dry gel chemical additive system and hydration unit ... · pdf filedry gel chemical additive...

Dry Gel Chemical Additive System and Hydration UnitAccuFrac+ User’s Guide

Introduction to AccuFrac+

DRY GEL CHEMICAL ADDITIVE SYSTEM AND HYDRATION UNIT ACCUFRAC+™ USER’S GUIDE

INTRODUCTION TO ACCUFRAC+™

Rev 1.1.2 Page 1

TABLE OF CONTENTS INTRODUCTION TO ACCUFRAC+

1. Introduction .................................................................................................... 5

1.1 Copyright Notice ................................................................................................. 5

1.2 Translation Notice ............................................................................................... 5

1.3 About This Manual .............................................................................................. 5

1.4 Proprietary Notice ............................................................................................... 5

1.5 Use of this Manual .............................................................................................. 6

1.6 Manual Danger, Warning, Caution, and Note Statements .................................. 6

2. Introduction to AccuFrac+ .............................................................................. 7

2.1 Understanding Dry CAS and Hydration Functions.............................................. 7

2.2 System Access—Profiles .................................................................................... 7

2.3 Logo Screen ....................................................................................................... 8

2.4 System Navigation .............................................................................................. 9

2.5 Home Screen .................................................................................................... 10

3. Using the System Setup Screen .................................................................. 13

3.1 Select Units ....................................................................................................... 14

3.2 AccuFrac Diagnostics ....................................................................................... 16

3.3 HMI Diagnostics ................................................................................................ 18

3.4 View Alarms ...................................................................................................... 20

3.5 Alarm Setup ...................................................................................................... 22

4. Programming a Job ...................................................................................... 23

4.1 Stage Definition ................................................................................................ 23

4.2 Staging .............................................................................................................. 23

4.3 Entering Job Profile for Stages ......................................................................... 23

4.4 Job Summary .................................................................................................... 25

4.5 View Job Totals ................................................................................................ 26

4.6 Edit Chemicals .................................................................................................. 27



Page 2 Rev 1.1.2

5. AccuFrac PDF Bookshelf .............................................................................. 29

5.1 Accessing Documents in the Bookshelf ........................................................... 30

5.2 Managing the Document Library ...................................................................... 31

6. Running a Job .............................................................................................. 33

6.1 Choosing Flow Meters ...................................................................................... 33

6.2 Tank Level Control ........................................................................................... 34

6.2.1 Tank Level Control .................................................................................... 35

6.2.2 Tank Paddles ............................................................................................ 35

6.3 Dry Gel Setup ................................................................................................... 36

6.4 Mix Water Setup ............................................................................................... 39

6.5 Feeding Dry Gel ............................................................................................... 39

6.6 Manual and Auto Chemical Control Mode ........................................................ 41

6.6.1 Manual ....................................................................................................... 41

6.6.2 Auto ........................................................................................................... 41

6.6.3 Base Rates ................................................................................................ 41

6.7 Job Controls .................................................................................................... 41

6.7.1 Start Job ................................................................................................... 41

6.7.2 Hold Stage and Resume ........................................................................... 41

6.7.3 Abort Job ................................................................................................... 42

6.7.4 Next Stage ................................................................................................. 42

6.7.5 Modifying a Running Job ........................................................................... 42

7. Monitoring Trends ......................................................................................... 43

8. Error Conditions ............................................................................................ 47

8.1 Panel Display Alarms ....................................................................................... 47

8.2 System Alarms ................................................................................................. 48

9. Hardware Reference .................................................................................... 49

9.1 Signal Reference Main Control Module ............................................................ 49

9.2 Signal Reference ESX-IOX I/O Module ............................................................ 51

9.3 Signal Reference Closed-loop Control Module ................................................ 53

9.4 Signal Reference Open-loop Control Module ................................................... 54



Rev 1.1.2 Page 3

9.5 Signal Reference Analog Control Module ......................................................... 56

10. Glossary ....................................................................................................... 57

11. Index ............................................................................................................ 59

TABLE OF FIGURES Figure 1, Logo Screen .......................................................................................... 8

Figure 2, Home Screen ...................................................................................... 10

Figure 3, System Setup Screen .......................................................................... 13

Figure 4, Units of Measurement ......................................................................... 14

Figure 5, AccuFrac Diagnostics .......................................................................... 16

Figure 6, HMI Diagnostics .................................................................................. 18

Figure 7, Alarm Viewer Screen ........................................................................... 20

Figure 8, Alarm Setup ......................................................................................... 22

Figure 9, Enter Job Profile for Stage Screen ...................................................... 23

Figure 10, View Job Volumes Screen ................................................................. 25

Figure 11, Job Totals .......................................................................................... 26

Figure 12, Chemical Setup Screen ..................................................................... 27

Figure 13, AccuFrac Bookshelf Screen .............................................................. 29

Figure 14, Open File in the AccuFrac Bookshelf ................................................ 30

Figure 15, AccuFrac PDF Bookshelf Screen ...................................................... 31

Figure 16, Mix Water and Suction Flow Meter .................................................... 33

Figure 17, Tank Level Control Screen ................................................................ 34

Figure 18, Trends Screen ................................................................................... 43



Page 4 Rev 1.1.2

TABLE OF TABLES Table 1, System Navigation Touch Areas ............................................................. 9

Table 2, Home Screen Fields .............................................................................. 10

Table 3, System Setup Screen Icons .................................................................. 13

Table 4, Units of Measurement Fields ................................................................. 15

Table 5, AccuFrac Diagnostics Fields ................................................................. 17

Table 6, HMI Diagnostic Fields ........................................................................... 18

Table 7, Alarm Viewer Fields .............................................................................. 21

Table 8, Enter Job Profile Fields and Navigation ................................................ 24

Table 9, View Job Volumes Fields ...................................................................... 25

Table 10, Job Totals Fields ................................................................................. 26

Table 11, Chemical Setup Fields ........................................................................ 28

Table 12, Flow Meter Fields ................................................................................ 33

Table 13, Tank Level Control Fields .................................................................... 35

Table 14, Trend Fields ........................................................................................ 43

Table 15, Panel (Micro Display) Alarms .............................................................. 47



Rev 1.1.2 Page 5

1. Introduction

1.1 Copyright Notice Unpublished work © 2014 Stewart & Stevenson. The information in this publication, including text, images, and links, which may change at any time, is provided AS IS by Stewart & Stevenson without warranty of any kind, either expressed or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose, or non-infringement. Stewart & Stevenson is a registered trademark of Stewart & Stevenson LLC.

