Cement Bulk Truck Op Manual v.1.0 (Web)

OPERATION AND MAINTENANCE MANUAL
Version 1.0
C E ME N T B U
LK T
RU C K
Volume: 1 of 1
Employee Development Center Manual Status: Active
Locator Code: 353
Training Media Group JD Edwards P/N: 82351
Tomball, Texas Origin: BJ
BJ Services • Cement Bulk Truck Operator Manual • Version 1.0
Cement Bulk Truck

Equipment Operator’s Manual
Introduction
This manual is designed to be used in conjunction with field training to teach Equipment Operators to
properly operate the Cement Bulk Trucks.
The information in this manual has been compiled from BJ Standard Practices, experienced equipment
operators, and technical data.
Unit customizing will vary depending on area conditions, job requirements, and other factors. District
Training and Safety personnel can help identify proper procedures relating to the various differences.
Efforts have been made to cover the majority of configurations and modifications, and whenever they are
known, they will be mentioned in this manual.
Operators should be acquainted with proper operation and maintenance of Cement Bulk Trucks and other
related stimulation equipment.
Acknowledgements:
This manual could not been produced without the efforts and teamwork of the following individuals:
Bryan District: Bob Buckbee, Ron Gasch, Thomas La Fountain, Brad Camper, Tony Figueroa;
Edinburg District : Jerry Dailey, Bo Kestler, Joe Mejia
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
CEMENTING OPERATlONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
I. Basic Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
II. Cementing Job Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
III. Spotting and Connecting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BULK TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
I. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
II. OBJECTIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
III. OVERVIEW OF PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1. PRE-JOB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2. LOADING OF THE BULK TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. BEFORE LEAVING FOR THE JOB-SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4. DRIVING TO THE JOB-SlTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. AT THE JOB-SITE & BEFORE DISCHARGING THE CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6. DISCHARGING OF CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7. AFTER DISCHARGING CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8. RETURN TO STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9. POST-JOB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10. POST-JOB REPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
IV. PROCEDURE 1 : PRE-JOB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

STEP 1. INSPECT THE TRACTOR AND THE TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
STEP 2. INSPECT THE AIR COMPRESSOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
V. PROCEDURE 2: BEFORE LOADING THE CEMENT . . . . . . . . . . . . . . . . . . . 25

STEP 1: POSITION THE TRUCK AT THE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BULK PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
STEP 2: PREPARE THE FRONT POD FOR LOADING THE CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEP 3: LOAD THE FRONT POD WITH CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
VI. PROCEDURE 3: BEFORE LEAVING FOR THE JOB-SITE . . . . . . . . . . . . . . 29

STEP 1 : Perform The Final Bulk Truck Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
STEP 2: Check Your Personal Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
STEP 3: Before Leaving For The Job Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
STEP 4: Prepare To Depart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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SUMMARY AND REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VII. PROCEDURE 4: ON YOUR WAY TO THE JOB-SlTE . . . . . . . . . . . . . . . . . 34
VIII. PROCEDURE 5: PRE-DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

STEP 1 : PERFORM YOUR ARRIVAL DUTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
STEP 2: PERFORM YOUR FIELD CHECK OF THE COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
STEP 3: PERFORM BACK-UP MANEUVER TO THE CEMENT PUMPING UNITS MIXING HOPPER . . 39
IX. PROCEDURE 6: DISCHARGE CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

STEP 1: UNLOADING CEMENT FROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
THE FRONT POD: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
X. PROCEDURE 7: POST DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

STEP 1 : PERFORM THE SHUT DOWN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
STEP 2: PERFORM THE DUTIES THAT ARE REQUIRED BY YOUR SUPERVISOR . . . . . . . . . . . . . . . 47
XII. PROCEDURE 9: POST-JOB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 48
XI. PROCEDURE 8: RETURN TO THE DISTRICT YARD . . . . . . . . . . . . . . . . . . 48
XIII. PROCEDURE 10: POST -JOB REPORTING . . . . . . . . . . . . . . . . . . . . . . . . 51

PREPARE YOUR POST-JOB REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SUMMARY AND REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CEMENT BULK TRUCK OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . 54

1.0 CEMENT MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.1 Discharge Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.0 UNION CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 VICTAULIC COUPLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.0 AIR MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 BALL VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.2 CHECK VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3 FRONT TANK CHECK VALVE, (Inspection Procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 REAR TANK CHECK VALVE, (Inspection Procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.0 AERATOR PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.0 AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.0 MAN WAY COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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Objectives
After studying and practicing the procedures described in this manual, along with on-the-job
training and instruction, a Cement Bulk Truck operator should be able to:
• Perform pre-job maintenance inspection of the unit.
• Perform procedures to ready the unit for pumping procedures.
• Perform en route job duties. Observe BJ Convoy Procedures.
• Perform on site job duties for operating a Cement Bulk Truck within the needs of the particular job.
• Perform return to district duties.
Equipment Operator testing will cover seven areas of competency:
1. Health, Safety & the Environment
2. Emergency Response
3. Maintenance
4. Pre-Job
5. Job Execution
6. Post-Job
7. Interpersonal Skills
iv
CEMENTING OPERATlONS
I. Basic Knowledge
Conductor
Cementing is one of the many services that BJ
Services provides its customers. This process involves
securing the pipe in the wellbore by cementing it to the
formation rock.
Surface
Intermediate
Production Casing
Cement
Casing Shoe
To perform this service, BJ Services brings a high-pressure cement pump truck and a cement
bulk truck (or some other type of storage container) to the location.
Falcon Cement Pump with Bulk Trucks Falcon Cement Pump with Field Bin
5
The cement pump has the capability of combining the bulk (dry) cement and water into a slurry,
(the combination of both), and pumping it down the well. The cement slurry is pumped down the
casing, out the bottom of the casing, and back up the annulus (around the outside of the pipe).
Plug Container
Surface Casing
Dry Cement
Production Casing
Displacement Fluid
Water Under
Pressure
Cement Slurry
Top Plug Displacement Fluid
Top Plug
Seated
Bottom Plug
Bottom Plug
Seated
Valve
Closed
Float Collar
Centralizer
Guide Shoe Job In Progress Job Finished
6
II. Cementing Job Responsibilities
As a member of a BJ Services cementing

crew, you will have definite and important
duties. Upon arrival at the location, you should
park your truck and join the rest of the crew
for instructions as to what order the vehicles
will enter the location and where they will be
spotted on the well site.
Remember, you are a working member of

a crew, not an observer. Even though things
may be confusing at times, you will not learn
by watching. Hands-on experience is the best
teacher. It is your responsibility to help in any
work that is being done on the location by BJ
Services. Your Supervisor will instruct you in
what needs to be done.
BJ Cementing crew working together
You should also remember to wear your

safety equipment (PPE) when you are working
on the well site.
7
III. Spotting and Connecting the Equipment
When you are spotting the equipment, you must

be extremely careful to prevent personal injury or
equipment damage. Always ask someone to assist you
if you must back your truck into position to spot it.
After all equipment has been spotted, a cement

discharge line must be connected from the cement
pump truck to the well. This line is connected to the high
pressure side of the pump and is commonly referred to
as the discharge line. This connection process is called
“hook-up.” Included in this line are various components
such as pressure transducers, tees, valves, and other
items that your supervisor may require for the job.
Cement Pump’s High

