53375_80_bpm_calfrac_hydration_unit.pdf

Document Number: 53375 Revision Number: 01

Calfrac 80 Bpm Hydration Unit Operators Manual

Company Address

Enerflow Industries Ltd. 4800 - 27th St. SE Calgary, Alberta Canada T2B 3M4

Service Department

Telephone: (403) 279-9696

Fax: (403) 279-9633

Website: www.enerflow.com

Calfrac Hydration Unit Operator's Manual

This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express

authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent grant or registration of a product or design patent are reserved.

Document Number: 53375 Revision Number:01

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Record of Revisions

Revision # Date Brief Description Initials

01 May 11 09 Date of Initial Release CC





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About this Manual This Operators manual provides sufficient information to use and maintain the hydration equipment safely.

Enerflow Industries Inc. accepts no responsibility for incorrect use of equipment, inadequately trained personnel or improperly maintained equipment.

The use of this manual for anything other than the safe and correct operation and maintenance of the equipment constitutes misuse.

Enerflow Industries Inc. accepts no liability for any persons failing to follow correct equipment operation and safety guidelines.

Please ensure that this manual is thoroughly read, prior to operating or maintaining the equipment.

All information contained in this manual is based on the latest production information at time of publication.

Conventions Used All screen names and navigation icons in the following screen descriptions will be in Bold Text.

Notes especially of interest to the user are offset slightly from surrounding text and are highlighted with a light gray background.





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Table of Contents About this Manual...............................................................................................4 Conventions Used ..............................................................................................4 Table of Contents ...............................................................................................5 List of Figures.....................................................................................................7 List of Tables......................................................................................................8

1 Equipment Description................................................................................9 1.1 Introduction.................................................................................................9 1.2 Hydrator Components.................................................................................9 1.2.1 Trailer Chassis .....................................................................................10 1.2.2 Control Cab ..........................................................................................11 1.2.3 Deck Engine .........................................................................................11 1.2.4 Hydraulics System................................................................................11 1.2.5 Manifold Systems .................................................................................11 1.2.6 Centrifugal Pumps................................................................................12 1.2.7 Hydration Process Components...........................................................12

1.3 Principle of Operation ...............................................................................13

2 ECAMS Screen Descriptions.................................................................15 2.1 Typical ECAMS Screen Layout .............................................................16 2.1.1 Input Fields...........................................................................................18

2.2 Main Menu Screen....................................................................................19 2.3 Hydrator Monitoring Screens ....................................................................23 2.3.1 Hydrator Process Control Screen.........................................................24 2.3.2 Engine Information Screen ...................................................................26 2.3.3 Hydraulic Pressures Screen .................................................................28 2.3.4 Digital Data Screen ..............................................................................29 2.3.5 Suction Flow Meter Screen ..................................................................30 2.3.6 Hydration Tank Flow Meter ..................................................................32 2.3.7 Calmixer Flow Meter.............................................................................34 2.3.8 Pump Pressure Setpoints.....................................................................36 2.3.9 Alarms Screen......................................................................................38

2.4 Hydrator Calibration Screens....................................................................41 2.4.1 Hydrator Calibration Menu Screen .......................................................42





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3 Hydrator Operating Procedures ...............................................................59 3.1 Pre-Startup Equipment Check List............................................................60 3.2 How to Power-up the Hydrator .................................................................61 3.3 How to Acknowledge an Alarm Code .......................................................63 3.4 How to Calibrate the Siemens Touch Screen ...........................................65 3.5 How to Reset the Rig Saver .....................................................................66

Appendix A The Units Button...........................................................................67

Appendix B Centrifugal Pump Troubleshooting ...............................................68

Appendix C Hydration Unit Control Panel ........................................................69





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List of Figures

Figure 1 Hydrator Components..........................................................................10 Figure 2: Typical ECAMS Screen Layout ........................................................16 Figure 3 ECAMS Main Menu Screen .............................................................19 Figure 4 Hydration Process Screen ...................................................................24 Figure 5: Engine Information Screen ..................................................................26 Figure 6 Hydraulic Performance Screen ............................................................28 Figure 7 Digital Data (Gauges) Screen ..............................................................29 Figure 8 Suction Flow Meter Screen..................................................................30 Figure 9 Hydration Tank Discharge Flow Meter.................................................32 Figure 10 Calmixer Flow Meter Screen..............................................................34 Figure 11 Pump Pressure Setpoints Screen......................................................36 Figure 12 Alarms Screen ...................................................................................38 Figure 13 Hydrator Calibration Menu Screen.....................................................42 Figure 14 Process Pressure calibration Screen.................................................45 Figure 15 Hydraulic Pressure Screen ................................................................46 Figure 16 Temp/Fuel Calibration Screen ...........................................................47 Figure 17 Tank Inlet Valve Calibration Screen...................................................49 Figure 18 Hydrator Data van Rate Calibration Screen.......................................51 Figure 19 Calmixer Flow Rate Calibrations Screen ...........................................53 Figure 20 Wits/ Flash Log Output Setup Screen................................................56 Figure 21 Alarm Screen .....................................................................................63 Figure 22 Hydrator Deck Engine Rig Saver .......................................................66 Figure 23 Hydration Unit Control Panel .............................................................69





