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JET Manual 24PCM and Hydration

Units

Version 1.0

JET Manual 24 PCM and Hydration Units

InTouch Content ID#: 4221757 Version: 1.0 Release Date: January 31, 2007 Owner: Well Services Training and Development, IPC

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Copyright © 2006 Schlumberger, Unpublished Work. All rights reserved.This work contains the confidential and proprietary trade secrets of Schlumberger and may not be copied or stored in an information retrieval system, transferred, used, distributed, translated, or retransmitted in any form or by any means, electronic or mechanical, in whole or in part, without the express written permission of the copyright owner.

Trademarks & service marks“Schlumberger,” the Schlumberger logotype, and other words or symbols used to identify the products and services described herein are either trademarks, trade names, or service marks of Schlumberger and its licensors, or are the property of their respective owners. These marks may not be copied, imitated or used, in whole or in part, without the express prior written permission of Schlumberger. In addition, covers, page headers, custom graphics, icons, and other design elements may be service marks, trademarks, and/or trade dress of Schlumberger, and may not be copied, imitated, or used, in whole or in part, without the express prior written permission of Schlumberger. A complete list of Schlumberger marks may be viewed at the Schlumberger Oilfield Services Marks page: http://www.hub.slb.com/index.cfm?id=id32083

An asterisk (*) is used throughout this document to designate a mark of Schlumberger.

Other company, product, and service names are the properties of their respective owners.

iii

Table of Contents

JET 24 - PCM and Hydration Unit |

1.0 Introduction 51.1 Learning objectives 6

2.0 Safety Issues 72.1 Personnel safety 82.2 Equipment safety 8

3.0 Introduction to PCM Mixer 93.1 Models of PCM mixers 9

3.1.1 PCM SBF-211 93.1.2 PCM SBF-214 103.1.3 PCM SBF-215 103.1.4 Comparison of PCM mixers 12

3.2 PCM operator responsibilities 143.2.1 Pretrip check 143.2.2 Prejob check 15

3.3 Locating and rigging the PCM 153.4 Location hookup 173.5 Weights and limits 18

4.0 PCM Components 194.1 Slurry gel tank 194.2 Hydration tanks 194.3 Liquid additive tanks 214.4 Centrifugal pumps 214.5 Hydraulic system 224.6 Flowmeters 224.7 Control panel 24

5.0 PCM Operation 295.1 Normal operation 295.2 Shutdown stages 29

5.2.1 Stage I 305.2.2 Stage II 315.2.3 Stage III 32

5.3 Recirculation 336.0 Systems Operation 35

iv | Table of Contents

6.1 Slurry gel system 356.1.1 Pumping gel in normal or recirculating operations 366.1.2 Flushing the slurry gel piping 366.1.3 Unloading slurry gel from the PCM 37

6.2 Hydration system 386.3 LASs 45

6.3.1 Operating the LAS 466.3.2 Zeroing the Micro Motion flowmeters 47

6.4 KCl system 486.5 Pneumatic system 486.6 Lubricant oil system 48

7.0 Continuous Mix Chemistry 497.1 Fluids 497.2 Polymer hydration 497.3 Additives and additive system 50

7.3.1 Liquid additive blends 507.3.2 Mixing blends 507.3.3 Dry additives 50

8.0 J876 and J877 Spill and Disposal Procedures 519.0 Prejob and Postjob Procedures 53

9.1 Pretrip checklist 539.2 Prejob checklist 549.3 Postjob checklist 55

10.0 Services Not Performed by PCM Unit 5711.0 GelSTREAK 59

11.1 Main applications 6011.2 Equipment overview 6011.3 Operator responsibilities 60

11.3.1 Pretrip responsibilities and inspection 6011.3.2 Driving to location 6111.3.3 On location 61

11.4 Environmental 6211.5 Weights and units 62

12.0 Check Your Understanding 63

5JET 24 - PCM and Hydration Units |

1.0 Introduction

Hydration units are used in fracturing treatments. Process-controlled blending equipment that meters and continuously mixes polymer slurry, concentrated potassium chloride (KCl) solution, and liquid additives has made continuous-mix operations a viable alternative to batch-mix operations.

There are several advantages to performing a fracture treatment in continuous-mix mode, using the PCM* precision continuous mixer (Fig. 1-1) for fracturing. Environmental concerns are greatly reduced because only freshwater residuals remain in the fracture tanks after a treatment. Besides eliminating the cost of replacing tank bottoms that have gelled residuals, there is no tank cleaning or disposal costs.

In addition, a more predictable and consistent viscosity is obtained for large treatments because bacteria can degrade the gel viscosity of a batch-mixed fluid before pumping begins.

Figure 1-1. PCM Mixer

Polymer storage bin

Hydration tanks

The continuous-mix process eliminates the need to have gelling crews precede fracturing operations, resulting in direct savings in personnel and equipment.

Finally, viscosities can be easily changed throughout the treatment. This flexibility allows tapering the polymer loading so that fluid damage to proppant conductivities can be minimized or a net pressure limitation can be met.

To ensure that a continuous-mix operation goes smoothly, several requirements must be observed.

For the PCM, the polymers should be of a •liquid or slurried variety to ensure that they can be added at precise concentrations.

6 | Introduction

The GelSTREAK* gel continuous mixing •and hydration unit (see Fig. 1-2) uses dry polymer rather than slurry gel to produce the aqueous gel, thus providing a fluid that is completely free from diesel or oil-based material. The dry polymer is especially designed for very cold environments where it would be impossible to pump liquid slurry.

Figure 1-2. GelSTREAK Gel Continuous Mixing and Hydration Unit

Slurried and dry polymers are hydrated •better and quicker when mixed with process-controlled equipment. Specialized mixing and hydration units provide the metering capabilities, proper shear environment, and sufficient residence time for proper hydration. The hydration process related to time and shear has proved to be extremely important for continuous-mix treatments. If the base fluid has not progressed sufficiently in the hydration process before the fluid is crosslinked, the fluid may experience stability problems.

1.1 Learning objectivesThis job execution training (JET) manual will introduce job operators to the PCM and GelSTREAK hydration units.

After finishing this manual, you should be able to

name PCM and GelSTREAK components•

understand the systems operation of the •PCM and GelSTREAK

understand continuous mix chemistry•

know spill and disposal procedures for the •J876, J877, and J916 additives

know prejob and postjob procedures•

understand basic PCM operation: normal, •shutdown stages, and recirculation

know which services are • not performed by the PCM.


2.0 Safety Issues

Because of the many hazards in the oilfield industry, all Schlumberger employees must be familiar with the appropriate safety regulations and precautions described in the WS Quality Management System - QHSE Standards, InTouch Content ID# 4055049.

Note:Anyone who feels an operation is unsafe has the right and duty to stop the operation.

Note:When handling chemicals, ensure that you know the applicable material data safety sheets (MSDSs) regarding required personal protective equipment (PPE) and handling procedures.

PPE is important, but does not in itself prevent accidents; that is the responsibility of the individual—you. It is vital that your working knowledge of the following be kept up to date and practiced at all times:

Well Services Safety Standard 5: Pressure •Pumping and Location Safety, InTouch Content ID# 3313681

Well Services Safety Standard 9: Pumping •Carbon Dioxide, InTouch Content ID# 3313683

Well Services Safety Standard 11: Pumping •Nitrogen, InTouch Content ID# 3313684.

Note:Well Services Safety Standards are the current safety standards document InTouch Content ID# 4055049. It replaces the Safety and Loss Prevention Manual (SLPM).

You should also be familiar with the following:

Schlumberger QHSE Standard S001: •Journey Management and Driving, InTouch Content ID# 3051691

Schlumberger QHSE Standard S002: •QHSE Reporting, InTouch Content ID# 3260257

Schlumberger QHSE Standard S007: •Management System Audit, InTouch Content ID# 3260262

Well Services Safety Standard 4: Facilities •and Workshops, InTouch Content ID# 3313678

Well Services Safety Standard 5: Pressure •Pumping and Location Safety, InTouch Content ID# 3313681)

Well Services Safety Standard 17: Storage •and Handling of Oxidizers, InTouch Content ID# 3313693

Well Services Safety Standard 18: •Hazcom, InTouch Content ID# 3313694

JET 15 Introduction to Fracturing and •Matrix Treatments, InTouch Content ID# 4221748

8 | Safety Issues

2.1 Personnel safety Follow these safety procedures.

Ensure that all relevant procedures and •standards are followed at all times.

Make certain that PPE is always worn •around the units.

Do not wear any loose clothing or finger •rings.

It is important to remember the dangers of •the heat this unit generates. The exhaust lines, some hydraulic components, and parts of the engine become extremely hot during operation and can cause severe burns.

Be aware of and stay clear of all moving •parts on the unit while it is running.

All nonessential personnel should stay •away from the unit during operation. If it is necessary to climb up on the unit, exercise extreme caution.

2.2 Equipment safetyEquipment should be maintained according to the standard equipment maintenance system (STEM). Print out the full-size STEM form (InTouch Content ID# 4248056), and complete the STEM I, II, and III preventive maintenance checks for the appropriate units at the specified intervals.