Pressure Discharge Line
Discharge Iron from Cement

Pump to Well
Pressure
Transducer
Fluidend Plug Valve Check Valve
Pumping
Tee
Most of our connections, whether they are attached

to iron pipe or to rubber hoses, will be of the same type;
a thread connection on one end and a wing connection
on the other end.
Thread Half Wing Half
8
After the threads on both the wing and the thread connections have been cleaned and oiled, the
thread (male) end is pressed firmly against the wing (female) connection of the other joint (against
the rubber seal in the thread half); and then the wing connection is screwed onto the thread half
by turning it to the right until it is tight. Next a hammer is used to finish tightening the connection by
striking the “ears” on the wing half of the connection.
Putting Oil On the Threads Press the Connection Togrther Making Up Connection
Along with the discharge line, other connections must be made. One of these is connecting
the cement pumping unit to a water Supply. This connection is made with special rubber hoses.
These rubber hoses are called suction hoses. The suction hoses have steel braids in them to
ensure that they keep their shape when water (or other fluid) is sucked to the pumping unit.
Wire Brush Hose Connections Connecting Wing Half to Thread Half
Press the Connection Togrther Made Up Connection
9
The suction hoses should not be Confused with discharge (or supercharge) hoses. Discharge
hoses are not normally used in cementing, but are used in stimulation. A discharge hose’s
connection is always heavier and has a larger wing half than a suction hose.
Discharge Hose Suction Hose
10
The (dry) bulk cement that has been transported to the location has been specially prepared for
use on our customer’s location. The cement was dry mixed at the station in the bulk plant.
Cement Bulk Plant
Several chemicals may have been

added to the cement so that the slurry
will do what the customer wants. On
land, the bulk cement is loaded onto
a truck commonly referred to as a
bulk truck. This truck may unload the
cement directly into the cement pump’s
mixing system or it may just transfer the
cement to another storage device.
Bulk Truck Being loaded at Bulk Plant
Before Pressuring The Pod:

• Close the cement valve
• Blow cement line with air
to clean and also aerate the
As the time for the job approaches, cement in the pod
air will be pumped into the bulk truck
(or other storage device) in order to Cement Valve Closed
pressurize the bulk containers. This
pressure forces the dry cement out of
the bulk storage containers and into the
cement pump’s mixing hopper.
Air Valve Closed
11
BJ Services uses three primary mixing systems for cement:
1. Recirculating Averaging Mixer- RAM
2. Precision Slurry Mixer -PSM
3. Jet Mixer
Each of these mixing systems has a slightly different mixing hopper that it uses to mix the
cement. This requires that the cement bulk truck be spotted in such a way that the dry cement can
be unloaded properly into the mixing hopper.
12
The purpose of the cement mixing and pumping

unit is to combine a set amount of water with a set
amount of dry cement to make a slurry (mixture
of water and cement). The slurry is then pumped
down the discharge line, into the pipe, and finally
comes to rest in the annulus. The primary duty for
the bulk truck operator is to meter the cement from
the bulk truck to the mixing unit.
Wiper Plug
Cement Slurry
Float Shoe
When the casing has been run into the hole

and the rig crew is ready for it to be cemented into
place, a device called a “cementing head” (or plug
container) is made up on the top joint of the casing.
The cementing head provides a connection from
the discharge line to the casing, so that cement
may be circulated.
Cementing Heads
13
When double plugs are used, a bottom wiper plug

and a top wiper plug are placed inside the cementing
head. The first plug to go into the cementing head is the
bottom plug.
Bottom Wiper Plug Top Wiper Plug
As the cement slurry from the cement pump reaches

MUD
the cementing head, the bottom plug is released and
starts down the casing with slurry behind it. The plug
wipes mud off the inside of the casing and keeps the
mud separated from the cement. When the bottom plug
reaches the float collar (at the bottom of the casing), it
stops.
Pumping pressure increases and ruptures the MUD

diaphragm in the plug. The slurry goes through the plug
Top Wiper Plug
and continues its circulating path. Once the calculated MUD
volume of cement has been pumped, a retainer pin is
pulled to release the top plug from the cementing head.
The top plug follows the cement into the casing and
wipes cement off the inside of the walls of the casing. CEMENT
It also reduces the mixing together of cement and
the displacement fluid (usually water or mud) behind
the plug. This plug is solid. When it seats (bumps) on
the bottom plug at the float collar, pumping pressure
increases since no fluid can get past the solid top plug.
This pressure increase signals that the cement has Bottom Wiper Plug
been displaced, and pumping stops. The pressure is
bled off, and the cement is then allowed to set.
CEMENT
14
When the cement job is finished, you will usually be expected to clean the mixing unit and the
back portion of the pump truck by washing them off with water. As with the hook-up procedure,
your job is to assist in taking all connections apart and placing them in their storage racks. After all
of BJ Services equipment has been stored in their proper areas; the location has been policed of
all trash; and the service supervisor has given you his instructions; you may leave the location in a
safe and orderly manner.
Washing Down Cement Pump Placing Chicksan in storage rack
Loading Hose’s on Cement Pump Meeting with Service Supervisor
15
BULK TRUCK OPERATION
I. INTRODUCTION
Most of BJ Services cement bulk trucks are of the 18-wheeled tractor / trailer variety. There are
a few of the body-load version of the cement bulk trucks in use at this time, but the main type of
bulk truck that we use is the tractor / trailer. The only real difference in the two vehicles is the total
volume of cement that can be safely transported. Our cement bulk trucks have only one function:
to transport bulk cement for use in oil and gas well cementing operations. For the purposes of this
Operator’s Manual, we are going to concentrate only on the tractor/ trailer version.
The major components of this 32,000 pound bulk truck are. A tractor, trailer with a front pod and
a rear pod. An air compressor, (or, in some cases a blower ), and a diesel engine for powering the
compressor (or blower ) . Some trucks have a power take-off Trailer (PTO) drive-Iine to operate the
compressor instead of the compressor /diesel engine combination. A surge tank, dust collector or
filter unit. The two pods hold dry bulk cement. Each pod on a BJ Services’ tractor / trailer cement
bulk truck holds approximately 250 cubic feet of cement when properly and legally loaded.
Front Pod Rear Pod