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List of Tables

Table 1 Metric and US Units ..............................................................................67 Table 2 Centrifugal Pump Troubleshooting Guide ..............................................68


1

Equipment Description



1 Equipment Description This section provides an overview of the Calfrac Hydrator major components:

1.1 Introduction The Calfrac Hydrator is a trailer mounted unit that has been designed for gel preparation and chemical blending of frac fluids that are the fracturing base for proppants used to stimulate existing, completed oil or gas wells.

The Hydrator can be controlled manually or automatically with ECAMS (Enerflow Control And Measurement System) which provides touch screen access to Hydrator controls and operating information.

1.2 Hydrator Components The following section provides a brief description of the Hydrators major components:

Trailer chassis. Deck Engine. Hydraulics. Manifold System. Centrifugal pumps. Blending system.


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1




Figure 1 Hydrator Components

1.2.1 Trailer Chassis The trailer chassis includes the following features:

Custom manufactured tandem axle semi-trailer chassis with 400 inch wheelbase. Antilock brakes. Holland style manual crank landing gear. Hydraulic levelling jacks for levelling the unit during operation.


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1.2.2 Control Cab The control cabin includes a cabin lift system which will lift the cabin platform three (3) feet to the operating position. This provides the operator with a line of sight into the hydration tank. The control cabin also includes an air conditioner, heater, ventilation/defroster fans and a UPS for the control system.

1.2.3 Deck Engine The Calfrac Hydrator has one (1) Caterpillar C15 diesel engine that can supply 575 BHP at 2100 rpm to power the unit: The C15 engine includes the following features:

Direct drive hydraulic power through a pump drive gear box. Webasto engine heater. Electronic engine controls. 150 USG fuel capacity. Rig saver shutdown. Turbo conveyor for blowing out the process piping.

1.2.4 Hydraulics System The Hydrator hydraulic pumps are run from the deck engine from a direct drive pump. The centrifugal pumps are all run from a closed loop hydraulic system with individual speed controls.

An open loop load sense pump is utilized for the hydraulic actuators for the tank level control valve, the cabin lift, the four hydraulic levelling jacks and the thermostatically controlled fan on the hydraulic oil cooler.

A hydraulically actuated valve controls the fluid entering the hydration tank as part of the automated levelling system.

1.2.5 Manifold Systems The Calfrac Hydrator manifold system includes a crossover manifold, suction manifold and a discharge manifold.


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The suction and discharge manifolds are fitted with electric/air operated butterfly valves with actuators. The crossover manifold allows the suction pump to discharge directly to the discharge manifold.

1.2.6 Centrifugal Pumps The Calfrac Hydrator has three centrifugal pumps: suction pump, auxiliary suction pump and a mix pump.

Suction Pump Gorman Rupp VG8HD3-B 10 x 8 centrifugal pump with a closed 5 vane impeller. Powered by a hydraulic motor with independent variable speed drive. Maximum pump output is 100 BPM. Auxiliary Suction Pump Gorman Rupp VG series centrifugal pump with closed impeller. Powered by a hydraulic motor with independent variable speed drive. Maximum output is 15 BPM at 50 psi. Mix Pump Goulds 2 x 3 x 11 with closed impeller and mechanical seal. Powered by a hydraulic motor with independent variable speed drive. Maximum output is 15 BPM at 250 psi. The mix pump is supercharged from either the main suction pump or the auxiliary

suction pump.

1.2.7 Hydration Process Components The hydration process includes a hydration tank, shear plates and retention tubes.

Hydration Tank Steel open top tank rated to hold 60 bbls of hydration gel. Internal baffles to channel water through tank for first in/first out process flow.


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Internal baffles also include one 12 butterfly valve with a pneumatic actuator so that the restriction through the tank can be minimized when running slick water at up to 100 bpm.

Level transducer and high water level switches. Shear Plates There are four (4) shear plates in the Calmixer. The shear plates ensure proper mixing of the gel solution and can be replaced with different types of shear plates depending on the mixing differential pressure and flow rate requirements of the gel.