1.2 Translation Notice This operation and maintenance manual is written in English. If the equipment owner translates this manual using in-house personnel or a professional service, then the equipment owner acknowledges responsibility for the accuracy of the translated manual. Stewart & Stevenson assumes no responsibility for unit operation errors, damage to or improper use of equipment, improperly trained personnel, improperly maintained equipment, or failure to follow normal safety precautions outlined in this manual or in the vendor literature that may result from inaccuracies in the translated manual.

1.3 About This Manual Please read through this manual in its entirety before attempting to operate the equipment. Stewart & Stevenson assumes no liability for failure to do so.

All information in this manual is based on the latest production information available at the time of publication. Direct any questions concerning the contents or format of this manual to:

Stewart & Stevenson 611 W. 38th Street

Houston, Texas 77018 Phone: (713) 803-0700

Fax: (713) 803-0721 Email: [email protected]

1.4 Proprietary Notice This work contains the CONFIDENTIAL and PROPRIETARY INFORMATION of Stewart & Stevenson. Neither this document nor any information disclosed herein shall be reproduced in any form, used, or disclosed to others for any reason, including manufacturing, without the expressed written permission of Stewart & Stevenson. All pages of this document are original pages of published material produced on or before the publication release date of September, 2014, unless otherwise noted by a revision (REV) number.

mailto:[email protected]



Page 6 Rev 1.1.2

1.5 Use of this Manual This operations and maintenance manual contains valuable description, operation, maintenance, and troubleshooting information. However, it cannot foresee every eventuality that will arise. While every effort is made to ensure that the information included in this manual is accurate and complete, no guarantee is made to that effect. When a situation of doubt, uncertainty or lacking information exists, the engineering and/or service departments at Stewart & Stevenson should be consulted.

1.6 Manual Danger, Warning, Caution, and Note Statements

Throughout this manual, statements may appear which emphasize important and critical information. These statements will be set off from the rest of the text, and will be formatted and defined as shown.

Indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. This type of statement is limited to only the most extreme situations.

Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

Indicates a potentially hazardous situation, which, if not avoided, could result in minor or moderate injury or serious damage to equipment. It may also be used to alert against unsafe practices.

NOTE: Is used to notify personnel of installation, operation, or maintenance information that is important, but not hazard related.



Rev 1.1.2 Page 7

2. Introduction to AccuFrac+ The AccuFrac+ system, developed by Stewart & Stevenson, controls chemical delivery. Once chemical functions have been pre-programmed into the computer, the system makes it possible for the dry chemical additive system (CAS) and hydration unit (hydrator) to carry out the most complicated stimulation programs without operator assistance during the job. The basic function of the system is to create base fluid and chemical mixtures.

2.1 Understanding Dry CAS and Hydration Functions The dry CAS unit is a skid-, truck- or trailer-mounted assembly designed to produce homogenized oilfield gels from both guar gum powder and traditional liquefied gel concentrated (LGC) chemicals for use in fracturing fluid operations. The unit is capable of operating in temperature ranges of -4 ºF to 122 ºF. If equipped with an optional cold weather kit, the unit can operate in temperatures down to -40 ºF.

A typical frac set-up will have a hydrator which is often in-line between the fluid storage tanks and the blender. Fluid storage tanks or a reservoir at the job site store water used to mix chemicals and gelling agents. The hydrator takes "clean" water from the tanks and then sends the fluid to the blender, where additional chemicals may be added and proppant (sand) are blended together to form the slurry. The resulting slurry discharges to several manifolded frac pumps. These frac pumps are used to pump the final slurry down hole.

2.2 System Access—Profiles A user profile determines the access to screens in the system. Access to some screens requires a username and password. These screen icons appear with a padlock in the lower right corner.

While logged in, the user can access any screen allowed by the account profile. After a period of inactivity, the account is automatically logged out and the logo screen is launched.



Page 8 Rev 1.1.2

2.3 Logo Screen The logo screen is loaded each time the system is started (Figure 1). Touching the logo screen launches the Home screen.

Figure 1, Logo Screen



Rev 1.1.2 Page 9

2.4 System Navigation Navigation through the system is controlled by touch areas shown in Table 1.

Table 1, System Navigation Touch Areas

SYSTEM NAVIGATION

TOUCH AREA FUNCTION

A set of back and forward buttons navigate to the previous screen or forward to the next screen.

The row of tabs across the top of the screen provides easy access to various screens. Tabs from left to right: Home, Job Setup, System Setup, Charts, and Hydration Tank. The active tab has a white background.

The job control commands are available from any screen and are located in a column on the right side of the screen. Use of these buttons does not change the active screen.

Activate the calculator by touching the logo located on the top right of each screen.



Page 10 Rev 1.1.2

2.5 Home Screen The Home screen (Figure 2) is an informational display screen. The information displayed reflects the status of the job in real time.

Figure 2, Home Screen

Table 2, Home Screen Fields

HOME SCREEN FIELDS


FIELD NAME VALUE DEFINITION

State Running Currently running programmed job.