Dust Collector
Compressor Assembly
Surge Can
Tractor Trailer
16
II. OBJECTIVES
After studying and practicing the procedures described in this manual, an operator of a BJ
Services bulk truck should be able to:
Preform pre-job maintenance inspection of the tractor / trailer
Perform pre-loading, loading, and post-loading procedures
Preform en route-to-the-job-site duties
Preform pre-discharge procedures essential to a successful discharge operation
Preform return-to-station duties
Preform post-job maintenance and reporting functions.
III. OVERVIEW OF PROCEDURES

The following ten procedures describe the operation of a bulk truck, from inspecting the truck
before loading to making a final report.
1. PRE-JOB INSPECTION
Inspect tractor and trailer
Inspect the blower ( or the compressor) assembly
2. LOADING OF THE BULK TRUCK
Position the truck at bulk plant
Prepare the front pod for loading of the cement
Load the front pod with cement;
Prepare the rear pod for loading of the cement;
Disconnect the front pod;
Connect the rear pod;
Load the rear pod; and
Disconnect the rear pod
17
3. BEFORE LEAVING FOR THE JOB-SITE

Complete the final bulk truck check;
Complete your check of personal safety equipment;
Complete your final check with the dispatcher; and
Prepare to depart
4. DRIVING TO THE JOB-SlTE
Drive with caution
Follow convoy procedures per Standard Practices Manual.
5. AT THE JOB-SITE & BEFORE DISCHARGING THE CEMENT

Be ready to complete your arrival duties;
Complete the field check of the compressor;
Safely back the truck up to the hopper;
Be certain to wear the proper safety equipment before you begin to discharge the cement, (these safety
items include: a dust respirator, safety goggles, gloves, hard hat, steel-toed safety boots, and BJ uniform
or coveralls);
Clear the discharge lines to the front and the rear pods; and
Perform the aeration of the cement
18
6. DISCHARGING OF CEMENT
Perform the discharge operation for the front pod; and perform the discharge operation for the rear pod.
7. AFTER DISCHARGING CEMENT
Perform the shutdown operation; and perform the duties required by your supervisor
8. RETURN TO STATION
Drive with caution
Follow convoy procedures per Standard Practices Manual.
9. POST-JOB INSPECTION
10. POST-JOB REPORTING
19
IV. PROCEDURE 1 : PRE-JOB INSPECTION

The success of the cementing operation depends
on the use of bulk trucks which have been properly
prepared for the difficult job of transporting cement
to the well. Conducting a complete inspection of
the entire bulk truck before you begin loading is
important for your safety and for the overall effective
use of the bulk truck. This inspection is the first step
to successfully complete the entire job. The truck
must not be used to transport a load of cement
until you are certain that it is in safe mechanical
condition. Your first job is to inspect every item listed
below.
STEP 1. INSPECT THE TRACTOR AND THE TRAILER
You should understand that this part of your inspection is what you are required to perform
as a commercially licensed driver of any type of vehicle. The items mentioned in this “Roading”
portion of the inspection are for informational purposes only. For a complete description of the Pre-
Job Inspection that is required on all of BJ Services’ equipment, please refer to the BJ Services
Commercial Driver Training Manual.
COMMERICAL DRIVER TRAINING
TRAINING DEPARTMENT
TOMBALL, TEXAS
Equipment Report
WHENEVER YOU DO PERFORM A PRE- OR A POST - JOB INSPECTION OF A BJ SERVICES

VEHICLE, USE THE DRIVER VEHICLE INSPECTION REPORT .
20
You can begin your Inspection by:
Checking the fuel level in all of the unit’s fuel

tanks. If the fuel tanks are low, always add fuel
before you leave the district yard on your way
to the well site. Being certain that the fuel tank
caps are tightly screwed on and that there are
no fuel leaks under or on the vehicle are several
things that you can do that may prevent future
problems with your truck.
Check the engine’s oil and water levels. If

either one is low, always add the necessary fluid
to ensure that the vehicle is ready to be driven to
the job site.
Check the engine’s fan belts. This is important.

When the engine’s belts are in reasonably good
condition and are properly adjusted, the engine
will run smoother and more economically.
Once these checks have been verified, you

may start the tractor engine. Be sure you check
to see that the engine oil pressure gauge is
registering the required amount of start-up oil
pressure. Now, while you allow the engine time
to warm up, continue with the remainder of the
vehicle’s inspection.
21
Check all of the tires. You should check not only the
tire’s pressure, but the condition of the tires and their
tread depth. Refer to the BJ Services’ Commercial
Driver Training manual for special instructions in
inspecting the tires on BJ Services’ tractor / trailer
vehicles.
Check all of the lights. This, again, is an important

inspection. There is a strong probability that you will
be using your vehicle’s lights before you return to
your district’s yard. Be certain that all of the lights are
operating.
Check the vehicles’ brake systems. Refer to the BJ Services’ Commercial Driver Training
manual for special instructions in inspecting the brakes on BJ Services’ tractor / trailer vehicles.
Check the vehicle’s windshield wipers. Replacing worn

or broken windshield wiper blades is recommended.
Be certain that the fifth wheel safety latch is locked in

place.
This concludes the overview of the “Roading” portion of the Bulk Truck’s Pre-Job Inspection. The
following items are considered to be associated with the auxiliary or the “Deck” portion of the Bulk
Truck. These items are also very important and must be inspected before you leave for the job site.
22
Determine that ALL of the valves on the trailer

are closed.
Inspect the surge tank. Pay particular attention

to the mounting supports for missing bolts / nuts
or for broken welds. Report all damage to your
supervisor. Be sure that any damage has been
repaired before you attempt to drive the Bulk Truck.
Dust Collector
Inspect the dust collector.
Top View of Bulk Trailer
23
STEP 2. INSPECT THE AIR COMPRESSOR ASSEMBLY
Check the compressor’s diesel engine oil and fuel;
Check the oil in the compressor;
Check the compressor’s belts;
Start the compressor’s engine;
Check the running condition of compressor’s

engine; and
Stop (or “Kill”) the compressor’s engine.
24
V. PROCEDURE 2: BEFORE LOADING THE CEMENT