Retention Tubes Stainless steel retention tubes are sized to provide a three (3) minute hydration time

for gel within the hydration unit when pumping at 60 bpm. The flow through the hydration tubes is 15% of the overall unit flow rate.

The retention tubes have removable end connections to provide cleanout access. The retention tubes are in four (4) sections that can be isolated during pumping

operations so that the hydration time can be modified based upon current through flow rates.

The retention tubes discharge into the inlet of the suction pump as part of the Calmixer system.

1.3 Principle of Operation There are several hydration processes that can be performed in the Hydrator. One of these is the mixing of a liquid chemical additive (polymer) with clean mix water to form a gel. This process includes the following steps:

a. Clean mix water is pumped from an external source or from the hydrator tank to the Calmixer.

b. Before entering the Calmixer liquid chemical additive is added to clean mix water. The chemical additive is a polymer that will form a gel when mixed with water.

c. The Calmixer boost pump then pumps the water/chemical solution through an array of four (4) shear plates. The Boost pump maintains a preset flow rate and differential pressure across the shear plates to ensure proper mixing of the solution.


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d. The solution then flows through up to four (4) retention tubes that are configured with a specific volume and length. The retention tubes limit the solution to a flow rate that allows it to thicken into a gel with a specific density before it is pumped to a Hydrator where proppant is added.


2

ECAMS Screen Descriptions




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2 ECAMS Screen Descriptions This section provides a description of a typical ECAMS screen layout and detailed descriptions of the following screens in the ECAMS menu system:

Main menu screen Hydrator monitoring and control screens. Hydrator transmitter calibration screens.


2

2.1


Typical ECAMS Screen Layout



2.1 Typical ECAMS Screen Layout Each ECAMS screen is divided into three (3) information areas (see Figure 2):

Figure 2: Typical ECAMS Screen Layout

1. The menu bar located along the top of each screen displays the following navigation buttons and information fields:


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2

2.1





Navigation Buttons

The Main Menu button displays navigation buttons to the ECAMS major screens and flow rate and pressures at critical points in the hydration process.

The Calibrations button displays links to control valve and process temperature and pressure transmitter setpoints.

The Process button displays hydration process valve controls and the following process variables:

Pressure. Temperature. Pump rpm. % slip. Residing time in hydration tubes.

Information Fields

The menu bar displays the following information fields:

Discharge Rate where??? Suction pressure before the hydration tank. Calmix Rate Shear Inlet Pressure. Shear outlet Pressure.

2. The main screen display area located below the top menu bar displays hydrator

control buttons, operating settings and transmitter output fields. 3. An alarm code bar located below the main screen display area displays a description

of the most recent system faults.


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2

2.1






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2.1.1 Input Fields All ECAMS touch screen fields that are displayed with a white background are input fields. They allow the operator to change equipment operating control variables.

To change a control variable simply press on its input field and using the displayed numeric keypad enter a new value.


2

2.2


Main Menu Screen



2.2 Main Menu Screen The ECAMS main menu screen displays software information and navigation buttons for password and non password protected screens.

To open this screen select the Main Menu button displayed on the top menu bar of each ECAMS screen.

Figure 3 ECAMS Main Menu Screen


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2

2.2


Main Menu Screen



The Main Menu screen displays the following software information:

Screen version number. Software version number. The main screen displays the following control and navigation buttons:

The Flow/Vol Units and Pressure Units toggle buttons set each ECAMS screen to display input and output values in US (imperial) or Canadian (metric) units.

The Engine Info button displays deck engine performance data and diagnostic indicators.

The Process button displays hydrator valve controls, hydration tank controls and process pressure, temperature and flow rates.

The Hydraulic Pressure button displays hydraulic system performance data.

The Digital Data button displays fluid level, pressure and flow rates at critical points in the hydration process.

The Suction Flow Meter button displays the hydration tank suction line flow rate, total volume and flow meter communication status.

The Hydrator Tank Flow Meter button displays the hydration tank discharge line flow rate, total volume and flow meter communication status.


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2

2.2


Main Menu Screen



The Calmixer Flow Meter button displays the Calmixer flow rate, total volume and flow meter communication status.

The Pump Pressure Setpoints button displays operating setpoints and output performance information for each centrifugal pump.

The Calibrations button displays links to control valve and process temperature and pressure transmitter setpoints.

The Alarms screen displays active and acknowledged system alarms.

The Control Panel button displays Siemens touch screen calibration settings.