Stopped Job not running.

Viscosity 0–1000 cP Measured viscosity of the hydration fluid. Viscosity is the extent to which a fluid resists a tendency to flow.

pH 0–14 Measured acidity or alkalinity of the hydration fluid on a scale of 0 to 14, where less than 7 represents acidity, 7 neutrality, and more than 7 alkalinity.

Water Temperature °C or °F Measured temperature of the hydration fluid.



Rev 1.1.2 Page 11


Job Progress End of Job Measures remaining job volume.

Stage 1 of X Displays the number of the stage currently running and the number of stages programmed for this job.

End of Stage Measures remaining stage volume.

Suction Rate: gal kgal bbl m3 L

Rate and Total for this stage.

Discharge Rate: gal kgal bbl m3 L

Rate and Total for this stage.

Chemical 1-6 Rate (liquid): gal L Rate (dry): lbs ft3

kg

m3

Rates and Totals for this stage.

Stage Completion Stage number Displays the percentage completion of the stage currently running.

Powder Gate LED Green LED indicates powder gate is

completely open. Gray Led indicates powder gate is half open. Red LED indicates powder gate is closed.

Mix Water Ready LED Green LED indicates mix water is ready. Gray LED indicates mix water is not ready.

Dry Gel Enabled LED Green LED indicates dry gel target rate is above the threshold. Gray LED indicates dry gel target rate is below the threshold.

Dry Gel Mix Water Rate Current flow rate of the mix water.

Dry Gel Mix Water Pressure Current pressure of the mix water.



Page 12 Rev 1.1.2

This Page Intentionally Left Blank



Rev 1.1.2 Page 13

3. Using the System Setup Screen

Select the System Setup icon to select display options and access diagnostic information. The System Setup screen has several functions.

Figure 3, System Setup Screen

Table 3, System Setup Screen Icons

SETTING SCREEN ICONS


ICON NAME FUNCTION

Units of Measure Allows choices of display units for suction/discharge, pressure, proppant, slurry density, liquid chemicals, and dry chemicals.

AccuFrac+ Diagnostics More detailed system information than shown on the Home screen; allows access to HMI diagnostics.

Audit Trail Password protected.

Edit Chemicals User entered chemical names, choice of base rates, bulk density, and control to auto or manual.

Operation Guide Accesses the AccuFrac Bookshelf.



Page 14 Rev 1.1.2

ICON NAME FUNCTION

User Accounts Password protected.

AccuFrac+ Classic Password protected.

Hardware Setup Password protected.

Language Allows selection of the language used on the display. Currently, English and Russian languages are supported.

3.1 Select Units

Touch the Units of Measurement icon from the Settings screen to select the Units of Measurement screen. Next, choose the units for each data type by using the drop-down menus.

Figure 4, Units of Measurement



Rev 1.1.2 Page 15

Table 4, Units of Measurement Fields

UNITS OF MEASUREMENT



Suction / Discharge

gal Gallon – one US gallon.

kgal Kilogallon – 1,000 US gallons.

bbl Barrels – 42 US gallons.

m3 Cubic meters.

L Liters.

Pressure psi Pounds per square inch.

kPa kilopascal; Pascal is the Standard International unit of pressure.

Viscosity cP Centipoise.

Pa S Pascal-second.

Chemicals Rates/ Concentrations

Toggle switch between rates and concentrations for Liquid Chemicals and Dry Chemicals.

Liquid Chemicals gal US gallon.

L Liter.

Dry Chemicals lbs Pounds.

ft3 Cubic feet.

kg Kilograms.

m3 Cubic meters.



Page 16 Rev 1.1.2

3.2 AccuFrac Diagnostics

Touch the AccuFrac Diagnostic icon from the Settings screen to select the AccuFrac Diagnostics screen. This is an informational display screen and shows more detailed information than the Home screen about the job. The information displayed reflects the status of the job in real time.

It also allows access to the HMI Diagnostics screen.

Figure 5, AccuFrac Diagnostics



Rev 1.1.2 Page 17

Table 5, AccuFrac Diagnostics Fields

ACCUFRAC DIAGNOSTICS SCREEN FIELDS


ACCUFRAC+ DIAGNOSTICS


Stage X of Y X Current Stage Y Number of Programmed Stages

The current stage running of the total programmed stages.

Chemical 1-6 Status Auto or Manual or Disabled.

‰ Symbol used to denote concentration. It is equivalent to parts-per-thousand or tenths of a percent. For liquid chemicals it means the units of chemical added to each 1000 units of clean water (i.e., gallons/1000 gallons, liters/m3). For dry chemicals the units are lbs/1000 gallons or kg/m3.

Target Target Concentration.

DAC Digital to Analog Converter count.

Suction Suction rate and total.

Blender Blender rate and total.

Discharge (Optional)

Discharge rate and total.

Dry Gel Weight Load Cells Individual load cell reading.

Total The sum of all load cells.

Zero Zeros empty hopper weight.

Dry Gel Mix Water Measured in BBL/Min.

Measured in PSI.

Vacuum Measured in PSI.

Return to the previous display screen.

Proceed to the HMI Diagnostics screen.



Page 18 Rev 1.1.2

3.3 HMI Diagnostics

Touch the HMI Diagnostics button to access the HMI Diagnostics screen from the AccuFrac+ Diagnostics screen. The HMI Diagnostics screen allows the operator to view the status of the computer interface with the dry gel hydrator and also allows access to the View Alarms screen.

Figure 6, HMI Diagnostics

Table 6, HMI Diagnostic Fields



Internal Temperature Gauge 0–85 °C Internal temperature of the display.

CPU Load Gauge 0–100 Usage of the CPU expressed as a percentage of the total available.

View Alarms Touch to display the Alarm screen.

Set Time & Date Touch to display the set time and date screen. User can set time and date using a calendar and digital clock.