3.0 Introduction to PCM Mixer

The PCM mixer (see Fig. 3-1) is a pumping and blending system that enables us to continuously add polymer slurry, a concentrated KCl solution, and up to four other liquid additives simultaneously in a fracturing base fluid. The PCM mixer is a standalone system that can competently hydrate the polymer slurry, and maintain a constant hydrostatic head for a downhole fracturing blender. The PCM can also continuously mix CMHPG (J916) and thermafoam (J584).

Figure 3-1. PCM Mixer

The PCM mixer can continuously mix all of the water-based fracturing liquids by using the guar (J877) or hydroxypropyl gel (HPG) (J876) slurry gels. Fracturing fluids with polymer loadings of 10 to 60 lbm/1,000 galUS may be continuously mixed at rates of 10 to 70 bbl/min. The hydration rates of the fracturing fluid are a function of water temperature and pH.

The PCM mixer

continuously meters and hydrates the •polymer by blending it with water

maintains constant hydrostatic head for the •POD blender

can be used to transport the slurry gel to •the wellsite.

3.1 Models of PCM mixersSeveral models of PCM mixers have been developed over the years.

3.1.1 PCM SBF-211The PCM SBF-211 ws the first model PCM. This pumping and blending system continuously adds polymer slurry, optional concentrated KCL solution, and four other liquid additives to make a fracturing base fluid. The PCM SBF-211 is a standalone system that can hydrate the polymer slurry and maintain a constant hydrostatic head for a POD blender.

The PCM SBF-211 could continuously mix all the water-based fracturing fluids by using the guar (J877) and HPG (J876) slurry gels. Fracturing fluids with polymer loadings of 10 to 80 lbm/1,000 galUS can be continuously mixed at rates of 10 to 70 bbl/min.

The PCM SBF-211 uses 6 interconnected residence tanks that hold approximately 250 bbl of fluid long enough to hydrate the polymer.

The PCM has the following capabilities to store and transport:

four individual liquid additive systems •(LAS). Each LAS has a 345-galUS tank.

1,500 galUS capacity for slurry gel•

optional liquid KCL solution: because of the •volume, the KCL solution is not transported by the PCM SBF-211.

10 | Introduction to PCM Mixer

SBF-211 mixers built before 1998 had two Fischer & Porter 12-in magnetic flowmeters: one for the input rate and the other for the output rate. From 1998, all SBF-211s have been built with two 12-in Johnson Yokagowa magnetic flowmeters. Slurry gel and KCL are added proportionally according to the suction (input) flowmeter.

3.1.2 PCM SBF-214The PCM SBF-214 was the second model of the PCM. All of the general characteristics of SBF 211 are the same, with the exceptions noted in the following paragraphs.

This mixer is built with a CAT C12 engine instead of the Detroit Diesel 8V 92 TA engine that was used in the SBF-211 mixer.

SBF 214 mixers have an updated control mixer. The operator interface is a touch screen computer. It displays the rate in a setpoint, which is communicated by CAN bus daisy-chained to the distributed control mixers (DCUs). Each metering system has one DCU that reads the flow rate for its system, compares it to the setpoint, and adjusts the output command.

Flow rates are communicated by CAN bus back to the touch screen computer for display. The DCU also reads a speed sensor on the metering pump, from which it calculates the tachometer rate.

Currently, the touch screen computer communicates to FracCAT* fracturing computer-aided treatment system via serial link. It will communicate by Ethernet when the wellsite network is implemented.

The suction flowmeter is read by the LSG DCU. The DCU for the liquid additive system 1 (LAS1) reads the discharge flowmeter.

The LAS systems are identical to those in the SBF-211 except that LAS2 has a hydraulic motor with a mixer that is installed on a tote tank lid. A slurried additive can be mixed, kept suspended, and pumped by using this mixer. The additive pumps have lip seals, which are tolerant of slurries. Therefore, no oil is injected to flush LAS 2 pump seals as must be done with the PCM SBF-211 mixers.

3.1.3 PCM SBF-215The SBF-215 is an upgrade to the slurry PCM SBF-214 to handle dry powdered polymer. All the basic functionalities of the slurry PCM mixer were kept. The mixer uses dry polymer rather than slurry gel to produce the aqueous gel (if the fluid is free from diesel or oil-based material) continuously and gravity feeds it to the fracturing blender. It uses the LAS systems.

With the SBF 215 mixer, it is not possible to add polymer to an already hydrated gel. The original mixer could not pump KCl; however, on newer mixers, a KCl pump has been added. Electronic communication of the PCM upgrade requires FracCAT software version 4.3 or above to monitor and record the new dry polymer parameters. The same coaxial cable can be used as PCM SBF-214 mixers use.

The dry polymer is metered by a volumetric feeder that is continuously calibrated by a loss in weight system. The metered polymer is dispersed and mixed through an eductor-based mixing system with the exact amount of water to provide the required loading of the polymer gel. The resulting gel is discharged into the first in-first out (FIFO) hydration tank until hydrated. The steps of gel mixing inside the tank and discharging to a POD blender are identical to those followed for the PCM SBF-214 mixer.

The mixer can continuously mix polymer loadings up to 50 lbm/1,000 galUS, at output rates from 10 to 60 bbl/min. The maximum guar feed rate is 126 lbm/min (equivalent


to 50 lbm/ 1,000 galUS at 60 bbl/min or 60 lbm/ 1,000 galUS at 50 bbl/min); the guar bin can hold and transport 8,000 lbm of dry polymer powder.

The following major components are new to the PCM SBF 215 mixer:

powder polymer storage bin for holding and •transporting the dry polymer and feeding it by gravity to the metering feeder

volumetric metering feeder using •gravimetric automatic calibration (based on load cells)

eductor-based mixing and dilution system •for dispersing and mixing the polymer gel, and for transporting the gel into hydration tank #1

control system for the new components, •including an additional DCU

video camera on the feeder downspout for •monitoring from the touch-screen area

an additional C-pump (powered by the •tractor) so the rate can be increased to 80 bbl/min

recently, a KCl pump.•

The PCM mixer should only be used with polymers intended for continuous mixing, such as J580. Batch mix polymers such as J576 and J424 should never be used in the mixer; they are chemically buffered to delay their hydration, which results in very low hydration percentages if they are used in continuous mixing.


3.1.4 Comparison of PCM mixers Table 3-1 provides a comparison of the different models of PCM mixers.

Table 3-1. Comparison of Different Models of PCM Mixers

SBF211 SBF214 SBF215

Engine 8V-92TA Detroit Diesel; 450 hp at 2,150 rpm

CAT C12: 455 hp at 210 rpm

Suspension Neway Airlift–AR 95-A9 Ridewell Model RAR240-1-8.5-25-USW, #2400308 air ride or equivalent with proper ride height for trailer

Axles DANA–C22AXAX503-275 5 in round, friction weld spindles, 25,000 capacity, 71 1/2 in track

Brakes 16 1/2 x 7 in 16 1/2 x 7-in S-CAM quick change with dust shields

Wheels Webb–six spoke 76209 GCA ACCURIDE 28408 PW ACCURIDE 28408 PW

Fuel tank capacity 140 galUS

Batteries 6 Group 31 6 Group 31 6 Group 31

Length 46 ft 48 ft 48 ft

Width 96 in 102 in 102 in

Height 13 ft, 4 in 13 ft, 6 in 13 ft, 6 in

Fifth wheel 51 in wheelbase clearance 51 in wheelbase clearance 51 in

Flowmeters

Slurry gel flowmeter Micro Motion D-150 (added proportionally according to the suction (input) flowmeter); rate range 2 to 40 galUS/min concentration range 5 to 13.5 galUS/ 1000 galUS

Micro Motion T-100; 1 to 40 galUS/min; backup is the tachometer rate of Waukesha pump.

KCL flowmeter 4-in Fischer and Porter flowmeter (added proportionally according to the suction (input) flowmeter); 1 to 12 bbl/min; 100 to 171 galUS/ 1000 galUS

4-in Johnson Yokogawa magnetic flowmeter; 1 to 12 bbl/min

No KCI

LAS flowmeters Individual Micro Motion D100 mass flowmeters (proportioned to the hydrated gel according to the discharge (output) 12-in flowmeter; .25 to 15 galUS/ min; 0.5 to 5 galUS/100 galUS

Micro Motion T-075; 0.25 to 15 galUS/min



Flowmeters

Input/output flowmeters Units built before 1998 had two Fischer and Porter 12-in magnetic flowmeters; beginning 1998, all units built with two 12-in Yokagowa magnetic flowmeters

12-in Johnson Yokogaw; 0 to 70 bbl/min

Guar metering system Volumetric screw feeder and loss in weight automated calibration

Pumps

C-pump Two 10x12 centrifugal pumps (C-1 and C-2) Two 10x12, maximum rate of 60 barrels per minute at 40 psi (9.54 m3/min at 276 kPa)

LAS metering pump Liquiflo Series 312 that has a rate range of 0.25 to 15 galUS/min; concentration range 0.5 to 5 galUS/1,000 galUS

Waukesha Universal Model 18 with lip seal; rate range 0.25 to 15 galUS/min (concentration can be as high as 15 galUS/1,000 galUS

KCL pump Raven 4 – O/STD with rate 1 to 12 bbl/min; may be bypassed if it fails

Raven positive displacement pump with rate 1 to 12 bbl/ min; may be bypassed if it fails

No KCI system

Slurry gel pump System contains two pumps: 4x5 C-pump and Waukesha metering pump; rate range 2 to 40 galUS/min; concentration range 5-13.5 galUS/1,000 galUS

System contains two pumps: 1. 4x5 C-pump keeps positive pressure on the metering pump; 2. Waukesha Model 30 with Lipseal (some early models have Waukesha 5040 DI pumps); rate 1 to 40 galUS/min

Other

Guar payload 3,630 kg (8,000 lbs)

Slurry load Stores and transports 1,500 gal of slurry; it is divided into two equal 750 gallon compartments, each compartment can be recirculated back into itself, or all 1,500 gallons may be recirculated

Residence tanks 6 residence tanks; holds 250 barrels of frac fluid

Additives 6 additives• 4 liquid additives: store and transport 345 galUS each• KCI (solution not transported by unit)• Slurry gel (1,500 galUS)



Other

Mixers Mixers in compartments 2, 3, 4, and 5. Compartment 5 has two mixers to add shear to the gel and increase hydration rate, and eliminate the dead spaces in the unit (first in, first out principle).