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2

2.3


Hydrator Monitoring Screens




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2.3 Hydrator Monitoring Screens This section provides detailed descriptions of the Calfrac Hydrator process and equipment monitoring screens:

Hydrator process control screen. Engine information screen Hydraulic performance screen. Digital data screen. Suction (tank inlet) flow meter. Hydration tank flow meter screen. Calmixer flow meter screen. Pump pressure setpoints screen. Alarms screen.


2

2.3.1


Hydrator Process Control Screen



2.3.1 Hydrator Process Control Screen The Hydrator Process Control screen displays a big picture view of the entire process and the following process monitoring and control features:

Suction, discharge and Calmixer valve controls. Auto or manual Calmixer control and hydration tank level control. Pressure, temperature, flow rate and Calmixer Slip% output fields. To open this screen press the Process button displayed on the top menu bar of each ECAMS screen.

Figure 4 Hydration Process Screen


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2

2.3.1


Hydrator Process Control Screen



The Hydration Process Control screen displays the following control buttons valve icons and input fields:

The Manual/Auto toggle button provides the option to select manual or auto flow control of gel through the Calmixer shear plates and retention tubes.

The Baffle Open and Baffle Close buttons control a baffle in the hydration tank.

The % Setpoint input field is the hydration tank level setpoint that controls flow through the tanks 12 inlet butterfly valve.

Each manifold valve icon is a control button that opens or closes a valve. The icon is green when the valve is open and red when it is closed.

The Slip% value is an ECAMS calculated value for the Calmixer gel flow rate. It is a percentage of the flow rate measured by the hydration tub suction or discharge flow meter or the Hydrator flow meter.

Note: the flow rate source for the Slip% calculation is selected in the Slip Calculation and Data van Output Configuration screen.


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2

2.3.2


Engine Information Screen



2.3.2 Engine Information Screen The Engine information screen displays deck engine performance information and diagnostic indicators.

To open this screen press the Engine Info button displayed on the ECAMS main menu screen.

Figure 5: Engine Information Screen

The Engine Info screen display the following engine diagnostic indicators and screen navigation buttons.


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2

2.3.2


Engine Information Screen



The Check warning light indicates engine maintenance action is required. For example: low oil level or a locked filter.

Note: when this warning light is on the engine does not require an immediate shutdown.

The Stop warning light indicates a serious situation that requires the engine to be immediately shut down. Failure to do so could result in serious engine damage.

The Protect warning light indicates that the engine has stopped itself or de-rated its torque or power to protect itself.

The Extended Diagnostics button displays the following engine diagnostic information:

SPN (Suspect Parameter Number). This number indicates which engine input value is questionable.

FMI (Failure Mode Indicator). This indicates the type of engine failure.


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2

2.3.3


Hydraulic Pressures Screen



2.3.3 Hydraulic Pressures Screen The Hydraulic Pressures screen acts as a gages screen providing the operator with an array of hydraulic performance data.

To open this screen select the Hydraulic Pressures button displayed on the ECAMS main screen.

Figure 6 Hydraulic Performance Screen


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2

2.3.4


Digital Data Screen



2.3.4 Digital Data Screen The Digital Data screen displays output values from the hydration tank, suction manifold and Calmixer pump transmitters.

To open this screen select the Digital Data (Gauges) button displayed on the ECAMS main screen.

Figure 7 Digital Data (Gauges) Screen


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2

2.3.5


Suction Flow Meter Screen



2.3.5 Suction Flow Meter Screen The Suction Flow Meter screen displays the flow rate and total volume of clean water that has entered the hydration tank. This screen also displays the total amount of fluid that has passed through each flow meter in the hydrator and the suction flow meter communication status.

To open this screen select the Suction Flow Meter button displayed on the ECAMS main screen.

Figure 8 Suction Flow Meter Screen

The Suction Flow Meter screen displays the following output fields and control buttons:


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2

2.3.5


Suction Flow Meter Screen



Volume Flow flow rate in the hydration tank inlet line.

Total 1 total amount of fluid that has been pumped to the hydration tank.

Total 2 total amount of fluid that has left the hydration tank.

Total 3 total amount of fluid that has entered the Calmixer and retention tubes.

The Reset Totals button sets Total 1 field to zero (0).

Reset All Flow Meter Totals button sets Totals 1, 2 & 3 fields to zero (0).

The Back button displays the last opened screen.


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2

2.3.6


Hydration Tank Flow Meter



2.3.6 Hydration Tank Flow Meter The Hydration Tank Flow Meter screen displays the flow rate and total volume of fluid that has flowed through the hydration tank discharge line. This screen also displays the total amount of fluid that has passed through each flow meter in the hydrator and the hydration tank discharge flow meter communication status.

To open this screen select the Hydration Tank Flow Meter button displayed on the ECAMS main screen.

