Serva Corporation PO Box 8121

Wichita Falls, TX USA 76307

Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

Model PCTLR-721A Double Pump Cementer Trailer w/Recirculating Mixer

DESCRIPTION:

The Serva Model PCTLR-721A system is a complete mixing and pumping unit that is trailer mounted. This unit is
state-of-the-art in mixing and automatic control. This system is designed for the most demanding oil and gas well
cementing requirements. The quality of design, component selection, and quality manufacture makes it a benchmark
in the industry. The high energy mixing system can mix the most difficult slurries and the automatic density control
will provided superior density control. The 20 bbl averaging tank makes the operator's job easier, provides a cushion
for fluctuations in bulk delivery, and provides excellent density and additive concentration averaging. The trailer
model of this system design provides good axle weights and height is lower than truck mounted units. In addition
there is plenty of room for extra iron without going over weight limits.

A. MIXING and PUMPING SECTION of trailer

 (2) CAT C-13 Diesel Engines, 475 HP each*1

 (2) 4700OFS ALLISON transmission

 (1) SERVApump TPD600 X 4.5" Dia Plunger Triplex Pump (left pump)

 (1) SERVApump TPD600 X 3.5" Dia Plunger Triplex Pump (right pump)

 (1) 7 bbl mixing tank

 (1) 20 bbl averaging tank

 (1) 20 bbl displacement tank, (i.e. 2 - 10 bbl tanks)

 (2) SERVApump 6x5 centrifugal pumps (cement mixing recirculation and transfer to triplex pumps)

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

 (1) SERVApump 4x3 centrifugal pump (mix water and displacement fluid)

 (1) Automatic Mixer Control (SERVAacm) for density

 (1) Air reservoir, 40 gal

 Radiator cooling of engines and hydraulics

B. AUXILLARY HYDRAULIC POWER PACK
 (1) 3126Tor C7 CAT Diesel Engine, 260 HP*2

 (3) Closed loop hydrostatic transmissions

 (1) Fuel capacity, 200 gal (used by all three engines)

 Radiator cooling of engines and hydraulics

Notes:
1. CAT C13 with 475 HP (electronic fuel injection and air to air aftercooler) meets USEPA Tier II emissions. CAT
3406 with 490 HP and mechanical fuel injection system has Tier I emissions (per USEPA) is still available at a
reduced cost. Tier I does not meet current US emission standards.
2. CAT 3126 with 260 HP and mechanical fuel injection system has Tier I emissions (per USEPA). CAT 3126 with
275 HP (electronic fuel injection and air to air aftercooler) meets USEPA Tier II emissions .

TRAILER DIMENSIONS AND WEIGHT

Cementer Weight:
Gross Weight w/o Iron, dry = 58,000 lb. (less tractor)
Gross Weight w/Iron, dry = 60,000 lb. (less tractor)
Tractor weight estimate: = 15,000 lb.
Gross Weight with tractor and iron (estimate) = 75,000 lb.
Length, overall: 34 ft. (10363 mm) (without averaging tank)
Length, overall: 38 ft. (11582 mm) with averaging tank
Width [Link]. (2540 mm)
Height 152.5 in. (3.87 m) (to top of valves on displacement tank)
Trailer Description:
Single drop: 34 or 38 ft. (depending on averaging tank inclusion)
Axles: 2x25,000 lb.
Tires: 8.5x24.5
Brakes: 16.5 x 7 air w/ ABS
Jack: 2 speed w/ 150,000 lb static capacity
Frame: 20" deep high strength steel
King pin height: 56"

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

DOUBLE PUMP CEMENTER TRAILER MOUNTED

1. General Specifications
1.1. The PCTLR – 2007 is a trailer mounted high pressure-pumping unit. The unit is
comprised of a high-pressure pumping system, recirculating mixing system, all required
controls and instrumentation and a hydraulic system to drive fluid handling and mixing
equipment.
1.2. The high pressure pumping system consists of two diesel engines, two automatic
transmissions, and two triplex pumps. The fluid handling system consists of centrifugal
pumps for recirculation, boost and mix water. Manifold consists of necessary piping,
valves and connections to perform cementing jobs.
1.3. The triplex pumps are horizontal single acting plunger pumps and consist of fluid end
and power end. The fluid ends are made of alloy steel and are recommended for
pumping cement, acid, water, drilling fluids and other well service fluids.
1.4. The mixing system consists of a high-energy jet mixing system, high rate recirculating
pump and tub agitator. The diffuser aids in removing air entrainment from bulk cement.
A densitometer is mounted in the recirculating line and the mix water is measured with a
turbine flow meter. The one compartment 1 M3 (7bbl) mixing tank maintains the ability
to mix cement on the fly with good density control and provides adequate residence time
for good cement mixing.