Mixers in compartments 2, 3, 4, and 5. Compartment 5 has two mixers to shear the gel, increasing hydration rate, and prevent new gel from mixing with old gel.

Polymer loading 10 to 60 lb/1,000 galUS; can be continuously mixed at 10 to 70 bbl/min

10 to 80 lb/1,000 galUS can be continuously mixed at 10 to 70 bbl/min

50 lb/1,000 galUS at 60 bbl/ min or 60 lb/ 1,000 galUS at 50 bbl/min

Maximum guar rate 126 lb/min (57 kg/min)

Backup control mode Pneumatic and hydraulic backup on unit

Communication system Equipped with one rate DCU for outputting parameters to recording device

Schlumberger standard CAN bus

Dry polymer feeder 4.2 to 126 lb/min [1.9 to 56.7 kg/min]

Eductor 4 in size (10 bbl/min rate at 40 psi) [0.636 m3/min at 276 kPa]

Load cells Three at 4,000 lbs each

3.2 PCM operator responsibilitiesThe PCM operator sets up and performs all PCM operations, under the direction of the job supervisor (see Fig. 3-2).

Figure 3-2. Operator and Crew Setting Up PCM Mixer

3.2.1 Pretrip checkBefore leaving the district, the operator should complete the following actions:

STEM 1 check: Check all fluid levels.•

Start the engine and run it at idle for •approximately 5 min. Throttle up the engine to full.

Run the mixer for approximately 10 min to •circulate the hydraulics, and ensure that there are no abnormal sounds in the mixer.

Walk around the mixer to look and listen for •any air, hydraulic oil, or lube oil leaks.

Confirm that the bin is lifted to the driving •position and that the outriggers are completely retracted.

Throttle the engine to idle.•


Disengage the power train operations •(PTOs), and then engage the road gear.

Allow the engine to idle for 5 min.•

Shut down the mixer.•

3.2.2 Prejob checkThe PCM operator should perform a prejob check as described in Section 9.1.

3.3 Locating and rigging the PCMFollow these steps for spotting and rigging the PCM mixer.

STEP 01 Move the PCM onsite and spot it as near as possible to the fracturing tanks while allowing enough room to install suction hoses without excessive bending (see Fig. 3-3).

Figure 3-3. PCM Located Near Fracturing Tanks

STEP 02 Chock the wheels.

STEP 03 Lower the four independent legs.

STEP 04 Locate the POD blender near the PCM mixer (see Fig. 3-4).

Figure 3-4. POD Blender Located Near PCM Mixer

STEP 05 Rig up the appropriate hoses to the PCM mixer (refer to WS Safety Standard 5: Pressure Pumping and Location Safety, Section 5.10.3).

Figure 3-5. Hoses Rigged from Fracturing Tanks to PCM Mixer


STEP 06 Rig up a hard 8-in hose from the PCM mixer to the POD blender (see Fig. 3-6).

Figure 3-6. Hose from the PCM Mixer to the POD Blender

STEP 07 Set up and prepare the PCM mixer for operation (see Fig. 3-7).

Figure 3-7. PCM Mixer Setup and Preparation

STEP 08 Mix gel in the PCM mixer compartments (see Fig. 3-8).

Figure 3-8. Gel Mixing in PCM Compartments

STEP 09 Attend a prejob safety meeting with the crew, after the equipment is located and rigged and all materials are available (see Fig. 3-9).

Figure 3-9. Prejob Safety Meeting


3.4 Location hookupThere are three 8-in openings for suction. Two of these are on the road side. The discharge has two 8-in openings located at the rear of the mixer; however, some units can have more 8-in and 4-in connections for the discharge. The overall length of the PCM is 60 ft, and the suction openings are in the middle of the mixer, approximately 30 ft from either end.

Note:Refer to Well Services Safety Standard 5: Pressure Pumping and Location Safety, Section 5.10.3 (InTouch Content ID# 3313681) for requirements for locating and rigging up the PCM unit.

For jobs with rates above 35 bbl/min, care should be taken when locating fracturing tanks and Sand Chief* proppant storage/conveying systems for fracturing. Both sides of the blender must be rigged up and the 8-in hoses do not bend easily. Ideally, the suction connections of the PCM should be in the center of the fracturing tanks so that you will have an even number of hoses to the fracturing tanks. From the blender to the suction connection of the PCM is 40 ft, including the 10 ft for the 8- in discharge hose. The 15 to 20 ft from the fracturing tanks to the PCM is necessary to leave space for the 8-in to 4-in ground manifold for the PCM and the 4-in hoses to the fracturing tanks.

Hard suction hoses must be attached from the fracture tanks to the PCM. The number of suction hoses needed is determined by the rate required for the job. The fracture tank’s manifold can be connected to the PCM by an 8-in hose and up to four 4-in hoses, if necessary.

Note:If there are several fracturing tanks and both water manifolds are needed, use only one manifold at a time. When using both manifolds at once, the front 12-in magnetic flowmeter tends to oscillate.

For fracturing jobs with more than 12 fracturing tanks, a ground manifold or transfer blender should be considered. For this type of job, ground manifolds are preferred.

Note:The recommended maximum rate for the 4-in suction hoses is 8 bbl/min.

For tight locations, split the fracturing tanks and use both sides of the mixer for suction.

Note:Remember to use only one manifold at a time.

For jobs that are less than 35 bbl/min, the spotting of Sand Chief systems and fracturing tanks are not as critical because only one side of the blender has to be hooked up.


3.5 Weights and limits

Note:To allow versatility, the PCM unit’s capacity for additives and slurry gel is significantly greater than the legal limits in many countries. Regulations vary from country to country and you must know the limitations for your location.

Note:It is strongly recommended that you weigh your PCM per axle and know its limitations.


4.0 PCM Components

The PCM unit has the following components (see Fig. 4-1).

Figure 4-1. Components of PCM Unit

Slurry gel tank

Hydration tanks Control panel

Liquid additive tanks

Slurry gel flowmeter

KCL flowmeter

Suction flowmeter

Centrifugal pumps Discharge flowmeter

Hydraulic system

LAS

4.1 Slurry gel tankThe slurry gel tank (see Fig. 4-2) can store and transport 1,500 galUS (5,682 L) of slurry gel. This quantity can be used to mix up to 160,000 galUS of 40 lbm/1,000 galUS of a water-based fluid. It is divided into two 750-galUS compartments. The contents of each compartment can be pumped to the hydration tanks for mixing or recirculation.

Figure 4-2. Slurry Gel Tank

4.2 Hydration tanksThe polymer is mixed with water (hydrated) in the PCM hydration tanks (Fig. 4-3). There are two interconnected tanks. The front tank has four compartments or hydration reactors (Fig. 4-4), numbered 1 through 4 in the order that the fluid flows through them. It holds 150 barrels of gel. The second tank has two compartments, numbered 5 and 6, and it holds 100 barrels of gel.

Compartments 2, 3, 4, and 5 have mixers. The mixers agitate the gel and increase the rate of hydration.

20 | PCM Components

Figure 4-3. Hydration Tanks

Tank 5 Tank 6

Tank 3 Tank 4

Tank 2 Tank 1

Figure 4-4. Compartments in Hydration Tanks

Tank 1Tank 2

Tank 3 Tank 4

Tank 5 Tank 6

Mixer

Mixer Mixer

MixersPCM top view


4.3 Liquid additive tanksFour liquid additive tote tanks are located at the rear of the trailer store and transport additives (see Fig. 4-5). These tanks are numbered 1 through 4. Tanks 1 and 3 are located on the road side of the PCM. Tanks 2 and 4 are on the curb side. Each tank has a 345-galUS capacity and can discharge up to 15 galUS/min.