During this operation it is important that
you pay close attention to each step. Special
preparation of the pods and their piping is
important to the rest of the loading procedure.
Not remembering to do a step during this
preparation can be dangerous.
For example :
YOU MUST ALWAYS RELEASE THE AIR
PRESSURE BEFORE YOU ATTEMPT TO
OPEN A HATCH ON ANY BULK TRUCK
POD ...BEFORE LOADING CEMENT OR TO
CHECK FOR ANY CEMENT THAT MAY BE
INSIDE THE POD.
FAILURE TO OPEN THE BLEEDER
VALVE FIRST WILL CAUSE THE
PRESSURE LEFT IN THE POD TO BLOW
THE HATCH OFF, (IN YOUR FACE) WHEN
THE LATCHES ARE RELEASED.
As you follow the eight steps described

below, you’ll notice that they overlap in fairly
rapid succession. While the front pod is being
loaded with cement, under the control of the
bulk plant operator, your job includes helping
him by carrying sacks of additives and loading
them into the transfer tank. Then, while the
front pod is being loaded, it is necessary to
prepare the rear pod by cleaning and oiling
the threads of the load and vent lines. You
will soon be able to handle these procedures
smoothly.
STEP 1: POSITION THE TRUCK AT THE BULK PLANT
Remove the chock-block;
Stow-away the chock-block on tractor;
25
Drive to the bulk plant;
Park the truck. Turn off the tractor’s

engine, and position the chock-block
between the tractor’s left rear wheels.
STEP 2: PREPARE THE FRONT POD FOR LOADING THE CEMENT
Open the bleeder valve to be certain that the

pod does not have any air left in it.
Open the hatch, determine that there is no

cement in the pod, then close the hatch. There
will usually be a small amount of cement, (about
a sack), left over in the bottom of the cement pod
after every job. If there is more than this amount,
the pod will need to be cleaned out before any
additional cement can be loaded.
Close the hatch.
26
Close the bleeder valve.
Remove the cap from the vent line.

Clean and oil the threads.
Hook-up the vent line.
27
Remove the cap from the load line.
Clean and oil the threads.
Hook-up the load line.
STEP 3: LOAD THE FRONT POD WITH CEMENT
Check with the bulk plant operator concerning the

loading of the front pod;
Assist the bulk plant operator in the loading of the

bulk truck’s front pod by hauling any sacks of additives
that may be needed in the mixing of the cement. Follow
the instructions of the bulk plant operator to load the
additives into the transfer tank; and determine that the
front pod has been correctly and completely loaded.
28
VI. PROCEDURE 3: BEFORE LEAVING FOR THE JOB-SITE

After the bulk truck has been correctly and
completely loaded with cement, the job of
transporting it to the job-site safely and on time
begins. Wasted time means a loss of money,
since the cementing operation depends on a
timely delivery of the cement. The cementing
operation at the well depends on your delivery of
the bulk cement. If you get lost or are involved in
an accident, the cementing operation will suffer a
costly delay. Have all safety equipment available
and in good condition to guarantee that you are
prepared to do your part of the work at the job-site.
(Remember to close all caps and valves securely to
prevent a loss of cement while en route to the job
site.)
STEP 1 : Perform The Final Bulk Truck Check
Stow-away the loading hose and the vent hose.
29
Close all the valves.
Replace the caps on the vent and fill connections

on the bulk truck’s pods.
30
STEP 2: Check Your Personal Safety Equipment
Check the condition of your:
SAFETY GLASSES
SAFETY GOGGLES
GLOVES
DUST MASK
HARD TOE SHOES OR BOOTS
BJ SERVICES UNIFORM OR COVERALLS
DRIVER’S DAILY LOG BOOK.
STEP 3: Before Leaving For The Job Site
Check with either your supervisor or your

dispatcher, (depending upon the usual procedures
in your District), for possible changes that you
may need to be aware of before you leave for
the job-site. If necessary your dispatcher or
your supervisor will provide you with any special
changes or instructions. Your supervisor or your
dispatcher will also be able to tell you the names of
key BJ support personnel that will be working with
you on the job-site.
Your supervisor or your dispatcher will also

give you a bulk truck Load Sheet. It will contain
information on the exact type and amount of
cementing materials, (cement, additives, etc.), that
were loaded onto your bulk truck.;
31
Load any special equipment that you may need to

transport to the job-site.
Obtain either a map or the written directions

to the job-site.
STEP 4: Prepare To Depart
Remove the chock-block;
Safely stow the chock-block on the Bulk Truck’s

tractor.
Start the tractor engine:
32
SUMMARY AND REVIEW
In the first part of this Operator’s handbook, you have learned the names of the most important
parts of the BJ Services Cement Bulk Truck; the purpose of the bulk truck; and the step-by-step
operating procedures involved in the pre-job inspection and the pre-Ioading, loading, and the post-
Ioading duties. If you are comfortable with the information so far, check your understanding of all of
the steps that are involved by answering the following questions before you go on to Procedure 4.
Either write the answers on paper, or, if you are asked to do so, give them orally to your instructor.
You may check your answers by re-reading Procedures 1, 2, and 3.
1. List the major parts of a BJ Services Cement Bulk Truck.
2. Explain why you should inspect the BJ Services Cement Bulk Truck before you intend to use it.
3. What is the purpose of the BJ Services Cement Bulk Truck.
4. Which of the major parts of a Cement Bulk Truck require a check of the oil level?
5. Give the names of the two lines connected to a pod for loading of cement.
6. State the procedure required prior to safe to open the hatch on a BJ Services Cement Bulk Truck.
7. State the duties of a BJ Services Cement Bulk Truck operator during the actual loading of the front pod.
8. Describe where the chock-block is normally placed when the vehicle is parked.
9. List all items of the Bulk Truck operator’s personal safety equipment.
10. List each step performed during the Final Check with the dispatcher.
33
VII. PROCEDURE 4: ON YOUR WAY TO THE JOB-SlTE