AccuFrac+ HMI Firmware 1.0.3 Displays firmware version.

Controller Firmware 1.0.4 Controller firmware version.



Rev 1.1.2 Page 19



Communication errors 0 represents no communication errors. 1 represents a communication error between the display and the AccuFrac+ controller.

Backlight brightness level 0–100% Backlight strength of the screen.

Current user Login ID for the operator currently logged into to the system.

Physical RAM percent used 0–100% Amount of Random Access Memory currently in use expressed as a percentage of the total available.

Storage memory percent used 0–100% Amount of storage memory currently in use expressed as a percentage of the total available.



Page 20 Rev 1.1.2

3.4 View Alarms

Touch the View Alarms icon from the HMI Diagnostics screen to access the Alarm Viewer screen.

If the system detects an error condition, the alarm indicator appears on the screen. Navigate directly to the Alarm Viewer screen by touching the alarm indicator.

An alarm can be active or inactive, indicating whether or not the error condition is still present. An alarm is acknowledged or unacknowledged indicating whether or not the user has acknowledged the alarm. An alarm no longer displays once it is inactive and acknowledged. A listing of alarms appears in Section 9, Error Conditions.

Figure 7, Alarm Viewer Screen



Rev 1.1.2 Page 21

Table 7, Alarm Viewer Fields

ALARM VIEWER


Setup Press setup to access the Alarm Setup screen.

State Active Error condition currently exists and has not been acknowledged.

Inactive Error condition no longer exists and has not been acknowledged.

Acknowledged Error condition has been acknowledged but error still exists.

Normal Alarm condition ended.

Active Time Month/Day/Year Hour/Minute/Second

Date and time State occurred.

Text System generated Based on the error condition type. See Error Codes table.

Acknowledge Button activated Acknowledge all active alarms.



Page 22 Rev 1.1.2

3.5 Alarm Setup

Touch the Setup button from the Alarm Viewer screen to access the Alarm Setup screen.

The alarm setup screen allows the operator to choose the network device(s) that cause an alarm when an error condition exists. Only those devices present should be checked. Not all units have all devices.

Figure 8, Alarm Setup



Rev 1.1.2 Page 23

4. Programming a Job

4.1 Stage Definition A stage is defined by a volume (i.e. the length or duration of the stage) and targets or set-points for each chemical. The job ends when a zero length stage is reached.

4.2 Staging Stage length can be entered as suction (the amount of clean water entering the unit) or as blender calculated clean rate (the total amount of water leaving the blender minus sand and chemicals).

4.3 Entering Job Profile for Stages

Touch the Job Profile icon to access the Enter Job Profile for Stage. Next, choose the units for each data type by using the drop-down menus.

Beginning with stage 1, enter the volume and chemical targets. The target concentration follows a linear ramp from the Start density to the End density over the volume of the stage. If the Start and End density are equal, the target is held throughout the stage.

Figure 9, Enter Job Profile for Stage Screen



Page 24 Rev 1.1.2

Table 8, Enter Job Profile Fields and Navigation

JOB PROFILE FIELDS


Chemical Adds

Chem 1–6 Target concentration of each chemical during this stage.

Volume BBL Length of stage based on process flow total.

Pressing the Next Stage button advances through the scheduled job stage-by-stage.

If you want to copy all of the current stage’s settings to the next stage, touch the Copy to Next Stage button. You can then edit anything that needs to change and repeat until the final job stage as required.

To back up one stage, touch the Previous Stage button.

You can review the programmed stage volumes and Start and End densities Job Summary.

NOTE: For programming, you can also touch the stage number to skip directly to a particular stage.



Rev 1.1.2 Page 25

4.4 Job Summary

Touch the Job Summary button from the Enter Job Profile for Stage screen to access the Job Summary screen. This display only screen allows you to view the Job Volumes for the completed stages and current stage for the active job. To view totals for the job, touch the View Job Totals button.

Figure 10, View Job Volumes Screen

Table 9, View Job Volumes Fields

VIEW JOB VOLUMES

ICON FUNCTION

Displays the Job Totals screen.

Displays the previous 20 job volumes.

Displays the next 20 job volumes.

Returns the previous display screen.



Page 26 Rev 1.1.2

4.5 View Job Totals

Touch the View Job Totals button from the View Job Volumes screen to access the Job Summary screen. The View Job Totals screen displays the planned and actual totals for the current job. To create a comparison of the programmed job to the actual usage, select the Reset Job Totals on the Start Job feature which automatically resets the totals when the job starts.

Figure 11, Job Totals

Table 10, Job Totals Fields

JOB TOTAL FIELDS

FIELD NAME DEFINITION

Plan Shows the sum of each material required for the current job program.

Actual Total that can be reset at any time by the operator.

Units Expressed in the units selected in Units of Measurement.

Reset on Start Job Automatically resets the totals when the job starts when toggled to the on position.

Resets job totals.

Returns to Job Summary screen.



Rev 1.1.2 Page 27

NOTE: The totals displayed on the Job Totals screen are separate from the totals used by the system to control staging.

4.6 Edit Chemicals

Touch the Edit Chemicals icon from the Settings screen to access the Chemical Setup screen.

Touch the description field and enter the description for the Chemicals 1-6. The description has a 32 character limit.

The Base Rate can be selected from the drop down menu.

User-entered chemical descriptions help the operator by providing a consistent reference. The chemical additives can be labeled in whatever way makes the most sense to the operator. For example, the label can be “Dry Add 1” or “Breaker” or “Chem 5.” The label will appear on all the applicable screens as well as on the individual panel-mounted displays.

Figure 12, Chemical Setup Screen



Page 28 Rev 1.1.2

Table 11, Chemical Setup Fields

CHEMICAL SETUP FIELDS

FIELD NAME FUNCTION

Description Chemical 1–6; User entered chemical name or chemical description. Disabled chemicals do not display. Limit 32 characters.