1.5. A 20 bbl averaging tank allows for greater residence time, more mixing energy and
density averaging. The averaging tank along with the mixing tank allows the batch
mixing of up to 25 bbl of slurry for squeeze and plug jobs and other purposes that
require 25 bbl or less slurry.

1.6. The displacement tank consists of two 1.59 m3 (10 bbl) working volume compartments
with "barrel" marks. Tanks have full flow piping to rear of unit for ease of cleanup.
The system is capable of mixing 2.3 m3/min (14.4bpm) and densities up to 2.7 g/cm3 (22
lb./gal).
The following are included as part of the equipment specification:
1.6.1 Dust Eliminator
1.6.2 Third centrifugal pump for dedicated boost
1.6.3 Control panel labeled in English or Spanish
1.6.4 Control panel gauge units in English and Metric except for the high pressure
gauges, which are not available in dual scale
1.6.5 1502 103 MPa (15,000 psi) treating iron and discharge manifold

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

1.6.6 Triplex fluid ends, (1) pump w/3.5" Dia plungers and (1) pump w/4.5" Dia
plunger
Note: Other plunger sizes are available.

2. Environment Parameters
2.1. Temperature
Minimum operating -20° C (-4° F)
Maximum Operating 55° C (130° F) (dessert operation)
2.2. Humidity
Relative: 95%
2.3. Vibration/Shock
Maximum shock: 1.5g
3. Operational Performance
3.1 Job locations
The unit is designed for land operations.
3.2 Component Size
 Width: no component is greater than 2.58m (102 in.) Exception is the
removable ladders that are greater than 102 in when deployed.
3.3 Pressure Range
This unit has a maximum working pressure of 71.7 MPa (10,400 psi) w/3.5” plunger
pump.
This unit has a maximum test pressure of 103 MPa (15,000 psi) with 3.5” plunger pump.
3.4 Flow Rate
Maximum theoretical total flow rate is 3.3 m3/min (21 BPM)
3.5 Density Range of Slurry
Maximum slurry weight is 1.0 - 2.7 g/cm3 (8.33-22.6 lb/gal)
3.6 Slurry Mixing Capacity Range
Mixing range will be 0 - 2.3 m3/min (0 - 14.4BPM)

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

3.7 Automatic Control Density Tolerance

When mixing in automatic control mode the density ranges can be controlled to within
+/- 0.01 to 0.024 g/cm3 (±. 083 to .200 lb./gal) of indicated densitometer reading during
near steady state operations. This assumes reasonable steady output of bulk delivery
system.
3.8 Continuous Working Time at Rated WP of 70 MPa (10,200 psi): 2 hours
3.9 Continuous Working Time at Maximum Flow Rate: >1 hour

4. Power System

Two (2) diesel engines drive two (2) high-pressure triplex pumps via automatic transmissions
and flexible drivelines.
4.1 Diesel Engines
CAT C13, Tier II emissions is available).
Rated Power 365 kw (475 hp)
Rated Speed 2100 rpm
Lube oil pump and filter and cooling system
Fuel pump and filter system
4.2 Engine Accessories
Mode of Starting: Electric starter
Cooling: Engine jacket water is a closed loop circulating system with air to water
radiators.
Air filter (dry element type)
Engine governor Mechanical /variable speed
Throttle actuator
Stop actuator
Emergency kill actuator for air intake shutdown
Stainless steel muffler with flexible stainless steel connection
Air compressor – one included
Alternator – one included
5. Power Distribution System
5.1 Transmissions
Allison 4700 OFS automatic transmission, complete with fill tube, dip stick gauge, torque
converter, and 1800 series output flange.
Gear ratios as follows:

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

1-st gear 7.63

2-nd gear 3.51
3-rd gear 1.91
4-th gear 1.43
5-th gear 1.000
Gear ratios are selected manually, Reverse - Blocked out

5.2 Transmission Accessories

 Torque converter to go in lock-up mode: 0.96 efficiency
 Oil pan with level gauge and filler tube
 Oil Filter (spin on), positioned for easy access
 Engine driven power take-offs are used for driving hydraulic pumps and
triplex pump lube pump.
 An engine mounted water to oil tube and shell cooling system is used to cool
the transmissions at maximum sustained horsepower output at 120º F ambient
temperature without exceeding maximum allowable temperatures.