The weight of the bulk cement, (that you
will be transporting in the BJ Services Cement
Bulk Truck), as it shifts to one side in each pod,
combined with excessive speed or excessive
banking on a curve, can result in your loss
of control of the vehicle. In these cases, the
vehicle may tip over onto its side. This will cause
considerable damage to the truck and possibly
injure you, the driver.
The best way to prevent this from happening is
to maintain slow, safe speeds on all curves and
on all grades. As the truck moves forward, the cement stays
level in the pods and the truck / trailer remains
Remember that the bulk cement constantly balanced.
shifts inside the pods, causing it to be a very
unstable load. Skillful driving is required at all
times. This means that you must always watch
the road and be prepared for any changes in the
weather conditions. The speed of your vehicle is
also a factor. We prefer that you arrive safely at
all of your destinations.
When you are driving a BJ Services vehicle

always remember to:
When turning, or banking on a curve, the
Drive with caution cement will shift to one side of the pod. Make
turns slowly to avoid a sudden off-balance
Remain aware of the hazards of a shifting load; condition which could quickly flip the truck on
it’s side by shifting the center of gravity.
Determine the proper course of action should

you become lost:
Stop
Telephone your dispatcher; and
Await the arrival of your supervisor
34
Enter the trip’s details in your log book every time

that your “duty status” changes
Remember to stop to check the condition of your

vehicle and your vehicle’s tires every two to four
hours
Remember to stop and check your load after the

first 25 miles of driving.
35
VIII. PROCEDURE 5: PRE-DISCHARGE

Before attempting to discharge the cement
during the actual job, it is very important that
you perform the following two steps exactly as
required.
These steps are :
1. Clear the discharge lines.
During transporting, the cement

becomes packed in the pod and in the
cement line, making unloading more
difficult.
2. Aerate the cement in the pods.
If the discharge lines are blocked by cement,

the bulk cement will not flow freely during the
discharge operation. Clearing the discharge lines Cement Valve Closed
before the start of the actual job assures the free
flow of the cement out of the pods.
If, during the trip, the cement has become

packed too solidly at the bottom of the pods,
the free flow of cement will be hampered. The Air Valve Closed
aeration process loosens cement that has settled
at the bottom of the pods and helps break up any Before Pressuring The Pod:
• Close the cement valve
“clumps” that have • Blow cement line with air to clean and
formed. After arriving at the job-site, follow the also aerate the cement in the pod
pre-discharge procedures listed on the following
pages.
36
STEP 1 : PERFORM YOUR ARRIVAL DUTIES
Arrive at the job-site;
Locate your supervisor (or the pump truck

operator) ;
Receive your parking / spotting instructions;
Position your truck as you are directed by your

supervisor;
Properly place the chock-block;
37
Remember to:
Wear your hard hat, steel-toed boots, your

gloves and your BJ Services uniform coveralls.
STEP 2: PERFORM YOUR FIELD CHECK OF THE COMPRESSOR
Start the compressor’s deck engine;
Check the compressor’s pressure gauge;
Check the compressor’s pop-off valve.
38
STEP 3: PERFORM THE BACKING-UP MANEUVER TO THE CEMENT PUMPING UNITS MIXING
HOPPER
Properly store your chock-block on the tractor.
Position your truck to the cement mixing unit as

instructed; and
Safely place the chock-block between the

tractor’s drive wheels.
39
Open the front pod air valve to aerate

the cement;
# A-1 Front Pod
Obtain the desired air pressure on the

front pod (20 psi);
Open the rear pod air valve to aerate

the cement;
# A-2 Rear Pod
Obtain the desired air pressure on the

rear pod (20 psi) ; and
40
# A-1
Front Pod
# A-1 Jet line for Check for air leaks in all valves, lines, and pods.
Discharge Line
# A-2
Rear Pod # A-3 Jet Line
for Front Pod # A-1 Jet Line
for Rear Pod
IX. PROCEDURE 6: DISCHARGE CEMENT
The Cement Pump Operator or the supervisor in

charge of the job will signal you when he is ready
for you to begin unloading cement. Watch for his
signal.
Depending upon the type of cement pump truck

in use on the well site, you may or may not be
dumping cement into a cement hopper. You must
still maintain eye contact with the either the Cement
Pump Operator or the supervisor in charge of the
job.
41
STEP 1: UNLOADING CEMENT FROM

THE FRONT POD:
# D-2 Rear Pod

Discharge Closed
Ensure that valve #D-2 is closed.
# D-1 Front
Pod Discharge
# D-3 Surge
Tank Discharge Discharge Line
# D-2 Rear Pod

Discharge
Open valve #D-1
# D-1 Front
Pod Discharge
Open # D-3 Surge
Tank Discharge
Discharge Line
Stand next to valve #D-3. Open it when you

# A-1 Front Pod are ready to discharge cement. If cement starts
plugging, open valves #A-3 and #A-5 to Jet air into
# D-3 Surge the cement discharge line.
Tank Discharge
# A-3 # A-5
Jet Line For the Jet Line For the
Front Pod Surge Valve
42
Regulate the flow of cement by partially

opening valve #D-3. Maintain a smooth flow # A-1 Front Pod
Discharge
of cement.
# A-1 Front Pod

Close valve #D-1 when the volume of
cement stops and the volume of air coming # D-3 Surge
out of the surge tank increases. The Tank Discharge
pressure on the front pod’s pressure gauge

will drop when the pod is nearly empty. # A-3 # A-5
Front Pod Surge Valve
43
# D-2 Rear Pod

Discharge Open
STEP 2: UNLOADING CEMENT FROM
THE REAR POD:
With valve #D-3 open, open valve #D-2 (to

the rear pod).
# D-1 Front
Pod Discharge
Closed # D-3 Surge Discharge Line
Tank Discharge
Open
# D-2 Rear Pod

Discharge Closed
Continue to regulate the flow of cement

through valve #D-3.
# D-1 Front
Pod Discharge Close valve #D-3 when the flow of cement
Closed # D-3 Surge Discharge Line decreases. Then close valve #D-2.
Tank Discharge
Close
After both cement pods are empty , clean

the discharge line by opening valves #A-3,
#A-4 and #A-5 of the air manifold jet line.
# A-3
Jet Line For the
Front Pod Open # A-4 # A-5
Rear Pod Open Surge Valve
Open
# D-2 Rear Pod

Discharge Open
Next, open valve #D-3, #D-2, and #D-1.
# D-1 Front
Pod Discharge
Then close all of the valves on the air
Open manifold.
# D-3 Surge
Tank Discharge
# A-3 Open The discharge line has now been cleared.
Jet Line For the
Front Pod Close # A-4 # A-5
Rear Pod Close Surge Valve
Close
44
X. PROCEDURE 7: POST DISCHARGE