Base Rate Suction or Blender (External).

Bulk Density Only visible / necessary / meaningful for dry chemicals.

Control User selected; toggle from Manual to Auto. Can also be selected from the smaller panel mounted displays.

Staging Based on Blender volume or suction volume.



Rev 1.1.2 Page 29

5. AccuFrac PDF Bookshelf

Touch the Operation Guide icon to display the AccuFrac Bookshelf. The AccuFrac Bookshelf contains the AccuFrac+ Operations Manual. Use the blue buttons across the top row to navigate through the document.

The bookshelf also has the capability of storing other documents with a .pdf format.

Figure 13, AccuFrac Bookshelf Screen



Page 30 Rev 1.1.2

5.1 Accessing Documents in the Bookshelf

Touch the File Folder icon to display the AccuFrac Bookshelf list of available documents. The AccuFrac Bookshelf contains the AccuFrac+ Operations Manual and any other .pdf format documents loaded. Touch the name of the document to display and touch OK to open the document.

Figure 14, Open File in the AccuFrac Bookshelf



Rev 1.1.2 Page 31

5.2 Managing the Document Library

Touch Manage to display the AccuFrac Bookshelf documents. Move and/or copy documents to and from the Bookshelf to a USB drive using the arrows and the Move and Copy function buttons.

Figure 15, AccuFrac PDF Bookshelf Screen



Page 32 Rev 1.1.2




Rev 1.1.2 Page 33

6. Running a Job

6.1 Choosing Flow Meters The Dry Gel CAS unit can be equipped with up to two (2) suction flow meters and up to two (2) discharge flow meters. To select which flow meter signal is used, touch the FLOW METER button on the panel-mounted suction display or discharge display. The choices are Primary and Secondary (see Section 10, Hardware Reference for complete description).

Figure 16, Mix Water and Suction Flow Meter

Table 12, Flow Meter Fields

MIX WATER METER FIELDS

COMPONENT FUNCTION

Mix Water Meter Screen shows Mix Water Pressure, Auto/Manual status, Rate, and Temp.

Auto/Manual Button Press to toggle the chemical delivery control to either Manual or Auto.

Reset Total Button Not used on this meter.

Display Button Press to select which flow meter to read, primary (magnetic) or secondary (turbine).

Speed Control Knob Allows the operator to adjust the pressure of the Mix Water delivery while in manual mode. Turn clockwise to increase.



Page 34 Rev 1.1.2

SUCTION METER FIELDS

COMPONENT FUNCTION

Suction Meter Screen shows Suction, Auto/Manual status, flow meter selected, Rate, and Total.

Auto/Manual Button Press to toggle the chemical delivery control to either Manual or Auto.

Reset Total Button Press to reset the total volume pumped for the job to zero.

Display Button Press to select which flow meter to read. Primary (Magnetic), Turbine, or Backup.

Speed Control Knob Allows the operator to adjust the pressure of the Mix Water delivery while in manual mode. Turn clockwise to increase.

6.2 Tank Level Control

Touch the icon to access the Tank Level Control screen from the Navigation Bar.

The operator can touch the Tank Level Target Bar for quick adjustments or the up and down arrows for incremental adjustments. The lower half of the screen is display only, with the exception that the tank level target can be entered directly by touching the numeric field.

Figure 17, Tank Level Control Screen



Rev 1.1.2 Page 35

Table 13, Tank Level Control Fields

TANK LEVEL CONTROL FIELDS


Mode Manual or Auto; determined by the selection from the small panel mounted display.

Target Target Percentage of the level of fluid in the tank, 0–100%.

Measured Actual fluid level of the tank.

Output Suction pump speed, 0–100%.

DAC Digital-to-Analog-Converter – controller output to suction pump, 0–4095.

Clean Rate Rate of water being introduced as determined by suction pump speed.

Suction Pressure Pressure in between the suction pump and the tank-inlet valve in units selected from the Units of Measurement screen.

Discharge Pressure Pressure of the discharge mixture after the discharge pump in units selected from the Units of Measurement screen.

6.2.1 Tank Level Control Good tank level control is essential for a successful job.

In Manual mode, the suction rate (and therefore the tub level) is controlled by the operator through a potentiometer. It is completely up to the operator to monitor the level in the tub and adjust the potentiometer accordingly.

In Automatic mode, the control system monitors the tank level via the level sensor and speeds up or slows down the suction pump in order to maintain the target level. The operator sets the target in the Tank Level Control screen.

6.2.2 Tank Paddles Four dual-tier paddles are an essential element of the tank’s mixing energy. These paddles prevent formation of dead zones and increase fluid sheer.



Page 36 Rev 1.1.2

6.3 Dry Gel Setup

NOTE: Steps 1–3 should be performed by trained, authorized personnel.

1. On the Chemical Calibration screen, navigate to Chemical 6 and then select Dry Type. Chemical 6 can only be set to Dry or Disabled for the Dry Gel Hydrator.

2. On the Chemical Calibration screen, set the other parameters accordingly if altered from default settings (Pulses/Revolution, Avg Counts, ft3/revolution, and Offset).



Rev 1.1.2 Page 37

3. On the Chemical PID Control screen, set the RPM limits (Min and Max) for Chemical 6. The minimum limit is used as a threshold to open and close the dry gel powder gate.

4. On the Chemical Setup screen, rename the Chemical 6 description if desired. Then set Bulk Density (typically supplied by Gel vendor) and Base Rate accordingly.

garzam

Oval



Page 38 Rev 1.1.2

5. On the Enter Job Profile for Stage screen, set the Chemical 6 (Dry Gel) load in the job profile for each non-zero stage (i.e., Volume value > 0).

