Sie sind auf Seite 1von 90

eADP™ Advanced Dry Polymer Blender

Trailer Manual

SAP No. 102236003


Notice
All information contained in this publication is confidential and proprietary property of
Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings, or
photographs without the express written permission of an officer of Halliburton is forbidden.

© 2013 Halliburton. All Rights Reserved. Printed in the United States of America.

SAP No. 102236003

October 2013
Contents

Chapter 1—Unit Overview


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Deck Engine/Power Pack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Fluid-handling Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Bulk-Metering Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Suction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Tub Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Hydration Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Concentrate System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Bulk Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Fill Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Feeder Calibration Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Cyclone System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Liquid Additive (LA) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Flowmeters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Viscometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Power Package—Deck Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
Hydraulic Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-17
Control House/Lift Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-19

Chapter 2—Operation and Maintenance


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Manual Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Engine Startup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Cold Weather Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Hydraulic Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Manifold Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Concentrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Conventional Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Batching Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Suction Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Lubrication/Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Mixer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Mixer Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

October 2013 Table of Contents i


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Operating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5


Gel Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Gel Quality Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Hydration Tank Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Concentrate System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Gel Calculator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Bulk Tank Manual Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Handling Dry Gel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Filling the Bulk Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Filling the Tank by Super Sack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
Filling the Tank Pneumatically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-16
ADP™ (Dry Gel) Blender Dust Separation System. . . . . . . . . . . . . . . . . . . . . . . .2-17
How the System Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Why Dry Gel Can Exist on Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-18
Why Gel Might Come From the Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . .2-19
All Steps were Followed and Dry Gel Still Exists on Location . . . . . . . . . . . . .2-19
Diagnosing and Fixing a Seized Auger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-23
Removing Dry Gel from the Bulk Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-24
Liquid Additive Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Flowmeters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27
Bucket Test Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-28
LA Pump, DA Feeder, and Transfer Pump Manual Operation . . . . . . . . . . . . . . . . . . .2-29
Viscometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Transporting the Skid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Operating the Viscometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31
Power Package—Deck Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Hydraulic Power System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-32
Suction Pump, Concentrate Pump, and Mixer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-33
Automatic and Manual Tub Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-36
Manual Valve Banks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-37

Chapter 3—ACE™ Control System Controller Functions


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
ACE™ Control System Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Closed-loop Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
eADP Blender Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Manifold Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Chapter 4—Pre and Post-job Checklists


Chapter 5—Drawings
Appendix A—Load Cell Operation
Setup and Calibration for the Load Cell
(SAP No.101432326) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Connect to the Terminal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

October 2013 Table of Contents ii


Chapter

1
Unit Overview

Introduction
The eADP™ advanced dry polymer blender trailer (Figure 1.1) is a pre-gel unit designed to provide
gel and liquid additives in accurately metered quantities to a blender unit. The eADP blender trailer
can mix up to 126 lb/min of commonly available dry gels from DA1. The suction pump can run at
approximately 100 bbl/min. This allows the eADP blender to make up to a 33lb/Mgal finished gel at
maximum rate.

The concentrate pump should run between 420 and 1,000 gal/min (preferably at 1,000 gal/min, as the
unit and LA systems perform best at this rate). Under normal operations, the eADP blender can
produce a finished gel at a viscosity up to 250 cp. If the concentrate system is employed, these
parameters should be used with the gel calculator. See the Gel Calculator (Page 2-13) section in
Chapter 2 for more information on its operation. The eADP blender trailer’s basic systems are:

• Diesel hydraulic power pack.


• Fluid-handling components.
• Bulk-metering tank.
• Control systems.

The eADP blender trailer incorporates the necessary sensors and feedback systems to make full use of
the capabilities of the current ACE™ control system. Additionally, all components on the trailer are
backed with manual overrides. All control systems are located on the operator’s platform.

October 2013 Unit Overview 1-1


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.1—eADP blender trailer.

Deck Engine/Power Pack


The deck engine consists of a diesel engine, hydraulic pumps, radiator assembly, hydraulic coolers,
hydraulic reservoir, battery, gearbox, and maintenance access platforms, as well as storage for eight
suction hoses. The deck engine provides power for the following components:

• Fluid pumps—suction and concentrate.


