and small businesses and their leaders
are able to efficiently launch and coordinate the value-sharing and cooperation in new business opportunities and projects participated by more than 8,000 business strategic cooperation companies and their leaders in West China.
Relying on the business map of MOHIGO in West China, MOHIGO Customer Service Center provides services fully covering all levels of market frontiers.
1000 Customer Service Stations
We have established 1,000 Customer Service Stations in West China
to realize customer services in closer manners
9000 engineers
We have more than 9,000 professional installation and maintenance engineers assigned throughout the West China regions, which enables an efficient and accurate manpower scheduling with the help of central operation and management system.
Cooperate with MOHIGO to complement each other and create a great cause
Deep insights into business and customer needs
To achieve a success in an automotive service project, the first prerequisite is to gain an accurate insight and understanding of the Chinese market and users in China, and a “localized” market operation strategy applies to situation in China can only be established successfully based on that.
MOHIGO Corporation has 20 years of operating background in the West China market.
We have a good understanding of China, and even better understanding of the special needs of users beyond general needs for automotive service
Experienced in the operation & management in the West China market
It is a vast area in West China regions, where tremendous differences exist between different regions due to various factors such as humanities, geography, information, economy, and beliefs etc.
MOHIGO Company and its management team have a deep understanding and research on how to fulfill "localization" strategies for different cities in West China, and by which MOHIGO has established its current status and achievements in the industry.
We have mastered the key of successful operation of industry terminals in manufacturing and service fields
We’ve established a mode for vehicle service physical store construction and operation management, which is one of the key elements for the successful operation of projects
In West China regions, MOHIGO has opened 13,000 channel-sales stores and 657 4S flagship stores, achieving a 90% coverage of marketing channels from cities to rural areas in West China, which is the core competitiveness of the Company that can hardly be exceeded by others.
MOHIGO has a deep understanding of store operation as well as a good management of the key points during the overall process
Abundant public-relation resources in political/business field in West China
In China, close interaction and exchanges in field of public relations with the political & business circle are one of the core routes to successful implementation of projects and successful commercial operations.
With the help of MOHIGO's commercial resources, 8000 strategic cooperation companies formed by large, medium, and small businesses and their leaders
are able to efficiently launch and coordinate the value-sharing and cooperation in new business opportunities and projects participated by more than 8,000 business strategic cooperation companies and their leaders in West China.
Powerful enterprise back-end operation & supply system
A strong back-end management system is required to be established to ensure the sustainable operation of service projects in the automotive downstream market.
To meet the expansion and development of scale and standardization, MOHIGO has successfully established a basic support system required for entering the automotive service industry.
Most of the supply capacity apply to the development of automotive industry
Self-built storage base
3 logistics bases have been established in Chongqing, Chengdu, and Guiyang in West China with the storage area exceeds 250,000 square meters.
Logistics Transportation Network
Based in Chongqing, covering the whole country
1000 Customer Service Stations
We have established 1,000 Customer Service Stations in West China
to realize customer services in closer manners
Application Innovation System
9000engineers
We have more than 9,000 professional installation and maintenance engineers assigned throughout the West China regions, which enables an efficient and accurate manpower scheduling with the help of central operation and management system.
LIM Logistics Management System\SP Warehousing Management Platform\UOP Urban Distribution Management System
Strong capital initialization & investment
MOHIGO enjoys a large business system in the West China market, which provides stable cash flow and enable strong capital supports for the launch of projects.
There is an old saying in China:
"All are ready except for the opportunity"
MOHIGO Electric Company invites quality business partners from all over the world
to create new business opportunities and share new wealth hand-by-hand in West China.
Building 25, Hilltop Headquarters Base, No. 68 Middle Section of Huangshan Road, Jiangbei District, Chongqing City
No.96 Torch Avenue, Erlang Technology New City, Jiulongpo District, Chongqing, China
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Translation education
Bachelor's degree - Wuhan University
Experience
Years of experience: 16. Registered at ProZ.com: May 2018.
With 20 years of technical background, I have worked as a Measurement Engineer, an Electronic Engineer, and a Senior Electronic R&D Engineer in a number of large companies including China Eighth Bureau of Hydro-power Engineering (Measurement Engineer for 5 years), a Japanese company Finemost (Electronic R&D Engineer for 2 years), an American company Honeywell (Senior Electronic Engineer and Senior R&D Engineer for 10 years). As a fast learner with strong self-learning skills, I’m also a diligent, hard-working person, gaining me a wide range of knowledge across multiple fields, and I am particularly interested in language and literal work. so far I have translated materials involving in some fields in the language pairs of Chinese <-> English, with a total translation volume of 8 million Chinese characters, including Automotive, Electronics, Mechanics, Electricity, Industry, IT, Engineering, Construction, Petroleum, Finance, Textiles, Contract, Specifications etc.