6. On the Dry Gel Auger Delivery micro display, select Auto Control for automatic Dry Gel feeding or select Manual Control for manual Dry Gel feeding.



Rev 1.1.2 Page 39

6.4 Mix Water Setup 1. For normal Dry Gel feeding operation, set the mix water to Auto on the micro

display.

2. When the mix water is set to Manual on the micro display, the mix water pump can be controlled by the potentiometer on the control panel to flush the water pipe. In this case, the Dry Gel feed is disabled.

6.5 Feeding Dry Gel 1. If there are no alarms, the mix water pump starts as soon as the job starts. Within 10

seconds after the mix water pump starts, the water flow will reach a value between 450 gpm and 550 gpm and the water pressure will reach a value between 60 psi and 110 psi.

2. If the water flow and/or pressure do not fall between the above mentioned operating ranges in 10 seconds, the water pump will stop running and alarm(s) will be activated to indicate an error condition.

3. As soon as both the water flow and pressure fall within the operating ranges, the vacuum break valve closes and the Mix Water Ready green LED on the HMI main screen is activated.

4. Ten (10) seconds after the vacuum break valve closes, the Dry Gel feeding is

enabled, provided that the Dry Gel target is above the defined threshold (i.e., RPM Limits Min on the Chemical PID Control screen). The Dry Gel Enabled LED indicator on the HMI screen will turn green if the Dry Gel target rate is above the threshold and will turn off (gray LED) if it is below the threshold.



Page 40 Rev 1.1.2

5. If the Dry Gel target rate is above the threshold, the powder gate will open and the Dry Gel auger starts to spin. If the Dry Gel target rate falls below the threshold, the powder gate will close and the auger will stop. The Powder Gate LED indicator turns red when the powder gate is closed and turns green when the powder gate is completely open.



Rev 1.1.2 Page 41

If the mix water flow and pressure get out of the range (as defined in step #1) for 5 seconds, the Dry Gel feeding will stop (powder gate closes) and an alarm is activated to indicate abnormal water supply. The mix water will keep running, however, for 10 seconds for cleanup. The vacuum break valve will then open 5 seconds later and the mix water will stop.

At any time during the Dry Gel feeding, if the job is stopped by the operator, then the dry gel feeding will stop accordingly. If the job is stopped after the vacuum break valve is closed, the mix water will keep running for 10 seconds for cleanup.

6.6 Manual and Auto Chemical Control Mode

6.6.1 Manual In Manual mode, each chemical additive system is controlled by a potentiometer on the operator panel. The system does not make any adjustments to the chemical rate based on feedback nor does the system adjust if the clean rate changes. Any chemical that is delivered in Manual mode is counted toward a job total for that chemical.

6.6.2 Auto When a chemical additive system is set to Auto mode, the system sets the chemical rate according to the programmed recipe. The system monitors the appropriate base rate and adjusts the chemical rate so that the dosing matches the target.

6.6.3 Base Rates Each chemical additive system allows for two different base rates by which to control the recipe. These are the local suction rate as measured (on the unit on which the chemical pumps or dry add hoppers are mounted), or an external rate originating from other equipment (such as a blender).

6.7 Job Controls

6.7.1 Start Job The Start Job command is used to begin processing the pre-programmed job. If the rate used to control staging is zero, the controller immediately enters a waiting state. As soon as flow is detected, the controller begins controlling to the programmed targets.

6.7.2 Hold Stage and Resume The Hold Stage command will cause the system to hold the current target until the Resume button is pushed. While the job is held, the length of the current stage grows at the same rate as the control volume. The end of job volume is pushed back accordingly.



Page 42 Rev 1.1.2

6.7.3 Abort Job The Abort Job button stops the current job. The programmed job is not affected. Subsequently pushing START JOB will begin the job again from the beginning. There is no way to resume an aborted job.

6.7.4 Next Stage The Next Stage function causes the system to immediately advance to the next stage. The remainder of the current stage is discarded and the operator-programmed value for the length of the current stage is set to the current stage volume.

6.7.5 Modifying a Running Job Changes can be made to a job currently executing. Changes to stages not yet run take effect when the stage runs. If the length of a stage is changed, it will affect the end of job value. Changes to the current stage take place immediately.



Rev 1.1.2 Page 43

7. Monitoring Trends

Touch the icon to access the Monitoring Trends screen from the Navigation Bar.

The Monitoring Trends screen allows the operator to view the trends of a job over time.

Figure 18, Trends Screen

Table 14, Trend Fields

TUB LEVEL CONTROL FIELDS


Return to the previous screen.

Exports data for each of the available variables for trending by the red or blue pen.

Trend 1 - Red Selects which variable trended by the red pen from the top drop down box. Chemical 1 Chemical 2



Page 44 Rev 1.1.2


FIELD NAME DEFINITION Chemical 3 Chemical 4 Chemical 5 Chemical 6

Trend 2 - Blue Selects which variable trended by the blue pen from the bottom drop down box. Chemical 1 Chemical 2 Chemical 3 Chemical 4 Chemical 5 Chemical 6

Span Increment to show on the time line. Values: 30 seconds 1 minute 4 minutes 10 minutes 30 minutes

Zoom in.

Zoom out.

Scroll up.

Scroll down.

Stop scrolling.

Scroll right.

Scroll incrementally to the left.

Pause.

Resume.



Rev 1.1.2 Page 45



Scroll incrementally to the right.

Scroll right.

Scroll to the current time.



Page 46 Rev 1.1.2




Rev 1.1.2 Page 47

8. Error Conditions

8.1 Panel Display Alarms

Table 15, Panel (Micro Display) Alarms

PANEL DISPLAY ALARMS

SYMBOL NAME OF ALARM DEFINITION

Target under range The target is too low. The controller is programmed to run below its low limit.