Figure 9 Hydration Tank Discharge Flow Meter

The Suction Flow Meter screen displays the following output fields and control buttons:


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2

2.3.6


Hydration Tank Flow Meter



Volume Flow flow rate through the hydration tank discharge line.


Total 2 total amount of fluid that has left the hydrator tank.

Total 3 total amount of fluid that has entered the Calmixer and retention tubes.


Reset All Flow Meter Totals button sets Totals 1, 2 & 3 fields to zero (0).

The Back button displays the last opened screen.


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2

2.3.7


Calmixer Flow Meter



2.3.7 Calmixer Flow Meter The Calmixer Flow Meter screen displays the gel fluid properties measured by the Calmixer flow meter and calculated by the ECAMS program before the fluid enters the Calmixer. This screen also displays the total amount of fluid that has passed through each flow meter in the hydrator and the Calmixer flow meter communication status.

To open this screen select the Calmixer Flow Meter button displayed on the ECAMS main screen.

Figure 10 Calmixer Flow Meter Screen


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2

2.3.7


Calmixer Flow Meter



The Calmixer Flow Meter screen displays the following output fields and control buttons:


Total 2 total amount of fluid that has left the hydration tank.

Total 3 total amount of fluid that has entered the retention tubes.


Reset All Flow Meter Totals button sets the Totals 1, 2 & 3 fields to zero (0).

The Back button displays the previously opened screen.


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2

2.3.8


Pump Pressure Setpoints



2.3.8 Pump Pressure Setpoints The Pump Pressure Setpoints screen displays centrifugal pump auto and manual operating setpoints.

To open this screen select the Pump Pressure Setpoints button displayed on the ECAMS main screen.

Figure 11 Pump Pressure Setpoints Screen

The Pump Pressure screen displays the following centrifugal operating setpoints:

Suction Pump draws clean mix water from either the driver side or suction side manifold.


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2

2.3.8


Pump Pressure Setpoints




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Calmixer Suc Pump This is an auxiliary clean mix water pump that can draw water from an external source. For example: a water tank.

Note: On the drawing P&ID Hydration unit with Calmixer (part #33962) included in the Enerflow parts and service manual, this pump is labeled Aux Suction Pump

Cal Mixer Boost Pump This pump maintains a differential pressure across the shear plates.

Note: On the drawing P&ID Hydration unit with Calmixer (part #33962) included in the Enerflow parts and service manual, this pump is labeled Press Mix Pump.


2 ECAMS Screen Descriptions

2.3.9 Alarms Screen



2.3.9 Alarms Screen The Alarms screen displays a history of the most recent alarm events. This screen also provides the operator with the option to acknowledge alarm codes. Each alarm code is displayed in order of the time and date of the event.

To open this screen select the Alarms button displayed on the main menu screen.

Figure 12 Alarms Screen

The Alarms screen displays the following alarm codes and navigation buttons:


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2 ECAMS Screen Descriptions

2.3.9 Alarms Screen



Alarm Colour Codes The Alarm screen displays the following alarm colour codes:

Flashing red indicates an unacknowledged alarm. Steady blue indicates an alarm that has been selected for acknowledgment. Steady white indicates an alarm that has been acknowledged. The flashing alternate red and white box at the bottom of the screen displays the most

recent unacknowledged alarm.

Alarms Screen Button The Alarms screen displays the following buttons:

The Acknowledge button located on the right bottom corner of the screen allows the operator to acknowledge active alarm codes.


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2.4

Hydrator Calibration Screens




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2.4 Hydrator Calibration Screens ECAMS provides the following Hydrator valve and transmitter calibration screens:

Hydrator calibration menu screen. Process pressure calibration screen. Hydraulic pressure calibration screen. Temp/Fuel calibration screen. Tank inlet valve calibration screen. Hydrator/Data van rate calibration screen. Calmixer flow rate calibration screen. WITS screen.


2.4

2.4.1


Hydrator Calibration Menu Screen



2.4.1 Hydrator Calibration Menu Screen The Hydrator Calibration Menu screen displays navigation buttons to pump, valve and process transmitter operating setpoints.

To open this screen select the Calibration button displayed on the top menu bar of each ECAMS screen.

Figure 13 Hydrator Calibration Menu Screen

The Hydrator Calibration Menu screen displays the following navigation buttons:


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2.4

2.4.1





The Process Pressure Calibrations button displays valve hydraulic actuator pressure setpoints.

The Hydraulic Pressure Calibration button displays centrifugal pump hydraulic pressures and system air pressure setpoints.