5.3 Drivelines
Heavy-duty drivelines are used between the transmissions and triplex pumps. They are
built with heavy-duty universal joints using 1800 series components.
 Installation of drivelines is such that the manufacturer's maximum recommended
angle is not exceeded.
 Each driveline is equipped with a metal guard assembly complete with greasing
access.

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

6. High Pressure Pumping System

6.1 Triplex Pumps
The Serva TPA 600 triplex pumps are good for high-pressure well service. Each pump is
equipped with an integral gear reduction box. The triplex pumps are designed to pump
cement slurries, sand-laden fluids, crude oil, acids, mud and other oil well servicing
fluids. The pumps have the following specifications.
 Type of pump: horizontal triplex single acting reciprocating plunger

 Maximum Input Brake Horsepower: design capacity 447 kw (600HP)

 Hydraulic Horsepower: performance w/engine spec (estimated) 283 kg (380HP)

 Pressure rating
88.9 mm, (3.5 in) Dia plunger: 71.2 MPa (10,400 psi)
114.3 mm (4.5 in) Dia plunger: 43.4 MPa (6,290 psi)
 Flow Rate at Rated WP (limited by estimated Hydraulic Horsepower):
w/3.5" Dia @ 10,400 psi: .16 m3/min (1.0 bpm)
w/4.5"Dia @ 6,290 psi .26 m3/min (1.7 bpm)
 Maximum flow rate
3.5" Dia plunger (1) Pump 1.27m3/min (8.0 bpm)
4.5" Dia plunger (1) pump 2.0 m/min (13.0 bpm)
Total 3.3 m3/min (21. bpm) theoretical
Volumetric Efficiency (estimated) 0.97
Mechanical Efficiency (estimated) 90%

6.2 Power End Lubrication System

Positive displacement pumps driven by PTOs mounted to the Allison transmissions supply
the lubrication system for the triplex pump power ends. The power end lubrication system
contains:
Lube oil reservoir
Pressure relief valve

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

Required plumbing and hoses

Pressure gauge
Temperature gauge
Full flow filter
Suction strainer
6.3 Plunger Packing Lubrication System
The plunger lubrication system is provided by a pressurized oil supply system. The
packing lubrication system contains:
Lube oil reservoir
Distribution manifold
Required plumbing and hoses
pressure gauge
pressure regulator
Flow control valves for each plunger with setting locks

7. Fluid Handling System

7.1 Fluid Displacement Tank
The displacement tank full capacity is approximately 25 bbl. and has a working volume of
20 bbl. It consists of two 1.59 m3 (10 bbl) compartments each having graduated markers
measuring in increments of 1 bbl. The tank and piping manifold is constructed of steel
with reinforced structures. The discharge ports from the displacement tank are 152.4mm
(6 in) butterfly valves leading into a 127 mm (5 in) pipe that provides good velocity for
gravity flow to boost pump and triplex pumps. A flow back release line is provided to
allow the triplex pumps pressure to be discharged into the displacement tank. Standpipes
provide overflow protection with (3 in) butterfly valves located under the displacement
tank. These valves are connected to drain hoses to direct over-flow to desired location.
Drain valves are 76.2 mm (3 in) and connect to the over-flow line. They allow the draining
of each tank compartment. The piping manifold is designed with sufficient couplings to
allow complete disassembly of the piping.
Low-pressure piping:
 The suction manifold has a working pressure rating of 1.2 MPa (175 psi). The
manifold includes various butterfly valves, which are convenient to operate, and
various flanges, couplings, union connections, pipe and fittings that are easy to
connect.