The post-discharge tasks are just as important as the pre-discharge tasks. ThIs Includes
releasing any air pressure, closing all of the valves, and driving the truck away from the cement
pump. (This usually requires that the truck be driven off of the location’s “pad” and out of the way
of other traffic.) All of these steps should follow the order listed below. Your supervisor will ask you
to clean and rack-up the cement truck, and will give you your return trip instructions.
STEP 1 : PERFORM THE SHUT DOWN OPERATION
# A-1 Front Pod

Close all of the bulk truck’s valves;
# A-2 Rear Pod
# A-3 # A-4 # A-5

Jet Line For the Jet Line For the Jet Line For the
Front Pod Close Rear Pod Close Surge Valve
Close
Kill the compressor’s engine;
45
Open both the front and the rear

pods bleeder valves;
Listen for the bleed-off of air

pressure;
Close the front and the rear pods

bleeder valves;
Safely store the chock-block
Reposition the truck as directed;
Stop the tractor engine; and
Replace the chock-block.
46
STEP 2: PERFORM THE DUTIES THAT ARE

REQUIRED BY YOUR SUPERVISOR
Clean the cement pump truck;
Rack-up the cement pump truck’s equipment,

discharge line and discharge line connections.
Receive your return-trip instructions from your

supervisor.
47
XI. PROCEDURE 8: RETURN TO THE DISTRICT YARD

Careful driving should also be practiced on the trip
back to the District yard. Although you do not have
to contend with pods that are full of shifting cement,
operating the bulk-truck in unfamiliar surroundings is
always a challenge. To arrive at the District in a timely
manner, follow the steps listed on the next page.
Drive with caution;
Remain aware of the hazard of a shifting load;
Determine the proper course of action should

you become lost:
Stop;
Telephone your dispatcher;
Await the arrival of your’ supervisor in charge

of the job;
Enter your trip’s details in your Log Book

every time that you have a change of duty status;
and Check the condition of your vehicle every two to
four hours. Remember to check your tires, too.
XII. PROCEDURE 9: POST-JOB INSPECTION
Your job as a BJ Services bulk truck operator

includes service to the vehicle to prepare it for the
next job. During your servicing of the bulk truck, you
need to make a note of any needed repairs because
you’ll be required to write them up in a report.
By servicing the truck you’ll be certain that it is in
good mechanical condition for future use.
48
PREFORM POST JOB INSPECTION
Arrive at the District yard;
Park the truck at the fuel island;
Kill the tractor’s engine;
Safely place the chock-block between the

tractor’s drive wheels;
Check and refill the oil / fuel for the tractor

engine
Check and refill the oil / fuel for the

compressor’s diesel engine;
Fill out the fuel log;
49
Check and refill the oil in the

compressor;
Check all tires and lights;
Start the tractor engine;
Safely store the chock-block;
Drive to the wash rack;
Turn off the tractor’s engine;
Re-place the chock-block; and
Wash all of the equipment on the

BJ Services Bulk Truck.
50
XIII. PROCEDURE 10: POST-JOB REPORTING

Your job is not finished until you have submitted all of the required reports. Reporting assures that
records of vehicle inspections, maintenance and any accidents are all kept on file.
PREPARE YOUR POST-JOB REPORTS
Fill out the Driver’s Vehicle Inspection Report

Form. Also turn in to your supervisor, or to your
dispatcher, the completed copy of the Drivers
Vehicle Inspection Report which you filled out as
part of Procedure 1 (Pre-Job Inspection);
Fill out Your Driver’s Daily Log and turn it in to

your supervisor or to your dispatcher;
Swipe your time card and place it in the time

card rack.
51
Write up any maintenance

problems or repairs needed and turn
the report in to your supervisor or
maintenance personal.
52
SUMMARY AND REVIEW

In procedures 4 through 10 you learned the correct steps in the operation of the bulk truck,
en route to the job-site, pre-discharge, discharge, post discharge, return to station, post job
maintenance and reporting.
This review will help you check your understanding of all of the steps involved. Answer the
following questions either on another pice of paper or orally, as requested by tour instructor.
Check your answer by re-reading Procedures 4 - 10 in this Operator’s Manual.
1. State the major hazard while en route with the cement load.
2. Describe the proper source of action to take if you get lost.
3 Explain why the discharge lines must be cleared prior to discharge.
4. Explain in your own words “ aeration of the cement”
5. List three steps in performing a field check of the compressor.
6. During discharge, why is it necessary to provide a continuous flow.
7. Explain in your own words how to provide a continuous flow.
8. After all of the cement has been discharged into the mixing hopper, what duties may be required of
you by your supervisor?
9. State the correction procedures while driving on the return trip.
10. When is the bulk truck operator’s job completed?
53
Cement Bulk Truck Operator Maintenance

Preventive maintenance concerning the bulk truck’s equipment should be performed monthly, (unless
noted otherwise). Doing so will help ensure proper performance of equipment during its day-to-day
operation.
1.0 CEMENT MANIFOLD
The butterfly valves should be checked for

leakage around the valve seat. Since it is
not always practical to remove the valves for
inspection, the following procedure is used:
# D-2 Rear Pod

Discharge Close
1.1 Discharge Valves
1) Close all discharge valves.

# D-1 Front
Pod Discharge
Closed # D-3 Surge Discharge Line
Tank Discharge
Close
2) Pressure each empty pod to 10 psi.
# A-1
Front Pod
# A-1 Jet line for

# A-2 Discharge Line 3) Close air line valves to each tank.
Rear Pod
# A-3 Jet Line # A-1 Jet Line
for Front Pod for Rear Pod
54
# A-1 Front Pod 4) Open air jet valve #A-5 to discharge.
5) Leave the air compressor running and the air