• Mixer.
• Bulk tank systems—metering screw (DA1) conveying augers, and vibrators.
• Liquid additive (LA) pumps—transfer and metering.
• Actuators—tank fill, (LA1) concentrate, and mixer pressure control valves.

Fluid-handling Components
The manifolding, mixing, and pumping systems of the eADP blender trailer are extremely flexible and
potentially complex in function. These systems include:

• Suction pump.
• Mixer.
• Concentrate pump.
• Internal manifolding including mixer circuit.
• Hydration tank.
• Control valves.
• Mag flowmeters.

1-2 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Bulk-Metering Tank
The bulk-metering tank incorporates the necessary receiving, storage, and metering components to
accurately transfer dry gel to the mixer. These components include:

• Conveying augers.
• Metering screw (DA1).
• Vibrators.
• Pneumatic conveying.
• Inventory and calibration load cells.
• Control systems.

Equipment Description
The eADP blender can be broken into subsystems, each of which can be examined for configuration
and function. The following section examines these individual subsystems. The descriptions provided
represent a general overview. For more detail, see the drawings and bill of materials for any unit by
following the instructions found in Chapter 5—Drawings.

Manifold
The eADP blender manifold is extremely flexible and the operator must become familiar with it. When
making gel concentrate, the eADP unit draws in clean water from the driver-side manifold. The drawn
water is pressurized by the suction pump and sent to the mixer. The mixer combines dry gel with the
water to produce a concentrated gelled fluid. The concentrated gelled fluid is sent to the hydration tank
at the driver-side inlet. The gel concentrate then flows through the hydration vessel and is pumped and
metered by the concentrate metering system. The gel concentrate is pumped and metered to the suction
manifold of the blender. Concurrent with this process, the downhole blender draws clean fluid through
the suction crossover. The clean fluid is mixed with a metered amount of gel concentrate and makes
the desired downhole gel viscosity. Viscosity adjustment is quick and simply made by adjusting the gel
concentrate (LA1).

If base gel fluid is desired, clean water can be drawn from the driver side and sent to the mixer where
dry gel is added. Gel at the required downhole concentration then flows to the hydration tank where it
can be drawn by the downhole blender from the passenger-side header. Downhole rates of less than 25
bbl/min are required for this method. Viscosity adjustments can be slow and take 2 to 3 hydration tank
volumes to notice the change in viscosity.

WARNING This method requires extra time to make adjustments to the downhole viscosity.
Verify the correct viscosity is being mixed at the start of mixing the hydration tank.

If the hydration tank is bypassed, pressurized gel can be sent to an external work tank. Both the driver-
side and passenger-side manifolds can be divided. When the headers are divided, the unit can draw in
clean fluid on the same side from which it discharges gelled fluid. This can be useful when gelling
tanks.

October 2013 Unit Overview 1-3


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.2 and Figure 1.3 show the individual components of the eADP blender manifold. The light
blue portions of the components/manifolding represent manifolding containing clean water. The brown
portions of the components/manifolding represent manifolding containing a gelled fluid. The light
green components/manifolding represent the manifolding that makes up the concentrate system. For
additional information regarding operation of the manifold, see Manifold Operation (Page 2-2) in
Chapter 2.

Figure 1.2—eADP blender manifold (driver side).

1-4 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 1.3—eADP blender manifold (passenger side).

Suction Pump
The suction pump on the eADP blender trailer is a Gorman-Rupp 12 × 12. Figure 1.4 shows the pump,
motor, and coupling as installed. Table 1.1 shows the specifications for the pump. For additional
information regarding operation of the suction pump, see the Suction Pump (Page 2-3) section of
Chapter 2.

Figure 1.4—Suction pump.

October 2013 Unit Overview 1-5


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Table 1.1—Suction Pump Specifications

Manufacturer Gorman-Rupp

SAP No. 100059396


Suction size, in. 12

Discharge size, in. 12

Impeller diameter, in. 14.87


Maximum speed, rev/min 1,259

Mixer
The eADP blender trailer has a centrifugal pump. Wetting water is added through the wetting ring
located at the top of the mixer. The wetting water helps convey gel into the mixer to prevent dry gel
from accumulating and blocking the mixer inlet. The mixer has a mechanical seal.