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

 Fluid from the mixing tank connects to both the recirculating & boost pumps or to
the suction manifold for the two triplex plunger pumps. Fluid from the recirculating
pump
can be pumped into mixing tank via the densitometer and slurry mixer and into the
suction manifold of the triplex pumps.
 Remote valves that are required for normal operation are air actuated.
 The suction manifold for the transfer pump is supplied from either the
displacement tank, averaging tank or the mixing tank. The suction manifold of the
triplex pumps is supplied by either the transfer pump or gravity fed from the line
connecting the displacement tank and the transfer pump.
 A 76.2mm (3in.) fill manifold for filling the displacement tank from an external
mud or water supply is equipped with 76.2mon (3 in.) butterfly valves, and 76.2mm
(3 in.) union joints. An over pressure relief valve is included to protect the system
from receiving fluid with too much pressure.
7.2 Cement Mixing System
The mixing system is a high-energy recirculating slurry mixer type. It consists of a high-
energy eductor mixer, diffuser, mixing tank, agitator and recirculating and mix water
pumps. The mixer design maximizes wetting of all cement by forcing the dry bulk
cement into a high energy confluence of 4 annular water jets, 4 annular slurry jets and a
central slurry jet. The mix water centrifugal pump and the recirculating centrifugal pump
provide most of the high energy. The diffuser aids in removing air entrainment from the
bulk cement and eliminates dust in the mix tank. The 1.27 m (7bbl) mixing tank allows
adequate residence time for good mixing and averaging of density with varying bulk
cement delivery. The deep tank design provides good pump head and minimizes
vortexing and cavitation. A hydraulic driven paddle agitator provides improved mixing
and a more homogenous slurry. The mixing capacity range is 0 - 2.3 m3/min (14.4bpm)
with mixing density range of 1.0-2.7 g/cm3 (8.33-22 lb./gal). The mix tub piping delivers
fluid to the suction manifold of the recirculating centrifugal pump via 152.4 mm (6 in)
piping.
The triplex pump suction normally receives fluid from a 4 in. manifold and 102 mm (4
in) butterfly valves.
7.3 Mixing Centrifugal Pump
The 4x3 mixing centrifugal pump will meet the following specification.
Suction: 101.6- (4 in) pipe size
Discharge: 76.2- (3 in) pipe size

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

Flow rate at 110 psi: 1.65 m3/min (10.4 bpm)

Maximum closed-in pressure: 1.17 MPa (170 psi)
The mixing centrifugal pump takes on fluid from external sources or the
displacement tank through a manifold with 101.6 mm (4 in) union connections.
The pump can discharge fluid into the mix tub or displacement tank.
7.4 Recirculating Centrifugal Pump
The dedicated 6X5 recirculating centrifugal pump has the following specifications.
Suction: 152 mm (6 in) pipe size
Discharge: 127 mm (5 in) pipe size
Max. flow rate at 64 psi: 3.7 m3/min (23 bpm)
Maximum closed-in pressure: 0.49 MPa (70 psi)
The recirculating centrifugal pump is capable of receiving fluid from the mix tub and
from the displacement tank via the mix tank.
The recirculating pump can discharge fluid into the mix tub for recirculating or into
the suction manifold of the triplex pumps.

7.5 Boost Centrifugal Pump

The dedicated 6x5 boost centrifugal pump has the following specifications.
Suction: 152 mm (6 in) pipe size
Discharge: 127 mm (5 in) pipe size
Flow rate at 64 psi: 3.7 m3/min (23 bpm)
Maximum closed-in pressure: 0.49 MPa (70 psi)
The boost centrifugal pump is capable of receiving fluid from the mixing tank,
averaging tank and from the displacement tank.
The boost pump can discharge fluid into the mix tub for recirculating or into the
suction manifold of the triplex pumps.
Note: The recirculation and boost pumps are dedicated pumps for their respective
functions but in case there was a problem with either pump, the other pump can take the
place of the inoperative pump or can take both functions at the same time at a reduced
rate.

8. Hydraulic System
The hydraulic system consists of independent systems: one for closed hydraulic pumps
and the other for agitator open loop systems. Each system contains its own 160 liter (42
gal) stainless steel reservoir with sight gauge, filtration system, and heat exchanger. The

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

closed loop system is powered by an auxiliary 260 HP skid and drives the following
components:
Recirculating pump
Boost centrifugal pump
Mixing water centrifugal pump.
The open loop system is powered by the main cementing skid engines and drives the
following components:
Mix tub agitator
Averaging tank agitator Automatic Control Mixer (ACM) power for Metering Valve
actuator

9. High Pressure Discharge Manifold

Each of the triplex pump fluid ends has 50.8nim (2 in) API type 1502 threads.
Each pump discharge has 50.8min (2 in) 1502 integral plug valves. The two triplex
pumps are manifolded together and configured so as to be capable of discharging
singularly or
simultaneously to the same outlet or different outlets. A flow back manifold (connected to
the opposite side of the pump) connects to the pressure release line with an open end
connected to the displacement tank. Two 50.8min (2") X 25.4mm (1") 1502 integral plug
valve, one for each pump, controls the release line. Each of the pump discharge lines has
a pressure transducer and 105MPa (15,000 psi) pressure gauges. A master discharge
valve, 50.8 min (2 in) type 1502 integral plug, is located between the manifold and the
discharge pup joint. The discharge manifold/valves are mounted firmly by a heavy duty
mounting system.