Figure 4-5. Liquid Additive Tote Tanks

Figure 4-6. Pumps on PCM Mixer

Main suction pump

C1

C2

4.4 Centrifugal pumps The PCM has two centrifugal pumps (C-pumps) for suction and mixing (C1 and C2). The C1 pump is the main suction pump (see Fig. 4-6). It begins the hydration process by pumping water from the fracturing tanks into the PCM and to the hydration compartments. The C2 pump, the second centrifugal pump, recirculates the contents of the compartments 5 and 6 of the hydration tank. It can also perform the functions of the main suction pump if necessary.

22 | PCM Components

4.5 Hydraulic system The PCM hydraulic system, shown in Fig. 4-7, controls

auxiliary hydraulics (LAS* liquid additive •system and slurry gel hydraulics)

C1 pump hydraulics•

C2 pump hydraulics.•

The auxiliary hydraulics operates when the deck engine is started. The other hydraulics operates when the engine clutch is engaged.

Figure 4-7. PCM Hydraulic System

In Fig. 4-7, the labels correspond to the following descriptions:

1-LAS and slurry gel hydraulics: controls liquid additives and slurry gel system

2-KCl and mixer hydraulics: controls liquid additives and slurry gel systems

3-C2 pump hydraulic: controls the C2 centrifugal pump

4-C1 pump hydraulics: controls the C1 centrifugal pump

4.6 Flowmeters Flowmeters meter the slurry gel and liquid additives, enabling the correct proportions to be added to the fracturing fluid. The PCM has eight flowmeters (see Figs. 4-8 through 4-11) and can meter up to six different additives. The slurry gel and KCl are metered by the suction flowmeter located in the main intake pipe of the underside of the hydration system. The liquid additive system is metered by the discharge flowmeter located at the discharge line under the rear of the trailer. All the flowmeters have backup systems (tachometer rates).

Figure 4-8. Input Flowmeter on PCM

Input flowmeter just before C1

Figure 4-9. Slurry Flowmeter on PCM

Slurry flowmeter


Figure 4-10. Add 4 Flowmeter on PCM

Add 4 flowmeter

Figure 4-11. Add 2 Flowmeter on PCM

Add 2 flowmeter

24 | PCM Components

4.7 Control panelThe PCM control panel, shown in Fig. 4-12, is located in the operator station. The panel layout has three sets of controls: input section, output section, and auxiliary functions. Inside the control panel are two controllers that enable the system to operate valves and other PCM functions. (The left controller controls the KCl systems, slurry gel, and additive 1 rates.) The right controller controls additives 2, 3, and 4.

Figure 4-12. PCM Control Panel


The input section of the panel highlighted in Figure 4-13 consists of the input displays, KCl and slurry gel controls and displays, and calibration switch and knob. The calibration procedure also performs a system verification check. The calibration switch can also be used as a backup if a flowmeter fails.

Figure 4-13. Input Section Control Panel

26 | PCM Components

The output section of the control panel, highlighted in Fig. 4-14, consists of controls and displays for:

fluid discharge rate•

cumulative volume•

liquid additives.•

The LAS are metered proportionately to the output flowmeter. The control panel layout and basic operation of the liquid additive systems are the same as those of the slurry gel system controls.

Figure 4-14. Output Section Control Panel


The auxiliary section of the control panel, highlighted in Fig. 4-15, controls the auxiliary equipment.

Figure 4-15. Auxiliary Section Control Panel

28 | PCM Components

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5.0 PCM Operation

The PCM mixes slurry as described in the following sections.

5.1 Normal operationIn normal operation (see Fig. 5-1), water is sucked from the fracturing tanks by the C1 pump and discharged into compartment 1. Compartments 1 and 2 are connected from below, as are compartments 3 and 4. There are gates between compartments 1 to 4 and 5 to 6. These are closed during normal operation. Fluid passes from compartments 1 to 2 (underneath), from to 2 to 3 (on top), from 3 to 4, from 4 to 5, and then finally from 5 to 6. Fluid does not go from compartment 1 directly to 3, nor from 2 to 4.

Figure 5-1. PCM Mixer Operation

1 65432

V15

G1

V16

V13AC1

V17 C2

V14V18

V19

V23

V21

G2

V20V22

V13B

Flow meter

To POD

From add tanks

1 2 3 4

From slurry system

Flow meter

From fracture tanks

C-pump 1 discharge pressure

Fill and

shutdown

Stage II and

Stage III

Fill and

Stage III

Normal operation

Stage I Stage I and

Stage II

The fluid in compartment 4 then flows to compartment 5. The C2 pump draws fluid from compartment 5 and discharges it to compartment 6. It then flows back over into compartment 5. This flow helps the hydration of the gel and also maintains a constant hydrostatic pressure for the suction of the POD blender.

5.2 Shutdown stagesThere are specific steps to drain the fracturing fluid from the PCM, called shutdown stages. These stages ensure that the batches of hydrated gel leave the unit in the same order that they were mixed (first in, first out).

30 | PCM Operation

5.2.1 Stage I When the supervisor determines that there is sufficient fracturing gel to complete the job, the PCM operation switches to Stage I of the shutdown procedure (see Fig. 5-2).

The water from the fracturing tanks is shut off. The fluid from Compartments 1 and 2 are pumped to Compartments 3 and 4 by the C1 pump. The mixers in Compartments 2, 3, and 4 are turned off.

The slurry gel system is flushed with diesel.

Figure 5-2. Shutdown Stage I for PCM Mixer

1 65432

V15

G1

V16

V13AC1

V17 C2

V14V18

V19

V23

V21

G2

V20V22

V13B

Flow meter

To POD

From add tanks

1 2 3 4

From slurry system

Flow meter

From fracture tanks


Fill and

shutdown

Stage II and

Stage III

Fill and

Stage III

Normal operation

Stage I Stage I and

Stage II


5.2.2 Stage IIDuring Stage II shutdown (see Fig. 5-3), the gate between Compartments 1 and 4 is opened. The fluid from these tanks is pumped to Compartment 5 by the C1 pump.

When all of the fluid is in Compartment 5, the mixer in Compartment 5 is turned off. The fluid is then pumped from Compartment 5 to Compartment 6 by the C2 pump.

When Compartment 5 is empty, the C2 pump is turned off. Fluid is continually fed to the POD blender from Compartment 6 until the compartment is empty.

Figure 5-3. Shutdown Stage II for PCM Mixer

1 65432

V15

G1

V16

V13AC1

V17 C2

V14V18

V19

V23

V21

G2

V20V22

V13B

Flow meter

To POD

From add tanks

1 2 3 4

From slurry system

Flow meter

From fracture tanks


Fill and

shutdown

Stage II and

Stage III

Fill and

Stage III

Normal operation

Stage I Stage I and

Stage II

32 | PCM Operation

5.2.3 Stage IIIStage III is not a normal shutdown procedure (Fig. 5-4).

It is used

when the job requires more fluid than the •PCM has on board

for fracturing water breakdown.•

If the job requires fracturing water breakdown before the fracturing treatment, Compartment 1 is bypassed and the fracturing fluid is pumped from the fracturing tanks into Compartment 5 by the C1 pump. During Stage III, the levers on the control panel are moved in sequential order from left to right.

The levers must first be in Stage II positions before being moved to Stage III positions.

Figure 5-4. Shutdown Stage III for PCM Mixer

1 65432

V15

G1

V16

V13A C1

V17 C2

V14

V18

V19

V23

V21

G2

V20V22

V13B

Flow meter

To POD

From add tanks

1 2 3 4

From slurry system

Flow meter

From fracture tanks


Fill and

shutdown

Stage II and

Stage III

Fill and

Stage III

Normal operation

Stage I Stage I and

Stage II


5.3 Recirculation The recirculation of fluids and additives (see Fig. 5-5) is used to

check the system before starting any •mixing procedures.

prime the pumps on the different pieces of •equipment. Priming removes air from the piping, which can affect fluid flow.

increase the velocity of the fluid and •prevent the additives from clogging the lines and pumps.

Figure 5-5. Recirculation in PCM Mixer

V26

V24

V25 P3

V26

V24

V25 P3

V26

V24

V25 P3

V26

V24

V25 P3

Flow meter

Flow meter Flow

meterFlow meter

34 | PCM Operation



6.0 Systems Operation

This section discusses how to operate the PCM mixer systems.

6.1 Slurry gel systemThe slurry gel system mixes the slurry gel ingredients before they are hydrated. The following are the major components of the slurry gel system (see Fig. 6-1).

flush tank: 30-galUS diesel tank used for •flushing the slurry gel piping

slurry gel tank: 1,500-galUS tank used for •transporting and storing slurry gel

P-1: the 4x5 centrifugal pump that •keeps positive pressure on the metering pump, recirculates the slurry gel via the recirculation line, and is a backup to the metering pump

P-2: the main metering pump, a Waukesha •metering pump

Figure 6-1. Slurry Gel System

Flush tank

Slurry gel tank

V3

V2

V1

V4 V5

P1

V8

V7

V9V10

P2 FM1

V11

V6 To PCM plumbing

FM1: the Micro Motion™ D-150 flowmeter •for the slurry gel

V1: the manual flush tank valve•

V2: the manual 3-way slurry gel •compartment valve to direct flow to either slurry gel tank compartment

V3: the manual slurry gel fill-up valve•

V4 and V5: manual suction slurry gel •suction valves for each slurry gel tank compartment

V6: slurry injection 3-way valve at the C-1 •centrifugal pump injection point

V7: the air-actuated liquid slurry gel (LSG) •supply valve that separates the centrifugal pump from the metering pump. Allows the slurry gel to be recirculated without using the metering pump or the flowmeter

V8: manual recirculation valve•

36 | Systems Operation

V9: Waukesha by-pass valve that allows •slurry gel to bypass the metering pump

V10: pressure relief valve. If the line plugs •up, the discharge from the pressure relief valve flows to the ground between the hydration tank and the rear tractor tires

V11: air-actuated, 3-way, recirculate-normal •valve for recirculation or normal flow of the slurry gel downhole or into the PCM hydration tanks.