# A-2 Rear Pod jet valve (#A-5) open.
# A-3
Jet Line For the
Front Pod # A-4 # A-5
Rear Pod Surge Valve
Open
6) Watch the pressure gauges for each pod

to determine if a pressure increase occurs. If no
pressure increase occurs in the pods, the discharge
valves are holding.
7) Check and tighten all valve flange bolts and

valve handles.
If you find that the valve is not going to hold air

pressure, notify your supervisor of the problem.
Your supervisor will instruct you in what should be
done next.
2.0 UNION CONNECTIONS
Three 4-inch pipe size union connections branch

off the discharge manifold. Two of these union
connections are male subs. The first male sub is
located just to the rear of the intersection of the
manifold to the front and rear tanks and points to
the auto left side of the trailer. The second male
Pipe Union Connections union sub is just ahead of the first elbow going to
55
the surge tank and points to the inside of the

trailer. The third union connection is a female sub
coming off the lower elbow going to the surge
tank. There are also unions on the fill and vent
connections of each tank.
Fill & Vent Connections
When you perform an operator maintenance
inspection, it will be necessary to remove the
caps from the union ends to inspect the Fill &
Vent Connections inside of the discharge line.
The lines should be clean. Sometimes cement
will build up and harden within the 4-inch branch
pipe. Caked cement should be removed from the
manifold. Clean and lubricate. The threads on
the union subs and caps. Ensure that all sash
chains are in place.
2.1 VICTAULIC COUPLINGS
The victaulic couplings are maintenance free with the

exception of tightening bolts.
Victaulic Connections
3.0 AIR MANIFOLD

# A-1
Front Pod The air manifold delivers compressed air from
the compressor to the bulk cement tanks. The
# A-1 Jet line for air system’s “check valves,” which are a part of
# A-2
Rear Pod Discharge Line the air manifold, prevent cement from backing
# A-3 Jet Line # A-1 Jet Line up into the air lines and into the compressor. It
is important to routinely inspect the components
that make up the air manifold. The following
procedures should be used.
3.1 BALL VALVES
The ball valves are generally maintenance

free. The hex nut securing the operating handle
to the ball valve stem should be checked and
tightened when necessary .If you should find a
valve that is missing a handle, be certain to tell your
supervisor. He will tell you how to go about getting a
replacement.
56
3.2 CHECK VALVES
The purpose of the check valves is to prevent

cement from backing up into the air compressor
through the air manifold lines. Occasionally, cement
that has found its way back to the check valves may
cause the check valve to remain open by lodging
in the check valve mechanism. When this happens
the check valve does not perform its function. There
is a back up check valve at the air receiver in the
event cement does find its way through the first set
of check valves.
3.3 FRONT TANK CHECK VALVE, (Inspection

Procedure)
FRONT REAR
In order to determine that the check valves are
operating properly, and that they are not restricted
with cement, the following procedure should be
followed:
Compressor
Check Valve
1) Start the bulk truck’s air compressor engine,

(or properly engage the air compressor’s P.T.O.), to
begin supplying air pressure to the air manifold
at the rear of the bulk truck.
Pressuring The Pod

• Close the Cement Valve
• Pressure Up the Front Pod
20 PSI • Stop at 20 PSI
2) Pressure up the front pod using the bulk truck’s

Cement Valve Closed air compressor. Continue to pressure the front pod
until the internal pressure reaches 20 psi (1.5 bar)
Air Valve Opened
57
# A-1
Front Pod
3) Close all of the valves in the bulk truck’s air
system.
# A-2 # A-1 Jet line for
Rear Pod Discharge Line
# A-3 Jet Line # A-1 Jet Line
4) Shut down the bulk truck’s air compressor.
# A-1 Front 5) Bleed the bulk truck’s air manifold pressure

Pod
down to 5 psi using valve #A-6 located either on
5 PSI the bottom or the end of the air manifold.
#A-6
Air Manifold
Drain Open
# A-1 Front
Pod
5 PSI 6) Shut valve #A-6.

#A-6
Air Manifold
Drain Closed
58
# A-1 Front
Pod Open
7) Open valve #A-1 to the bulk truck’s front pod.
Carefully watch the air manifold’s pressure gauge to
see if the air pressure in the manifold increases.
#A-6
Air Manifold
After you have performed the procedure shown Drain Closed
above, and there is no “observed” pressure increase,

the check valve is operating correctly. A pressure
increase indicates cement has lodged in the valve
causing it to remain open. The check valve must be
removed from the line.
Cement can usually be cleaned from the valve if

serviced early. If the cement cannot be cleaned from
the check valve, the valve needs to be replaced. The
fact that cement has encroached to the check valve is
an indication that there are problems with the aeration
material inside the tank.
3.4 REAR TANK CHECK VALVE, (Inspection

Procedure) # A-1
Front Pod
The check valve inspection procedure for the rear

pod is the same as it was for the front pod. The only # A-2
exception is that valve #A-2 is used in Step 7. Rear Pod
# A-3 Jet Line # A-1 Jet Line # A-1 Jet line for
for Front Pod for Rear Pod Surge Valve
3.5 JET CHECK VALVES

FRONT REAR
There are three air jet lines to the bulk truck’s 5”
discharge manifold.
Each of these three jet lines have check valves that
will need to be inspected. These check valves are Compressor
very close to the cement line.
Check Valve
It is always a good idea to inspect the jet lines’
check valves to ensure that they are operating
properly.
59
20 PSI
Jet line valves inspection procedures: Both Pods
1) Pressurize both of the bulk truck’s

pods. [approximately 20 psi or 1.5 # A-1
bars (metric scale) Front Pod
Open
# A-2
Rear Pod
#A-6
Open
Air Manifold
Drain Closed
2) Bleed the pressure off of the air

manifold to approximately 5 psi.
# A-1
Front Pod
# A-2
Rear Pod
# A-6
Air Manifold
Drain Open
3) Open valve #A-3 and observe the

bulk truck’s air manifold pressure
gauge. An increase in the air
manifold’s pressure indicates the
( valve is defective and should either # A-1
be cleaned or replaced. Front Pod
# A-2
Rear Pod
Air Manifold # A-3 Jet Line
Drain Close for Front Pod
Open
4) Close valve #A-3.
# A-1
Front Pod
# A-2
Rear Pod
#A-6 # A-3 Jet Line
Air Manifold for Front Pod
Drain Close Close
60
5 PSI
5) Bleed the pressure off of the air manifold to

approximately 5 psi.
Air Manifold
Drain Open
6) Open valve #A-4 at the air manifold and

again observe manifold pressure gauge as in
Step 3 to check for a defective check valve at the # A-1
cement manifold coming off the rear tank. Front Pod
Open
# A-2
Rear Pod # A-4 Jet Line
Open for Rear Pod
#A-6 Open
Air Manifold
Drain Close
# D-2 Rear Pod