10. Operation and Display System

10.1 Operator Console
The Operator console is a custom built stainless steel cabinet with a protective stainless
steel cover. The instrument panel is stainless steel with permanently engraved labeling in
English. The location of the console allows the operator a full view of the various
instruments and gauges of the console.
10.2 Deck Instrumentation
 The engine gauges includes tachometers, oil pressure gauges, water temperature
gauges, voltmeter, and warning lights that indicate low engine oil pressure and
high water temperature.

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

 The transmission gauges includes the main oil pressure, lock-up clutch indicator
light, oil temperature and fluid level gauge.
 The triplex pump gauges includes oil pressure gauge, oil temperature, and an oil
gauge. The pressure and temperature gauges are switch gauge type and activate a
warning light whenever a certain level is reached. An over pressure warning light
indicates over pressure for the triplex pump discharge pressure.
 A transducer mounted on the triplex fluid-end is connected to a pressure gauge
measures discharge pressure. A proximity switch at the input to the triplex pump
measures pump displacement rate.
 The hydraulic system has pressure gauges for each pump circuit and an oil
temperature gauge mounted in the console.
 Console mounted pressure gauges are liquid filled with dual scale face reading in
standard U. S. units and metric units.
 Most gauges and instruments read in both standard U. S. units and metric units.
 Mixing pump is equipped with a flow meter and pressure gauge.
 The recirculating/boost pump is equipped with a pressure gauge.
10.3 Density Control
The cement mixing system can be operated in a manual or automatic mode. In manual
mode the operator uses a manually operated hydraulic control valve to control the
cement-metering valve. In the automatic mode, an electro-hydraulic control system
operates the cement-metering valve. The electro-hydraulic system is controlled by an
industrial process controller/computer. The slurry density can be quickly reduced by the
use of a bypass line (connected to the recirculation pump suction).

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

ADDITIONAL SYSTEM SPECIFICATION DETAILS

Mixing:
Mix Water Metering Valve approximate maximum capacity: 1.9 m3/mm (436 gal/min)
High Pressure Triplex Pumps:
Estimated Pump Performance: (Based on Estimated Hydraulic Horsepower of 380 HP)

Serva TPB 600 w/ 88.9 mm (3.5 in) Dia plunger

GEAR m3/min (gpm) MPa (psi)
1 .163 (42) (10,400)
2 .408 (108) (6,025)
3 .640 (169) (3,850)
4 .926 (246) (2,645)
5 1.29 (340) (1,914)

Serva TPB 600S w/ 114.3 mm (4.5 in) Dia plunger

GEAR m3/min (gpm) MPa (psi)
1 .27 (70) (6,290)
2 .67 (176) (3,697)
3 1.05 (278) (2,340)
4 1.53 (406) (1,602)
5 2.1 (562) (1,158)

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 Serva Corporation PO Box 8121
Wichita Falls, TX USA 76307
Telephone: 940-761-3361 Fax: 940-761-2288
E-Mail: sales@[Link]
[Link]
Total Commitment To Customer Satisfaction

High Pressure Discharge Manifold and Valves:

 All components are made of API type 1502 components and have a rating of 103
MPa (15,000 psi) at cold working conditions.
 The triplex pumps have working pressures that are less than 103 MPa (15,000
psi). See individual pump specifications for operating pressure limits.

Hydraulic Systems
 Hydrostatic Transmissions (Mix Water, Boost and Recirculating Pumps)
- 41.4 MPa (6000 psi) maximum
- 37.9 MPa (5500 psi) continuous

 20.7 MPa (3000 psi) Maximum Tank Agitator

Options:
a. Standard engines for this trailer are USEPA Tier II certified. USEPA now requires
Tier II certified engines for US locations. Tier I engines are still available with
some cost savings.

Options not included but recommended:

a. Displacement tank agitators – used when liquid additive system is used or when
mixing spacers prior to cementing. This is a good option for spacer mixing even if
there is no liquid additive system.
b. ServaView remote data recording and display software. Standard unit is wired to
accept ServaView.

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