The Temp/Fuel Calibration button displays Calmixer (shear plate) and hydraulic oil temperature setpoints and fuel level and Cleanout Blower setpoints.

The Tank Inlet Valve Calibration button displays hydration tank inlet valve controls.

The Hydrator/Data van Rate Cal button displays the option to select one (1) of three (3) flow meter outputs for the ECAMS Slip% calculation and input fields for configuring flow meter transmitters for output to a Data van.

The Calmixer Flow Rate Calibrations buttons displays the option to change the following Calmixer operating setpoints.

The WITTS button displays fields for assigning Enerflow WITS ID numbers to Hydrator transmitter output values that are stored in Flash memory.

The Baffle Open and Baffle Close buttons control a 12 butterfly valve that increases or decreases the flow through the mixing tank.


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2.4

2.4.1







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2.4

2.4.1.1


Process Pressure Calibration Screen



2.4.1.1 Process Pressure Calibration Screen The Process Pressure Calibration screen displays valve hydraulic actuator pressure setpoints.

To open this screen select the Process Pressure button displayed on the Calibration screen.

Figure 14 Process Pressure calibration Screen


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2.4

2.4.1.2


Hydraulic Pressure Screen



2.4.1.2 Hydraulic Pressure Screen The Hydraulic Pressure screen displays centrifugal pump hydraulic pressures and system air pressure setpoints.

To open this screen select the Hydraulic Pressure button displayed on the Calibration screen.

Figure 15 Hydraulic Pressure Screen


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2.4

2.4.1.3


Temperature and Fuel Calibration Screen



2.4.1.3 Temperature and Fuel Calibration Screen The Temperature and Fuel Calibration screen displays Calmixer (shear plate) and hydraulic oil temperature setpoints and fuel level and Cleanout Blower setpoints.

To open this screen select the Temp/Fuel Calibration button displayed on the Calibration screen.

Figure 16 Temp/Fuel Calibration Screen

The Temperature and Fuel Calibration screen displays the following control and navigation buttons;


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2.4

2.4.1.3


Temperature and Fuel Calibration Screen



The Fan On/Off toggle button overrides the hydraulic tank cooling fan setpoints.



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2.4

2.4.1.4


Tank Inlet Valve Calibration Screen



2.4.1.4 Tank Inlet Valve Calibration Screen The Tank Inlet Valve Calibration screen displays following Hydration tank valve control options:

run a hydration tank control valve calibration fully open or fully close the hydration tank control valve Override ECAMS control and set the control valve in full manual mode. To open this screen select the Tank Inlet Valve Calibration button displayed on the Calibration screen.

Figure 17 Tank Inlet Valve Calibration Screen


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2.4

2.4.1.4


Tank Inlet Valve Calibration Screen



The Tank Inlet Valve Calibration screen displays the following control and navigation buttons:

The Tank 1 Inlet Calibrate button enables an auto calibration of the hydration tank inlet valve hydraulic actuator using the factory set values displayed on this screen.

The Open and Close buttons displayed on the right side of the screen fully open or fully close the hydration tank inlet valve when the valve is in manual mode (set on the main control panel).

The Full Manual Mode Enable button sets the hydration tank level control valve in manual mode without feedback control.

When pressed this button will display Full Manual Mode Active and Open and Close buttons.



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2.4 Hydrator Calibration Screens

2.4.1.5 Slip Calculation and Data van Output Configuration Screen



2.4.1.5 Slip Calculation and Data van Output Configuration Screen The Slip Calculation and Data van Output Configuration screen provides the option to select one (1) of three (3) flow meter outputs for the ECAMS Slip% calculation. This screen also displays input fields for configuring flow meter transmitters for output to a Data van.

To open this screen select the Hydrator/Data van Rate Cal button displayed on the Calibration screen.

Figure 18 Hydrator Data van Rate Calibration Screen

The Hydrator/Data van Input Calibration screen displays the following selection buttons and input configuration fields:


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2.4.1.5 Slip Calculation and Data van Output Configuration Screen



The Use This For Slip button provides the option to select the mix tank suction or discharge line flow meter or Data van flow meter flow rate to calculate the %Slip for the hydration tubes.

Hydrator and Data van flow meter frequency and flow rate input fields. These are the operating values supplied by the flow meter manufacturer.

Slip%

The Slip% Current is a value for the gel flow rate in the hydration tubes that is calculated from the actual mix tub suction or discharge line flow meter.


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2.4

2.4.1.6


Calmixer Flow Rate Calibration Screen



2.4.1.6 Calmixer Flow Rate Calibration Screen The Calmixer Flow Rate Calibration screen provides the option to change the following Calmixer settings:

Shear plate flow rate. Retention loop setpoints. Cold or warm water auto flow control through the shear plates. Calmixer slip %. To open this screen select the Calmixer Flow Rate Calibrations button displayed on the Calibration screen.