Target over range The target is too high. The controller is programmed to run above its high limit.

Sensor calibration error The system has detected that the feedback sensor is not properly calibrated.

Output calibration error The system has detected that the control output is not properly calibrated.

Output on, no feedback

The controller is trying to drive the device but not seeing any feedback. The device may be stuck or otherwise non-functioning or the feedback sensor may be malfunctioning.

PID not set The closed-loop control parameters are not properly set.

High limit set to zero The device is effectively disabled because the high limit is set to zero.

Analog output not set The output used to control this device is not set up properly.



Page 48 Rev 1.1.2

8.2 System Alarms An alarm is activated and stored in the display’s alarm database if communication to a network device is disrupted or cannot be established. The following list shows the possible alarm messages.

• I/O Expansion Module Error

• Analog Control Module Error

• Open-Loop Control Module Error

• Closed-Loop Control Module Error

• Main Control Module Communication Error

• Chemical 1 Micro Display Communication Error






• System Micro Display Communication Error

• Tank Paddle Micro Display Communication Error

• Suction Micro Display Communication Error

• Discharge Micro Display Communication Error

• Blender Rate Micro Display Communication Error

• Hydration Rate Micro Display Communication Error

• Hydraulic Pressure Micro Display Communication Error

• Dry Gel Mixer Supply Water Pressure Out of Range

• Dry Gel Mixer Supply Water Flow Rate Out of Range

• Dry Gel Mixer Vacuum Break Valve Open Error



Rev 1.1.2 Page 49

9. Hardware Reference

9.1 Signal Reference Main Control Module

Function Signal Connector Pin Standard

Suction Flow Meter (Primary) Frequency KS2 47 Magnetic Flow Meter

Suction Flow Meter (Secondary) Frequency KS2 28 Low Rate Turbine Flow Meter

Discharge Flow Meter (Primary) Frequency KS2 9 Magnetic Flow Meter

Discharge Flow Meter (Secondary) Frequency KS2 67 Low Rate Turbine Flow Meter

Hydration Tank Paddle 1 RPM Frequency KS2 46 Encoder (300 pulses/rev)




Chemical 1 Feedback Frequency KS1 70 Coriolis Flow Meter or Encoder (360 pulses/rev)






Mix Water Supply Rate Frequency KS1 49 Coriolis Flow Meter or Encoder (360 pulses/rev)