6.1.1 Pumping gel in normal or recirculating operations

The only difference between normal and recirculating operations is the position of the 3-way valve (V11) in Step 8.

The following is the step-by-step procedure for pumping gel (refer to Fig. 6-1 for the location of the valves):

STEP 01 Turn air on.

STEP 02 Start deck engine.

STEP 03 Set the 3-way valve (V2 in Fig. 6-1) to the compartment with the slurry gel that you want to use first.

STEP 04 Open the suction valve (V4 or V5) corresponding to the slurry gel compartment you set V2 to.

STEP 05 Turn P-1, the 4x5 pump, on.

STEP 06 Open the C-pump recirculation valve (V8).

STEP 07 Close the bypass valve (V9).

STEP 08 Set the normal or recirculating valve (V11) on normal or recirculate.

STEP 09 Engage hydraulics.

STEP 10 (Optional) If you need to check that all charge pump pressures were normal, or if you are using more than one system (recirculating slurry gel and add system), you may find it necessary to engage high idle. If so, set the throttle on high idle.

STEP 11 Manually turn on the Waukesha valve (V9). This valve is used only when it is necessary to bypass the pump.

STEP 12 Open valve 7.

The slurry gel is injected into the 12-in plumbing between the 12-in suction flowmeter and C-1, by way of a 1 1/2-in rubber hose (the normal slurry gel line). The normal slurry line has two check valves in the line: a mechanical check valve at the end of the hose and a rubber check valve on the end of the knock-off unit (inside the 12-in plumbing).

6.1.2 Flushing the slurry gel pipingThe slurry gel settles out after some time. It is recommended to flush the entire slurry gel system with diesel after each job. The best time to do this is during the shutdown stage.

Follow these steps to flush the slurry gel system (refer to Fig. 6-1 for the location of the valves):

STEP 01 Put a bucket on the ground to catch the diesel.

STEP 02 Stop bringing on water.

STEP 03 Close suction valves (V4 and V5).

STEP 04 Open flush tank (V1).

STEP 05 Close recirculating line valve (V8).


STEP 06 Manually bring the Waukesha valve to a rate of 12 to 15 galUS/min (with the LSG valve, V7, open).

STEP 07 Pump until there is a good diesel flow at the end of normal slurry gel line (by C-1); this is done by opening the manual 3-way valve (on the end of the slurry gel line) to direct flow on the bucket on the ground.

STEP 08 Switch from normal to recirculate (V11).

STEP 09 Open the recirculate line valve (V8).

STEP 10 Pump 5 to 8 sec.

STEP 11 Close flush tank (V1).

STEP 12 Close LSG valve (V7).

STEP 13 Manually turn off the Waukesha pump.

STEP 14 Dispose of the diesel and slurry in an approved location. Your location should have documentation of the location with the local regulations.

6.1.3 Unloading slurry gel from the PCMSlurry gel may be transferred from the PCM by using the auxiliary hydraulics, and bypassing the Waukesha pump and Micro Motion flowmeter. When transferring gel, follow this procedure (refer to Fig. 6-1 for the valve locations):

STEP 01 Open manual suction valves (V4 and V5).

STEP 02 Close recirculating line (V8).

STEP 03 Close LSG valve (V7).

STEP 04 Turn 4x5 C-pump on (P-1).

STEP 05 Transfer the slurry gel through the 4-in inspection cap (located on the discharge side of 4x5 C-pump, P-1).

STEP 06 All lines should be flushed to prevent plugging.


6.2 Hydration systemThe hydration system mixes fluid from the fracturing tanks with slurry gel to increase the viscosity of the fracturing fluid.

The following are the components of the hydration system (see Fig. 6-2).

slurry gel tank: 1,500-galUS tank used for •transporting and storing slurry gel

KCl metering pump: KCl system•

KCl flowmeter: KCl system. The flowmeter •may be used to meter other additives at a high rate

suction flowmeter: flowmeter to meter the •water flowing from the fracturing tanks into the PCM

Figure 6-2. Hydration System

Slurry gel tank

KCL metering pump

KCL flowmeter

Suction

V12

Suction flowmeter

V15 V16

G1

V13A

V13B V17

V14

V18

V19 V21

V23

V20

C-1 C-2

G2V22

Discharge flowmeter

Discharge

Liquid additives

1 2 3 4 5 6

C-1: C-pump used as suction pump and to •provide shear to the hydration process of the fracturing gel

C-2: C-pump used to circulate fluids in •compartments 5 and 6, which maintains a constant hydrostatic pressure in compartment 6 for suction into the POD blender. May also be used as a backup for the suction pump.

discharge flowmeter: meters the fluid •discharge from compartment 6 of the hydration tank to the POD blender

V12: metering pump by-pass valve•


V13A, 13B: two air-actuated valves •connected together, but out of phase. When one valve is open, the other is closed. Valve 13A allows suction from the fracturing tanks for main suction pump (C-1). Valve 13B is used for Stage I and Stage II shutdowns.

V14: manual discharge valve for the suction •pump (C-1). It is open during normal operation. If the pump fails, the valve will be closed.

V15: manual valve 15 located in •compartment 1 by the control panel and used to control the rate and backpressure on the main suction pump (C-1).

V16: air-actuated valve located in •compartment 1. It is closed during normal operation and open during Stage I shutdown.

V17: manual valve used to separate C-1 •and C-2 pumps. It is located between the two hydration tanks. The valve is normally closed unless C-1 fails. Then it is opened to allow C-2 to function as the suction pump.

V18: manual valve located between the two •hydration tanks above the hydraulic heat exchangers on the curb side. It is normally closed unless C-1 fails. Then it is opened to allow C-2 to pump fracturing fluid into compartment 1.

V19: air-actuated valve between the first •and second hydration tanks. It is closed during normal operation and open for stage I, II, or III shutdowns.

V20: manual suction valve for second •centrifugal pump (C-2). It is located under compartment 5 on the curb side. It is normally open except when C-1 fails. Then it is closed so C-2 can get suction from the fracturing tanks.

V21: air-actuated fill valve for •compartment 6. It is opened to allow C-2 to discharge into compartment 6. Otherwise,

it is normally closed. If C-1 fails, C-2 will discharge into compartment 1.

V22: air-actuated valve located in the •discharge line from compartment 6. The valve can be closed to isolate the fracturing fluid.

V23: air-actuated valve used to pressurize •the discharge.

Note:It is necessary to maintain a discharge pressure of 15 to 20 psi on V23 to prevent cavitation, a vacuous space in the pump, and failure of the suction pump.

Before the hydration process can begin, hard suction hoses must be attached from the fracturing tanks to the PCM unit (see Fig. 6-3). The number of suction hoses needed is determined by the rate required for the job. One 4-in suction hose is needed for every 5 to 8 bbl/min. One 8-in suction hose can be used for every 32 bbl/min (review WS Standard 5, Section 5.10.3).

Figure 6-3. Hard Suction Hoses from Fracturing Tanks to PCM Mixer


Note:Safety and loss prevention standards require that hard hoses be used for suction.

The hydration system process is as follows.

The main suction pump brings fluid 1. from the fracturing tanks into the PCM hydration tanks (see Fig. 6-4).

Figure 6-4. Hydration Process: Fluid Brought from Fracturing Tank by Main Suction Pump

Slurry gel tank

KCL metering pump

KCL flowmeter

Suction

V12

Suction flowmeter

V15 V16

G1

V13A

V13B V17

V14

V18

V19 V21

V23

V20

C-1 C-2

G2V22

Discharge flowmeter

Discharge

Liquid additives

1 2 3 4 5 6Fracture

tanks


The slurry gel is then added to the line 2. and pumped by the C-1 suction pump into Compartment 1 (see Fig. 6-5).

Figure 6-5. Hydration Process: Slurry Gel Added by the C-1 Suction Pump

Slurry gel tank

KCL metering pump

KCL flowmeter

Suction

V12

Suction flowmeter

V15 V16

G1

V13A

V13B V17

V14

V18

V19 V21

V23

V20

C-1 C-2

G2V22

Discharge flowmeter

Discharge

Liquid additives

1 2 3 4 5 6Fracture

tanks


The fluid is blended by the mixers as 3. it moves through the Compartments. The mixing agitates the gel, increasing the hydration rate and eliminating dead spaces in the line (see Fig. 5-6).

Figure 6-6. Hydration Process: Fluid Blended by Mixers

Slurry gel tank

KCL metering pump

KCL flowmeter

Suction

V12

Suction flowmeter

V15 V16

G1

V13A

V13B V17

V14

V18

V19 V21

V23

V20

C-1 C-2

G2V22

Discharge flowmeter

Discharge

Liquid additives

Fracture tanks


The fluid is recirculated between 4. Compartments 5 and 6 (see Fig. 5-7).