Figure 19 Calmixer Flow Rate Calibrations Screen


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2.4

2.4.1.6





The Calmixer Flow Rate Calibration screen displays the following control and navigation buttons:

The Shear Plate Warm Water button enables auto control of the differential pressure and flow rate through the shear plates (Calmixer 1 -4) when warm water is used.

The Apply Calmixer Rates button is pressed after new Calmixer flow rates have been entered. This will save the new values to the PLC. At this point ECAMS will use the new values to control the gel in water mixing through the shear plates.

The Change Parameter / Parameter Locked toggle button allows the operator to change or lock the retention Loop Volume values.

Note: the Parameter Locked toggle button position is a safety feature that prevents the operator from accidentally changing a retention loop volume during hydrator operation.

Calmixer 1

Calmixer 2

Calmixer 3

Calmixer 4

The Calmixer 1 Calmixer 4 are the shear plate flow rates setpoints that are maintained by the Calmixer Boost pump when the Calmixer is in auto mode.

Note: These setpoints need to be changed each time the shear plates are replaced with different types of plates to satisfy job mixing requirements.

1st Loop Volume

2nd Loop Volume

3rd Loop Volume

4th Loop Volume

Retention tube volumes.

Note: There are four (4) loops. The total retention tube volume can be changed by closing the appropriate valve to suit the gel mixing time requirement. When this occurs the volumes


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2.4

2.4.1.6






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displayed on this screen must be updated.

Calmixer Slip% The Calmixer Slip% input field displays the Slip% value when using warm or cold mix water.



2.4.1.7 WITS / Flash Log Output Setup Screen



2.4.1.7 WITS / Flash Log Output Setup Screen The WITS / Flash Log Output Setup screen displays fields for assigning Enerflow WITS ID numbers to Hydrator transmitter output values that will be stored in Flash memory.

To open this screen select the WITS button displayed on the Calibration menu screen.

Figure 20 Wits/ Flash Log Output Setup Screen

The WITS / Flash Log Output Setup screen displays the following control buttons and navigation links:


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2.4.1.7 WITS / Flash Log Output Setup Screen



The Enable Unit Conversions button scales each Current Value with its Unit Factor and Unit Offset.


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3 Hydrator Operating Procedures




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3 Hydrator Operating Procedures This section includes detailed descriptions for the following Hydrator operating procedures:

Pre-start-up equipment check list. How to power-up the Hydrator. How to acknowledge and alarm code. How to calibrate the centrifugal pumps. Centrifugal pump setup for auto operation. How to calibrate the Siemens touch screens. How to reset the deck engine rig savers.


3

3.1

Hydrator Operating Procedures

Pre-Startup Equipment Check List




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3.1 Pre-Startup Equipment Check List Before Starting up the Hydrator perform the following equipment checks:

Note: We do not give detailed instructions on how to start up the Hydrator for safety and legal reasons. But there are some general instructions that do not require any specific instructions.

Deck Engines Check that the deck engine rig saver is in the open position.

Note: The rig saver leaver is in the open position when it is parallel to the rig saver body.

Check the deck engine oil levels. Also check the visual indicators on engine oil filters. Check the deck engine coolant level using the sight glass located on the engine

radiator or by removing the cap on the overflow tank.

Check the deck engine air filter by looking at the visual indicators mounted just below the filter.

Check the fuel level by simply opening the fuel tank cap.

Hydraulics Components Check the following hydraulic components:

Check the hydraulic oil level and temperature by viewing the sight glass mounted on the front of the hydraulic oil tank.

Check the centrifugal hydraulic oil filter flow visual indicators. Control Valves Ensure that all process control valves are in the closed position.


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3.2


How to Power-up the




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3.2 How to Power-up the Hydrator The Hydrator power-up procedure includes deck engine ignition, turning on the main and instrument power, and confirming engine communication.

To Power-up the Hydrator:

1. Turn the 24 Volt battery disconnect switch to the On position. The battery box is located above the passengers side rear tractor wheel.

Note: The 24 Volt battery provides DC power to the deck engine starter, transmitters, engine display screens mounted in the control cab, and control cab for the limited length of time before deck engine startup.

2. Turn the control panel Main Power switch to the On position. 3. Turn the Instrument Power switch to the On position. 4. Check the engine display screen on the cab control panel for the following

information:

Engine communication if there is communication the engine screen will display RPM and coolant temperature readings.

Note: The engine screen will display a default temperature of 32 F when there is no engine communication.