Clean Rate from External Source 4-20mA KS1 67

Mix Water Supply Pressure 4-20mA KS1 9



Page 50 Rev 1.1.2


Suction Pump Hydraulic Pressure 4-20mA KS1 28

Discharge Pump Hydraulic Pressure 4-20mA KS2 65

Vacuum Pressure 4-20mA KS1 68

Load Cell #1 4-20mA KS1 10



Suction Pressure 4-20mA KS2 48

Discharge Pressure 4-20mA KS2 29

Mix Water Hydraulic Pressure 4-20mA KS2 10

Mix Water Temperature 4-20mA KS2 68

Vacuum Break Valve DOUT KS1 32

Powder Gate Open DOUT KS1 33

Powder Gate Close DOUT KS1 51

TX+ Ethernet KS1 61

TX- Ethernet KS1 62

RX+ Ethernet KS1 80

RX- Ethernet KS1 81

CAN1_H CAN BUS KS1 7

CAN1_L CAN BUS KS1 26








Rev 1.1.2 Page 51



TX RS-232 KS1 44

RX RS-232 KS1 63

9.2 Signal Reference ESX-IOX I/O Module


Chemical 1 Potentiometer 0-32VDC ESX-IOX 2






Mix Water Centrifugal Potentiometer 0-32VDC ESX-IOX 8

Powder Gate Proximity Switch (Open) DIN ESX-IOX 9

Powder Gate Proximity Switch (Closed) DIN ESX-IOX 10

Battery Voltage 0-32VDC ESX-IOX 13

Self-Test Wired to Pin 32 ESX-IOX 21

CANopen NodeID

Left floating (open) ESX-IOX 22

pH input 4-20mA ESX-IOX 24

System Air Pressure 4-20mA ESX-IOX 25

Hydraulic Temperature 4-20mA ESX-IOX 26



Page 52 Rev 1.1.2


Open Loop #1 Hydraulic Pressure 4-20mA ESX-IOX 27

Hydrator Suction Pump Potentiometer 0-10VDC ESX-IOX 34

Hydrator Discharge Pump Potentiometer 0-10VDC ESX-IOX 35

CANopen NodeID

Left floating (open) ESX-IOX 36

Mixer/Aux System Hydraulic Pressure 4-20mA ESX-IOX 38

Hydration Tank Level 4-20mA ESX-IOX 39

Viscometer 4-20mA ESX-IOX 40

Open Loop #2 Hydraulic Pressure 4-20mA ESX-IOX 41



Rev 1.1.2 Page 53

9.3 Signal Reference Closed-loop Control Module


Power Gnd - GND 22200470-01 P1

Power Supply + 12/24 VDC + 22200470-01 P2

CAN + CAN BUS 4 22200470-01 P3

CAN - CAN BUS 4 22200470-01 P4

AIN/CAN0 Shield AIN/CAN0 Shield 22200470-01 P5

Address Input A Connect to Power 22200470-01 P10

Address Input B Connect to GND 22200470-01 P11

Address Input C Connect to GND 22200470-01 P12

S90 #1 Pin A, Ground B PWMOUT 22200470-01 P37

S90 #1 Pin D, Ground C PWMOUT 22200470-01 P38













Page 54 Rev 1.1.2

9.4 Signal Reference Open-loop Control Module


Power Gnd - GND 22200470-02 P1


CAN + CAN BUS 4 22200470-02 P3

CAN - CAN BUS 4 22200470-02 P4

AIN/CAN0 Shield AIN/CAN0 Shield 22200470-02 P5

Address Input A Connect to GND 22200470-02 P10

Address Input B Connect to GND 22200470-02 P11

Address Input C Connect to GND 22200470-02 P12

PVG/PVEH Coil 1 Error Pin DIN 22200470-02 P14










PVG/PVEH Coils 1&2 Power DOUT 22200470-02 P32

PVG/PVEH Coils 3&4 Power DOUT 22200470-02 P33

PVG/PVEH Coils 5&6 Power PVG pwr 22200470-02 P34



Rev 1.1.2 Page 55




Chemical 1 Control Signal PVGOUT 22200470-02 P37








Tank Paddle PVGOUT 22200470-02 P45







Page 56 Rev 1.1.2

9.5 Signal Reference Analog Control Module


CAN + CAN BUS 4 ACM 1 10

CAN - CAN BUS 4 ACM 1 11

CAN SHIELD CAN BUS 4 ACM 1 9

Clean Rate Output 4-20 mA ACM 1 2



Rev 1.1.2 Page 57

10. Glossary Base Fluid SG The Base Fluid SG (specific gravity) is a user-entered value that represents the ratio of the density of the fracturing fluid to the density of water. As a ratio, specific gravity is dimensionless (i.e., it has no units). Because the reference fluid (water) has a density of 1.0 gram/milliliter at standard temperature and pressure, it is easy and common to treat specific gravity as equivalent to density measured in grams/milliliter.

The system uses the Base Fluid SG, along with certain proppant characteristics, to convert between concentration and density.

DAC Digital-to-Analog-Converter – A device that converts a number in a computer to a voltage.

Per mille or parts-per-thousand (‰ ) The “per mille” symbol is used to denote concentration. It is equivalent to parts-per-thousand or tenths of a percent. For liquid chemicals it means the units of chemical added to each 1000 units of clean water (i.e., gallons/1000 gallons, liters/m3). For dry chemicals the units are lbs/1000 gallons or kg/m3.



Page 58 Rev 1.1.2




Rev 1.1.2 Page 59

11. Index

A Abort Job ................................................... 42

Accessing Documents in the Bookshelf .... 30

AccuFrac Bookshelf .................................. 29

AccuFrac Bookshelf Screen ...................... 29

AccuFrac Diagnostic Fields ...................... 17

AccuFrac Diagnostic Screen ..................... 16

AccuFrac Diagnostics ............................... 16

AccuFrac PDF Bookshelf Screen ............. 31

Alarm Setup Screen .................................. 22

Alarm Viewer Fields .................................. 21

Alarm Viewer Screen ................................ 20

Auto Chemical Control Mode .................... 41

B Base Fluid SG ........................................... 57

C Calculator ............................ 9, 10, 13, 15, 17

Chemical Setup Fields .............................. 28

Chemical Setup Screen ............................ 27

Clean Rate ................................................ 35

D DAC ..................................................... 35, 57

Digital-to-Analog-Converter ................ 35, 57

Discharge Pressure ................................... 35

Dry CAS Functions ...................................... 7

Dry Gel Setup ............................................ 36

E Edit Chemicals .......................................... 27

Entering Job Profile Screen ...................... 23

Error Conditions ........................................ 47

F Feeding Dry Gel ........................................ 39

Flow Meter Fields ...................................... 33

Flow Meters ............................................... 33

G Glossary .................................................... 57

H Hardware Reference ................................. 49

HMI Diagnostic Fields ............................... 18

HMI Diagnostics ........................................ 18

HMI Diagnostics Screen ............................ 18

Hold Stage and Resume ........................... 41

Home Screen ............................................ 10

Home Screen Fields .................................. 10

Hydration Functions .................................... 7

I Icons .......................................................... 13

Introduction .................................................. 7

J Job Controls .............................................. 41

Job Profile ................................................. 23

Job Profile Fields ....................................... 24

Job Totals Fields ....................................... 26

Job Totals Screen ..................................... 26

L Level sensor .............................................. 35

Logo Screen ................................................ 8

M Managing the Document Library ............... 31

Manual Chemical Control Mode ................ 41

Measured .................................................. 35



Page 60 Rev 1.1.2

Mix Water Meter Fields ............................. 33

Mix Water Setup ........................................ 39

Mode ......................................................... 35

Modifying a Running Job ........................... 42

N Navigation ................................................... 9

Navigation for Job Profile .......................... 24

Next Stage ................................................ 42

O Open File in the AccuFrac Bookshelf Screen

.............................................................. 30

Output ........................................................ 35

P Panel Display Alarms ................................ 47

Parts-per-thousand ................................... 57

Per mille .................................................... 57

Potentiometer ................................ 35, 39, 41

Profiles ........................................................ 7

Programmed recipe ................................... 41

Programming a Job ................................... 23

R Running a Job ........................................... 33

S Set Time & Date ........................................ 18

Setup Screen ............................................ 13

Stage Definition ......................................... 23

Stages ....................................................... 23

Staging ...................................................... 23

Start Job .................................................... 41

Suction Meter Fields .................................. 34

Suction Pressure ....................................... 35

Suction rate ............................................... 35

System Access ............................................ 7

System Alarms .......................................... 48

System Navigation ...................................... 9

System Setup Screen ................................ 13

System Setup Screen Icons ...................... 13

T Tank Level Control .............................. 34, 35

Tank Level Control Fields .......................... 35

Tank Level Control Screen ........................ 34

Tank Paddles ............................................ 35

Target ........................................................ 35

Target concentration ................................. 23

Trend Fields............................................... 43

Trend Screen ............................................. 43

U Units of Measurement ............................... 14

Units of Measurement Fields ..................... 15

V View Alarms......................................... 18, 20

View Job Volumes Fields .......................... 25

View Job Volumes Screen ........................ 25