Figure 6-7. Hydration Process: Fluid Recirculated Between Compartments 5 and 6

Slurry gel tank

KCL metering pump

KCL flowmeter

Suction

V12

Suction flowmeter

V15 V16

G1

V13A

V13B V17

V14

V18

V19 V21

V23

V20

C-1 C-2

G2V22

Discharge flowmeter

Discharge

Liquid additives

Fracture tanks


The fluid can be discharged from 5. Compartment 6 to the POD blender (see Fig. 5-8).

Figure 6-8. Hydration Process: Fluid Discharged from Compartment 6 to the POD Blender

Slurry gel tank

KCL metering pump

KCL flowmeter

Suction

V12

Suction flowmeter

V15 V16

G1

V13A

V13B V17

V14

V18

V19 V21

V23

V20

C-1 C-2

G2V22

Discharge flowmeter

Discharge

Liquid additives

Fracture tanks


6.3 LASsThe LASs (Fig. 6-9) can blend up to four different additives. Each liquid additive system has a Micro Motion D-100 mass flowmeter. There is also a tachometer that can be used as a metering backup. The system can circulate the additives back to the tote tanks to remove air when priming up the metering pumps or to ensure that the additives are evenly mixed. The plumbing of each liquid additive system is identical.

The following are the components of the liquid additive system:

tote tank: connected to the vent line and •recirculation line by a connection cross

sight glass: used to calibrate the PCM•

P3: Waukesha meter pump•

FM: 5 to 8 flowmeters that measure the •flow rate of the fluid for the LAS

Figure 6-9. LAS

Vent line

Recirculation line

Discharge to plumbing

Vacuum relief

Pressure relief

V27

To ground

V24

Tote tank

V25

Sight glass

Pressure relief

P3 FM 5 to 8 flow

meters

V26

V28

V25: drain valve used to drain excess •liquids or add fluids to the tote tank

V26: recirculate/normal valve that directs •the fluid to either recirculate back into the tote tank or discharge to the PCM discharge

V27: vent valve•

Note:Safety standards require that the vent valve be open when the liquid additive system is in use and closed while in transit.

V28: check valve on the line that delivers •additive to the POD to prevent fluid from returning to the liquid additive system tanks

pressure relief valve: relieves pressure •from inside the system if it exceeds a set operating pressure


vacuum relief valve: relieves pressure if •vacuum exceeds operating limit

level indicator: the hose on the front of •the tank is used as a level indicator. It is attached to a drain valve (V25) that is used to drain excess liquid or add additional fluids to the tote tank

recirculation hose: the top hose on the •connection cross. It is connected to the air-actuated recirculate/normal 3-way valve (V26) This valve directs the flow to either recirculate back into the tote tank or discharge to the PCM discharge. A check valve (V28) is on the line that discharges to the PCM discharge. It prevents fluid from coming back to the liquid additive system tanks. The connection cross has a nipple welded inside that allows fluid to bypass the vent hose when recirculating.

6.3.1 Operating the LASThe steps to operating the LAS are as follows (refer to Fig. 6-9 for the location of the components).

STEP 01 Open tote tank supply valve (V24).

STEP 02 Open vent valve (V27).

STEP 03 Remove the threaded cap from the top of the totes to eliminate the chance of damaging the tote if the vent valve plugs or malfunctions.

STEP 04 Set the recirculate/normal valve (V26) to recirculate.

STEP 05 Dial ratio on console for desired liquid additives.

Note:Prime-up and zeroing the flowmeters is done as part of the prejob checklist; see Section 6.3.2.

STEP 06 Put liquid additives into manual mode.

Note:The add pump must be started before circulating in the manual mode.

STEP 07 Turn manual knob to the desired flow rate.

STEP 08 Circulate for 30 to 45 sec.

Note:Ensure the LAS is free of air and the liquid is evenly mixed.

STEP 09 Shut pump off.

STEP 10 Zero the Micro Motion sensor (see Section 6.3.2).

STEP 11 Set the manual/auto switch to auto.

STEP 12 Set V26 to normal before job startup.


Note:If a rate is input to the output flowmeter, you can set the adds to ratio and switch the mode to auto, and the add pumps should start to move chemicals at the desired rate.

The LAS is now ready to pump automatically. It will start pumping downhole as soon as the discharge flowmeter shows a rate.

6.3.2 Zeroing the Micro Motion flowmeters

The Micro Motion flowmeters must be zeroed before every job to ensure accurate readings.

The control buttons for zeroing the Micro Motion flowmeters are located below the operator’s control panel (see Fig. 5-10).

Figure 6-10. Micro Motion Flowmeter Zeroing Control Buttons

Zeroing control buttons LEDs

Before zeroing the flowmeters, the LAS and slurry gel system must be free of air and no fluid can be circulating through the unit.

First, fluid is circulated through the systems to disperse the air. Then the fluid is stopped, and the flowmeters are zeroed by pushing the control buttons.

The LED flashes once per second if the zeroing is correct and the rate displays on the control panel show turns to zeroes.

If the zeroing is incorrect, the LED flashes four times per second and the rate displays on the control panel show erratic readings.

To check that the flowmeter is zero, complete the following steps:

Run the additive system and 1. recirculation at 2 to 5 galUS/min for 1 min.

Stop the additive pump.2.

Immediately climb down.3.

Close the C-pump circulation and the 4. tank valve and sight gauge valve to prevent the fluid from emptying out of the flowmeter.

Check that the density is constant within 5. ± 0.01 sgu, and that the flow rate is constant within ± 0.05 galUS/min.

Check the flow rate and density on the 6. transmitter, not the operator console. If either varies, the flowmeter is not full.

When both flow and density are stable, 7. check the indicated flow rate in the transmitter.

If flow and density are not stable, do not 8. zero, reprime the system.


6.4 KCl systemThe PCM can meter a concentrated KCl solution. The KCl system uses a positive displacement pump as the metering pump (rated to 12 bbl/min at 500 rpm). A magnetic flowmeter is used to monitor the KCl flowrate. The KCL solution is injected upstream of the 12-in input flowmeter. The input flowmeter measures both the KCl rate and clean fluid rate.

The PCM does not haul or store the KCl solution. There are two 4-in suction openings with a single 4-in opening on each side of the unit to draw in the KCl solution through. Because there is a single 4-in suction opening per side, the recommended rate for the KCl solution is 5 to 8 bbl/min.

6.5 Pneumatic systemThe pneumatic system serves the following four functions:

supplies pressurized air to the force feed •lubrication system

supplies air flow to control console cooling •system

uses pressurized air to actuate engine •operating controls

uses pressurized air to actuate process •piping valves.

6.6 Lubricant oil systemThe PCM is equipped with pumping components that require continuous lubrication. Among these are two 10x12 C-pumps, one 4x5 C-pump, gear pumps, and a Waukesha pump. There are two reasons for lubricating these components. The primary reason is to reduce the friction and thereby reduce the amount of heat generated and the wear on the pumps. The second reason is to prevent solids from entering the bearings and seals.


7.0 Continuous Mix Chemistry

The chemistry of the continuous mix is critical to perform a successful treatment.

7.1 FluidsSchlumberger offers a variety of fluid types to meet various treating conditions. The majority of these fluids are based on two polymer systems: guar and hydroxypropyl guar (HPG). With each polymer system, several different gelling agent systems are available that have been optimized for specific applications.

To facilitate continuous mix operations, two slurriable guar and HPG gelling agents were developed. J456 is a slurriable HPG while J457 is a guar-based system. Both of these gelling agents consist of fast-hydrating versions of each polymer and suspending agents. When mixed 50/50 with diesel, U51, these gelling agents form concentrated polymer slurries that rapidly hydrate, are readily pumpable, and easily disperse.

The slurries designated J877 and J876, respectively, for the guar and HPG versions, are used to prepare Waterfrac 100 (WF100) and Waterfrac 200 (WF200) fluids for both batch and continuous mix applications. These Waterfrac fluids may be crosslinked to produce all current guar or HPG-based fluids and also CMHPG fluids (J916).

7.2 Polymer hydrationPolymer hydration is the process by which polymer particles absorb water and dissolve to viscosity the fluid.

The process begins with the dispersion of the polymer, which is usually accomplished by intense mixing. Ideally the polymer should be dispersed as individual particles. Once the particles are dispersed, water begins to diffuse into the polymer particles. The rate of diffusion is determined by the temperature and particle size and is not affected by shear.

Upon entering the particles, the water molecules begin to interact with the polymer. The polymer-polymer interactions, which hold the particle together, are replaced by water-polymer interactions. This is the essence of the hydration of dissolution process.

The primary factors affecting the hydration of the J876 and J877 slurry gel systems are

the mix water temperature•

the time and intensity of mixing•

the fluid pH.•

In general, hydration can be increased by increasing the mix water temperature, mixing intensity, or mixing time. Fluid pH is more complicated. For each polymer type, an optimum pH range for hydration exists.