Engine coolant temperature should be above (0 C, 32 F).

Note: If the engine coolant is not at the minimum operating temperature, turn the Webasto control switch located on the battery box to the On position. The switch will illuminate green when the Webasto power is on.

5. Walk around the Hydrator to ensure that well site personnel are not in the operating area.

6. Turn and hold the HPU Engine switch in the Start position until the engine is running on its own power.


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How to Power-up the




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Note 1: Do not hold the Engine switch in the Start position for more than 10 seconds.

Note 2: If the engine does not run after two starts, check the fuel level. Then use the engine priming pump to build up enough fuel pressure for ignition. The minimum fuel pressure is reached when the operator can no longer move the plunger.

7. Open the Engine Information screens for both deck engines and check the transmitter values to ensure that they are operating correctly.

8. Turn the Siemens touch screen power switch to the On position then open the ECAMS HPU Status screen to ensure that the centrifugal suction pump has hydraulic pressure.

WARNING: DO NOT START THE CENTRIFUGAL PUMPS WITHOUT MIX WATER. THE PUMPS HAVE MECHANICAL SEALS THAT WILL SEIZE IF RUN WITHOUT FLUID LUBRICATION.

Note: The hydraulic drive pump oil pressures should be approximately 320-350 psi and the auxiliary hydraulic oil pressure should be between 1500 and 1850 psi. Check with Marius.

9. Press the Alarm button located on the ECAMS screen top menu bar to open the Alarms screen and check for system faults.


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3.3


How to Acknowledge an Alarm Code



3.3 How to Acknowledge an Alarm Code To acknowledge an alarm code:

1. Open the Alarms screen by selecting the Alarms button displayed on the main menu screen.

Figure 21 Alarm Screen

2. Select the active alarm code by touching the flashing red alarm code. The red alarm code will change to steady blue with white text.

3. Select the Acknowledge button located on the bottom right corner of the screen. The alarm code colour will change to white.


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3.3


How to Acknowledge an Alarm Code




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Note: An Alarm code will not disappear after it is acknowledged. To clear an alarm code, the alarm condition must first be rectified and then the alarm code acknowledged by the operator.


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3.4


How to Calibrate the Siemens Touch Screen




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3.4 How to Calibrate the Siemens Touch Screen

The following procedure describes how to calibrate the control panel Siemens touch screen:

1. Cycle power to the touch screen or press Control Panel button located on the main menu screen.

2. Press the Control Panel button on the main menu screen. 3. Double press the OP button. 4. Open the Touch tab and select Recalibrate. The screen will display a prompt that

will take you through each step in the screen calibration.


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3.5


How to Reset the Rig Saver



3.5 How to Reset the Rig Saver The Hydrator has a rig saver installed on the deck engine air intake line. The rig saver is a combustion air shut off valve that is designed to close when an Emergency Shut Down is enabled using the red ESD button on the control panel.

Figure 22 Hydrator Deck Engine Rig Saver

To reset the deck engine rig savers:

First pull the red Emergency Shut Down button to its fully extended position. Then physically locate the rig saver and rotate the control lever 180 to the open position.


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Appendix A The Units Button




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Appendix A The Units Button The Units button is displayed on the top menu bar of every ECAMS screen. It provides the operator with the option to display the input and output field values in metric or U.S. units.

Table 1 Metric and US Units

Measurement Metric U.S.

Pressure MPa PSI

Flow Rate M3/min BBL/min

Engine Speed RPM RPM

Temperature C F

Fuel Rate L/H GPH

Fuel Total L Gal

Power kW hp


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Appendix B Centrifugal Pump Troubleshooting Table 2 is a trouble shooting guide for problems that may occur during centrifugal pump operation:

Table 2 Centrifugal Pump Troubleshooting Guide

Problem Solution The pump will not spin or is very erratic in manual mode.

Switch to automatic mode and look at the pump outputs. If the speed is smoother, the dial is likely to blame. If it does not increase or decrease steadily as you move the dial then the dial needs to be replaced.

If the dial works but there is no output then check for alarms caused by a malfunctioning PLC.

The pump spins on its own when the Pump Output is 0.0

Disconnect power to the Strokers at the pump(s). If the pump continues to spin, the pump Strokers will need to be changed by a qualified mechanic.

Check for a failed suction pump RPM transmitter.


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Appendix C Hydration Unit Control Panel

Figure 23 Hydration Unit Control Panel


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Appendix A The Units Button Appendix B Centrifugal Pump Troubleshooting Appendix A Appendix C Hydration Unit Control Panel

Documents

53375_80_bpm_calfrac_hydration_unit.pdf