7) Open both the front tank discharge valve Discharge Open
(#D-1) and the rear tank discharge valve (#D-2)

in order to expose the rear section of the cement
manifold to the pressure in the pods and to test
the final air jet check valve at the back of the
# D-1 Front
cement manifold. Pod Discharge
# D-3 Surge
Open
Tank Discharge
8) Open valve #A-5 and observe the bulk

truck’s air manifold pressure gauge. An increase
# A-1
in the air manifold’s pressure indicates the valve Front Pod
is defective and should either be cleaned or Open
# A-2
replaced. Rear Pod
Open
#A-6
# A-5 Jet line for
Air Manifold
Surge Valve
Drain Close
61
9) Cement discharge valve (#D-3). at the rear of the

discharge line must remain closed.
# D-3 Surge
Tank Discharge
Close
4.0 AERATOR PADS
The front and rear pods both have a single aerator

pad located in the bottom of the tank.
The aerator pad disburses the compressed air Aerator Pad
supplied by the bulk truck’s air compressor, into the
bulk cement to simultaneously aerate. (or “fluff up”) Air From
the cement and pressurize the pods. Compressor
It is important to check the condition of the aerator
pads’ cloth material often.
The following items should be checked:
1) Sweep the aerator pads’ cloth clean with a steel

(wire), brush.
62
2) Check the aerator pads’ cloth material for

any holes or rips. A rip or a hole in the material
Check Pad for
will allow cement to back up Into the air Holes or Rips
manifold and possibly clog the check valves. A
rip or a hole in the material will also cause the
tank not to discharge cement efficiently. If you
find that the aged, be certain that you tell your
supervisor. Your supervisor will instruct you in
how the aerator pad should be replaced.
3) Check and tighten all bolts holding the

aerator pads’ cloth material down. Be careful
not to over-tighten bolts as the threads may
strip.
Check and Tighten All Bolts
Holding Down Aerator Pad
63
5.0 AIR COMPRESSOR
The bulk truck’s air compressor assembly provides

the air used to pressurize the pods and to aerate the
cement. The air compressor and the air compressor’s
engine should be inspected before every job.
The unloader valve located at the-front of the 30

gallon air receiver tank has been set at or near 20 psi.
Occasionally, this valve will need adjustment. Your
supervisor will show you how this is done.
A safety relief valve at the rear of the receiver tank

is set at 35 psi.
The safety relief valve’s setting should not be

changed under any circumstances.
The air compressor should have its crankcase oil

checked before and after every job.
64
The air compressor’s drive belts should be

inspected and adjusted periodically for wear,
if needed. When the drive belts are in need of
adjustment, be sure to tell your supervisor. Your
supervisor will show you how this is done.
Engine and compressor air filters must be

inspected before every job. These filters must be
changed as required. Your supervisor will explain the
replacement procedures.
6.0 MAN WAY COVER
The man way cover is located at the top of each

pod. If it is found that air is escaping around the
hatch, the man way cover must be adjusted. Should
you find that the man way cover is leaking air, be
certain to tell your supervisor. Your supervisor will
explain the repair procedures that should be used.
WARNING: ALWAYS BLEED THE AIR PRESSURE

FROM THE POD BEFORE OPENING THE MAN
WAY COVER.
NOTE: IF AN EXCESSIVE AMOUNT OF CEMENT

(8 OR MORE SACKS) REMAINS IN EITHER POD
AFTER THE POD IS THOUGHT TO BE EMPTY,
THE PROBLEM MAYBE WITH THE GRADE AND
QUALITY OF CEMENT USED. CHECK WITH
THE CEMENT RESEARCH DEPARTMENT IN
TOMBALL, TEXAS, FOR ANY CHANGE IN
FINENESS. PROCESS CONTROL. MIX DESIGN.
GRINDING AID OR FLOW ABILITY ADDITIVE.
65
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Employee Development Center
Training Media Group
Tomball, Texas

Cement Bulk Truck Op Manual v.1.0 (Web)

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OPERATION AND MAINTENANCE MANUAL

Cement Bulk Truck

BULK TRUCK OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

III. OVERVIEW OF PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

IV. PROCEDURE 1 : PRE-JOB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

V. PROCEDURE 2: BEFORE LOADING THE CEMENT . . . . . . . . . . . . . . . . . . . 25

VI. PROCEDURE 3: BEFORE LEAVING FOR THE JOB-SITE . . . . . . . . . . . . . . 29

SUMMARY AND REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

VII. PROCEDURE 4: ON YOUR WAY TO THE JOB-SlTE . . . . . . . . . . . . . . . . . 34

VIII. PROCEDURE 5: PRE-DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

IX. PROCEDURE 6: DISCHARGE CEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

X. PROCEDURE 7: POST DISCHARGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

XII. PROCEDURE 9: POST-JOB INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 48

XI. PROCEDURE 8: RETURN TO THE DISTRICT YARD . . . . . . . . . . . . . . . . . . 48

XIII. PROCEDURE 10: POST -JOB REPORTING . . . . . . . . . . . . . . . . . . . . . . . . 51

SUMMARY AND REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

CEMENT BULK TRUCK OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . 54

• Perform pre-job maintenance inspection of the unit.

• Perform procedures to ready the unit for pumping procedures.

• Perform en route job duties. Observe BJ Convoy Procedures.

• Perform return to district duties.

Equipment Operator testing will cover seven areas of competency:

1. Health, Safety & the Environment

Top Plug Displacement Fluid

Guide Shoe Job In Progress Job Finished

II. Cementing Job Responsibilities

As a member of a BJ Services cementing

Remember, you are a working member of

BJ Cementing crew working together

You should also remember to wear your

III. Spotting and Connecting the Equipment

When you are spotting the equipment, you must

After all equipment has been spotted, a cement

Cement Pump’s High

Discharge Iron from Cement

Most of our connections, whether they are attached

Thread Half Wing Half

Wire Brush Hose Connections Connecting Wing Half to Thread Half

Press the Connection Togrther Made Up Connection

Discharge Hose Suction Hose

Cement Bulk Plant

Several chemicals may have been

Before Pressuring The Pod:

Air Valve Closed

BJ Services uses three primary mixing systems for cement:

1. Recirculating Averaging Mixer- RAM

2. Precision Slurry Mixer -PSM

The purpose of the cement mixing and pumping

When the casing has been run into the hole

When double plugs are used, a bottom wiper plug

Bottom Wiper Plug Top Wiper Plug

As the cement slurry from the cement pump reaches

Pumping pressure increases and ruptures the MUD

Washing Down Cement Pump Placing Chicksan in storage rack

Loading Hose’s on Cement Pump Meeting with Service Supervisor

BULK TRUCK OPERATION

Front Pod Rear Pod

Preform pre-job maintenance inspection of the tractor / trailer

Perform pre-loading, loading, and post-loading procedures

Preform en route-to-the-job-site duties

Preform pre-discharge procedures essential to a successful discharge operation

Preform return-to-station duties

Preform post-job maintenance and reporting functions.