The HPG-based J876 slurry hydrates fastest in the 5.0 to 5.5 pH range, with acceptable hydration occurring from pH 5.0 to 7.0. The guar-based J877 hydrates fastest in a slightly higher pH range of 6.5 to 7.0 with acceptable hydration occurring from pH 6.0 to 8.0.

50 | Continuous Mix Chemistry

Note:Mixing water with pH values outside the acceptable range for a given polymer may result in insufficiently hydrated gel.

7.3 Additives and additive systemIn continuous mix applications, all additives must be added on the fly in the same way that the polymer is added. The PCM unit includes four liquid additive metering systems to facilitate on-the-fly addition of additives. The unit also includes a metering system for concentrated KCl solutions; however, KCl is seldom or never used.

7.3.1 Liquid additive blendsFor treatments employing more than four liquid additives, one can blend two or more compatible additives in the additive tank. The blend must be prepared in the appropriate ratio, loaded into one of the unit’s tote tanks, and metered at the combined rate for the two additives.

Note:Before preparing such blends, must be considered the storage and metering capacities of the PCM.

7.3.2 Mixing blendsThe mixing requirements for preparation of additive blends will depend on the viscosities and relative densities of the materials involved. Blends of low-viscosity materials with similar densities can be mixed by combining the additives in a tank and recirculating at a high rate for some time.

Blending additives by recirculation in the tote tanks on the PCM unit is not recommended because of the relatively low recirculation rate. For more viscous materials or where a large difference in density exists, more intense mixing will be required. In these cases, blends should be prepared in agitated vessels. The PCM unit is equipped with a lightning mixer, which is accessible to two of the tote tanks for preparing additive blends. Whether using the agitated vessels or the lightening mixer, the mixing vessel should be loaded with the less viscous or less dense liquid first, and then the more viscous or more dense liquid added slowly with good agitation. Mixing should be continued until a homogenous blend is obtained.

7.3.3 Dry additivesThe most convenient method of adding soluble, dry additives is to prepare a concentrated solution of the additive and meter it using the liquid additives systems on the PCM mixer.

The most commonly employed insoluble additives, other than the proppant, are the fluid loss additives such as J418. The best approach to on-the-fly addition of these additives is to prepare slurry in a concentrated Waterfrac fluid. This fluid can be prepared with either guar or HPG-based Waterfrac and is most conveniently done using J876 or J877.

Most dry additives are added using a chemical eductor connected from C-2 to compartment 6. Pressure can be increased by controlling V-21 (see figures in section 5 for the location of the valve).


8.0 J876 and J877 Spill and Disposal Procedures

Caution:Do not use water to clean up spills of J876 or J877.

Personnel involved in the cleanup should wear appropriate PPE. Spills of J876 or J877 should be contained as much as possible. All ignition sources should be removed from the immediate area and only explosion-proof equipment used for cleanup.

The spill should be soaked up with an inert, absorbent material such as sand and placed in steel or plastic drums approved for flammables. The recovered material should be shipped via a permitted waste hauler to a permitted waste disposal facility. In some cases, spills of J876 or J877 must be reported to local authorities; be familiar with the local regulations.

52 | J876 and J877 Spill and Disposal Procedures



9.0 Prejob and Postjob Procedures

Several tasks must be performed to prepare the PCM for a job and to leave the location after the job is completed.

9.1 Pretrip checklistIt may take approximately 1 hour to perform the pretrip inspection on the PCM, according to the appropriate STEM 1 checklist.

Go through the truck safety checklist. •Some of the following items may be redundant with this checklist.

Always be alert for emergency situations. •Failure to spot an emergency can result in equipment damage and personal injury.

Attend a prejob safety meeting with •the Schlumberger employees and the customer’s employees at the field location.

Understand each person’s responsibilities •during the job.

Tag or mark off any hazardous areas •around the unit if required by the Schlumberger district or rig site.

Review all appropriate MSDSs and place •them in the truck cab.

Properly store or tie down all loose •equipment.

Ensure that a first aid kit is available.•

Check the capacity and condition of the fire •extinguisher.

Check the eyewash bottle. Fill it if the level •is low, or clean and refill it if the water looks or smells unclean.

Review the trip report for hazardous •intersections and road conditions.

Check engine oil and coolant level; refill if •necessary.

Check hydraulic oil tank level; refill if •necessary.

Check pump packing lube reservoir level; •refill if necessary.

Check the fuel tank level; refill if necessary.•

Verify the amounts of additives loaded •on the PCM unit to the loading ticket and service order. Take an additional 10 to 15% excess of all additives for the slurry gel.

Fill out the additive worksheet specific to •your district for the anticipated job rate (clean fluid rate). This worksheet may be used as quick reference should a display fail during a job.

Check the liquid additive tote tank lids and •the screw-on caps.

Check and secure the metal tie down rods •for the tote tanks. There are two rods per tote tank. These rods run through the legs of the tote tanks and the frame of the tote tank supports.

Start the deck engine.•

Check warning light on control panel.•

Check the air pressure in the tires. It should •be from 100 to 110 psi.

Check all working lights.•

Check each recirculation/normal valve •actuation (five valves in all; see Figs. 6-1 and 6-2).

Check the LSG supply valve for actuation.•

Check each additive system that will be •used on the job. Check these additive systems manually and in auto.

54 | Prejob and Postjob Procedures

Kill the deck engine.•

Turn the control panel off and disconnect •the batteries.

Close the tote tank supply valves (V24 on •Fig. 6-9) and close the slurry gel suction valves (V4 and V5 on Fig. 6-1).

Close the vent valves (V27 on Fig. 6-9) on •the LAS. These valves should be closed when the PCM is on the road.

Close and fasten slurry gel dome lids.•

Close safety railings and control panel lid.•

Before driving the PCM to location, check •the trailer’s air suspension. When the trailer is fully aired, the mud flaps on the trailer should clear the ground by 1 1/2 to 2 in.

Caution:Damage to the output flowmeter could result if the air suspension is not holding the trailer up high enough off the ground.

9.2 Prejob checklistThe prejob checklist familiarizes the operator with the steps required to prepare the PCM to perform a job.

STEP 01 Extend all landing gears. There are four independent legs. The landing gears have a low speed and a high speed. Lower the legs (with the gear in high speed) until the handle cannot be turned. Do not raise the back of the trailer off the legs. The legs are designed to help support the load of the trailer.

STEP 02 Rig up suction and discharge hoses. To determine the number of hoses, refer to Safety Standard 5.

STEP 03 Open the LAS vent drain valves (V27 on Fig. 6-9) and the supply valves (V24) on the tote tanks.

STEP 04 Remove the threaded cap from the top of the tote tanks to eliminate the chance of damaging the tote tanks if the vent valve is plugged or malfunctions.

STEP 05 Position the valves on the slurry gel to the desired compartment.

STEP 06 Close all drain valves.

STEP 07 Zero the Micro Motion sensors on the additive systems that will be used during the job (see section 6.3.2).

STEP 08 Install the pH probe in Compartment 5.

Note:Not every PCM has a pH probe. If the one you are using does not, then the laboratory technician will take samples.

STEP 09 Reset all air valves before taking on water. Put lever 1, the normal and fill/shutdown lever, in normal operation (down). This position will prepare all air valves for normal operation.

STEP 10 Input the additive ratios on the control panel. Ratios should have been calculated in the pretrip checklist.

STEP 11 Check all toggle switches on control panel. Visually check each recirculation/normal valve actuation.


9.3 Postjob checklistThe postjob checklist is a set of steps for the operator to follow when preparing the PCM unit to leave the jobsite.

STEP 01 Close any open slurry gel dome lids and tote tanks caps.

STEP 02 Close the LAS vent valve (V27 on Fig. 6-9).

STEP 03 Close the tote tank supply valves (V24).

STEP 04 Open the drain valve (V25) until flow ceases.

STEP 05 Open the drain valves on the C-pumps and the 12-in discharge line until flow ceases.

STEP 06 Raise the four independent legs.

STEP 07 Shut off the deck engine and turn the control panel off.

STEP 08 Turn the main air valve off.

STEP 09 Make sure the drain valves opened in Steps 04 and 05 are closed before moving the unit.

STEP 09 Secure the control panel.

STEP 10 Close the safety railing on the operator platform.

STEP 11 Raise and secure the ladder for the slurry gel tank.

STEP 12 Disconnect the batteries with the quick disconnects.

STEP 13 Remove the pH probe from compartment 5, and install it in the storage well.

STEP 14 Before moving the PCM unit, check trailer suspension. The mud flaps should clear the ground by 1 1/2 to 2 in when the trailer suspension is fully aired. Damage to the output flowmeter could result if the air suspension is not holding the trailer up high enough off the ground.

56 | Prejob and Postjob Procedures



10.0 Services Not Performed by PCM Unit

The PCM unit is not designed to pump any of the gelled oil treatments because the tanks are open-topped and have impellers in them. A cloud of light diesel could form above the tank.

Warning:An explosive cloud of very light diesel could easily result in a huge location fire.

The PCM is also not suited to pumping acid. There are numerous aluminum components on the PCM (i.e., impellers and shafts, brackets, etc.) that cannot withstand acids.

58 | Services Not Performed by PCM Unit



11.0 GelSTREAK

The SBT-527 GelSTREAK (see Figs. 11-1 and 11-2) is a truck-mounted mixing and hydration unit that precisely mixes gelled fluid in a continuous mode and gravity-feeds it to the fracturing blender. The system uses dry polymer rather than slurry gel to produce the aqueous gel, thus providing a fluid that is completely free from diesel or oil-based material. The unit is built on a MAZ-MAN™ 6x6 chassis and is fully winterized specifically for the west Siberian oilfield environment.

Figure 11-1. GelSTREAK Unit (Left View)

Figure 11-2. GelSTREAK Unit (Right View)

The dry polymer is metered by a volumetric feeder that is continuously calibrated by a loss in weight system. The metered polymer is dispersed and mixed through an eductor-based mixing system with the precise amount of water to provide the required loading of the polymer gel.

The resulting gel is discharged into the first-in-first-out hydration tank, where it is held until it is hydrated. Agitators in the hydration tank add energy, homogenize the fluid, and maintain the flow. A constant level of fluid is maintained in the last compartment by the automatic level control system, which provides the hydrostatic head and a volume buffer feeding the POD blender, regardless of the output flow rate.

The unit is remotely controlled from the FracCAT* carrier where the unit computer and touch screen are located (PodSTREAK* cabin or FracCAT carrier if used with a skid POD* programmable optimum density blender). Communication between the distributed control unit (DCU) and the computer is via standard CAN bus (wireless is available for some locations). Unit operation is highly automated; complete sequences controlled by the proprietary human interface software are performed with minimum intervention from the operator.

The unit can continuously mix polymer, loading up to 50 lbm/1,000 galUS at output rates from 6 to 40 bbl/min. The maximum guar feed rate is 84 lbm/min (equivalent to 50 lbm/1,000 galUS at 40 bbl/min); the guar bin can hold and transport 4,000 lbm of dry polymer powder. The hydration capacity specification of the unit is a

60 | GelSTREAK

minimum of 80% hydration at 30 bbl/min and 68 degF water temperature.

11.1 Main applicationsThe GelSTREAK

provides hydrated polymer gel to the POD •blender

meters and mixes dry polymer powder •to produce polymer slurry of precise concentration

hydrates polymer slurry in a continuous •mode

maintains constant fluid head for the •fracturing blender

transports dry polymer powder to the •wellsite

powers and controls two off-board liquid •additive modules (SUP-511 or SUP-512).

11.2 Equipment overview Major components of the unit include

MAZ-MAN 6x6 truck chassis powered by •a 400-hp YAMZ engine for mounting and powering the installed equipment

one 6x8x14 centrifugal pump for picking up •fluids and mixing gel

powder polymer storage bin for holding and •transporting the dry polymer and feeding it by gravity to the metering feeder

volumetric metering feeder and gravimetric •automatic calibration

eductor-based mixing and dilution system •for dispersing and mixing the polymer gel

winterized system for arctic environments•

150-bbl capacity FIFO tanks for hydrating •the polymer gel

DCU-based control hardware•

remotely mounted computer and touch •screen for unit operation (from FracCAT carrier)

backup operator console with pneumatic •and hydraulic controls for running the unit locally in backup mode

magnetic flowmeter for metering mixing •water

level sensors in each compartment for •remote monitoring and control of fluid level

process fluid temperature sensors on •all manifolds for operation in arctic environments

video cameras on feeder downspout •and inside hydration tank for remotely monitoring critical components.

11.3 Operator responsibilities The GelSTEAK operator’s responsibilities are as follows.

11.3.1 Pretrip responsibilities and inspection

Pretrip responsibilities include

reviewing all appropriate MSDSs and •placing them in the truck cab

properly storing or tying down all loose •equipment

ensuring that a first aid kit is available•

checking the capacity and condition of the •fire extinguisher

checking the eyewash bottle; if the level is •low, filling it, or cleaning and refilling it, if the water looks unsafe or unclean

reviewing the trip report for hazardous •intersections and road conditions.

In addition, the operator should check the following items on the unit:


engine oil and coolant level•

hydraulic oil tank level C-pump packing •lube reservoir level

fuel tanks’ level.•

Before leaving the district, the operator should complete the following actions:

Start the engine and run it at idle for 1. approximately 5 min.

Disengage the road gear, and then 2. engage both power take-offs (PTOs).

Throttle up the engine to full speed.3.

Run the unit for approximately 10 min to 4. circulate the hydraulics, and ensure that there are no abnormal sounds in the unit.

Walk around to look for any air, 5. hydraulic, or lube oil leaks.

Confirm that the bin is lifted to the 6. driving position and that the outriggers are completely retracted.

Throttle the engine to idle.7.

Disengage the PTOs; then engage the 8. road gear.

Allow the engine to idle for 5 min.9.

Shut down the unit.10.

The pretrip inspection includes ensuring equipment and road safety, and visually checking the equipment for the following before leaving the yard (see Fig. 11-3):

oil leaks•

coolant leaks•

radiator core leaks•

damaged hoses•

loose or damaged components •(inadequately secured loose equipment and remote cables).

Figure 11-3. Pretrip Inspection of GelSTREAK Unit

11.3.2 Driving to locationThe operator may proceed to the job location only after completing the pretrip inspection. Travel must comply with the Schlumberger QHSE Standard S001: Journey Management and Driving, InTouch Content ID# 3051691.

11.3.3 On locationPosition the unit on location as instructed by the job supervisor (see Fig. 11-4 for an example of the setup). Once on location, you are required to comply with Well Services Safety Standard 5: Pressure Pumping and Location Safety.

62 | GelSTREAK

Figure 11-4. GelSTREAK on the Job

The prejob checklist includes

always being alert for emergency •situations. Failure to spot an emergency can result in equipment damage and personal injury.

attending a prejob safety meeting with •Schlumberger employees and the customer’s employees at the field location

understanding each person’s •responsibilities during the job

tagging or marking off any hazardous •areas around the unit if required by the Schlumberger district or rig site

performing a quick walk around inspection •of the unit while the unit is being warmed up before the job

paying attention to the information on all •decals, plates, and safety signs when around equipment.

11.4 EnvironmentalAny chemical spill must be contained, cleaned up, and reported according to local procedures. Refer to Well Services Safety Standard 17: Storage and Handling of Oxidizers, and Well Services Safety Standard 18: Hazcom, for more information. Dispose of oils, filters, and batteries in an environmentally acceptable way and in accordance with local regulations.

11.5 Weights and unitsAccording to Russian regulations, you can legally haul 24,000 kg using the SBT-527 GelSTREAK. The maximum weight limit for the front axle is 7,150 kg, and for the rear axle group, it is 18,000 kg. The maximum allowable payload is 1,815 kg. This is the weight of dry gel that can be loaded in the bin. Refer to unit specifications for allowable load configurations.

12.0 Check Your Understanding

63JET 24- PCM and Hydration Units |

1. The advantages of continuous-mix operations over batch mix operations are _________ .

A. Environmental concerns are greatly reduced because only freshwater residuals remain in the fracture tanks after a treatment.

B. The cost of replacing gelled tank bottoms is eliminated.

C. The fluid viscosity is more predictable and consistent during treatments.

D. The need to have gelling crews precede fracturing operations is eliminated, resulting in direct savings in time for personnel and equipment.

E. Viscosities can be easily changed throughout the treatment.

F. All of the above

2. A PCM is a _________ .A. proper concentration mixerB. precision continuous mixerC. precision constant mixerD. proper continuous mixer

3. Which of the following is not a function of the PCM?

A. continuously metering and hydrating the polymer by blending it with water

B. continuously mixing fracturing fluids at rates of 5 to 80 bbl/min

C. delivering fracturing fluid to the POD blender

D. maintaining constant hydrostatic head for the POD blender

4. The PCM mixer’s slurry gel tank can store and transport _________ .A. 1,500 galUS of slurry gelB. 1,000 galUS of slurry gelC. 750 galUS of slurry gelD. none of the above

5. Liquid additive tanks on the PCM _________ .A. have 300-galUS capacityB. have 345-galUS capacityC. are located at the rear of the trailerD. both b and c are correctE. both a and c are correct

64 | Check Your Understanding

6. Factors affecting the hydration of the J876 and J877 slurry gel systems are _________ .A. the mix water temperatureB. the time and intensity of mixingC. the fluid pHD. all of the above

7. The biggest difference between the GelSTREAK hydration unit and the PCM mixer is that the GelSTREAK hydration unit _________ .

A. is a truck-mounted mixing and hydration unit that precisely mixes gelled fluid in a continuous mode

B. gravity feeds the slurry to the fracturing blender

C. uses dry polymer rather than slurry gel to produce the aqueous gel, thus providing a fluid that is completely free from diesel or oil-based material

D. all of the above

8. The GelSTREAK hydration unit _________ .

A. provides hydrated polymer gel to the POD blender

B. meters and mixes dry polymer powder to produce polymer slurry of precise concentration

C. hydrates polymer slurry in a continuous mode

D. maintains constant fluid head for the fracturing blender

E. all of the above

jet manual 24 - amusement 21 and sound system rental · jet 24 - pcm and hydration units | 7 2.0...

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