For consistent hydrated gel, the amount of water delivered to the mixer is important and must be
regulated. To help ensure a consistent amount, Valve 12 (butterfly valve) is now being controlled by
the ACE system that opens and closes it using a hydraulic actuator, position feedback, and the input
from the downstream pressure transducer to allow more or less fluid through to the mixer. The desired
amount of water pressure delivered to the mixer through Valve 12 is 10 psi. This number can be
entered into the ACE system from the main screen by selecting the button that displays a pressure
value. Figure 1.5 shows the mixer, motor, coupling, and wetting ring as installed on the unit. For
additional information regarding operation of the mixer, see the Mixer Operation (Page 2-4) section of
Chapter 2.

Figure 1.5—Mixer, motor, coupling, and wetting ring.

1-6 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Tub Level Control


The tub level of the eADP blender trailer operates in the following three modes.

1. Once fill—the suction pump delivers a fixed pressure to the tub level valve. The tub level
valve actuator with feedback is controlled by the computer and varies the valve controlling
user defined flow rate. A float sensor monitors the tank level, and the ACE control system will
close the valve when the tank is filled.
2. Automatic leveling—the suction pump delivers a fixed pressure to the tub level valve. The
tub level valve is controlled by the computer and varies the valve controlling flowrate. A float
sensor monitors the tank level, and the ACE control system can maintain the tank level to a
desired level of 75%.
3. Manual—the operator controls fluid rate into the tank and the tank level.

• When the eADP blender trailer is producing gel to the onboard hydration tank, the flow rate is
governed by the tub level sensor and “Automatic Leveling” mode should be used.
• When the eADP blender trailer is producing gel to pump to an external tank, the valve position
must be controlled by a user defined flowrate that must match the downhole clean rate of the
blender. “Fill Once” mode of operation should be used.
The hydraulic actuator used on the tub level valve is supplied by Parker (SAP No. 101446252). This
actuator uses a cam-driven potentiometer that threads into a boss on the actuator. During application of
the eADP blender trailer, the actuator is equipped with two feedback potentiometers and slimpacks. In
the event of a failure, a switch on the control stand activates the backup sensor (Tub Level Valve
Feedback 1 and 2).

For additional information regarding the tub level system, see the Automatic and Manual Tub Level
Control (Page 2-39) section of Chapter 2.

Figure 1.6—Tub level valve.

October 2013 Unit Overview 1-7


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Hydration Tank
The eADP blender hydration tank provides a true first-in/first-out residence time for the gel before it
proceeds to the blender. This technology, combined with the ability to meter concentrate, enables the
eADP blender trailer to provide a hydrated gel for fracturing on-the-fly without an independent work
tank at rates up to 100 bbl/min.

The maximum working volume for the hydration tank is 75 bbl. Filled to the top, the tank holds 83 bbl.
The tank level can be checked with the gauge shown in the hydration tank. When the fluid level
reaches the bottom of the tab, the quantity of fluid is approximately equal to the number on the tab.

Concentrate System
The concentrate system is attached to the passenger side of the trailer below the hydration tank (Figure
1.7). The concentrate system includes:

• A Mission Magnum 10 × 8 centrifugal pump.


• A 6-in. Rosemount magnetic flowmeter.
• A control valve.

When concentrate is being made within the hydration tank, the concentrate system behaves like a
liquid additive system by metering concentrated gel to the suction header of the blender. The blender
then makes up the difference between the supplied concentrate and the total clean by pulling in water
from the frac tanks.

Figure 1.7—Concentrate system.

1-8 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Bulk Tank
The bulk tank is a dry additive metering, storage, and transport system mounted on the rear of the
trailer over the bogie. Within the tank are two conveying augers and a metering screw (DA1). The
primary function of the bulk tank is to meter gel into the mixer, as follows:

1. The horizontal auger conveys dry gel toward the vertical auger.
2. The vertical auger elevates the dry gel and discharges it into the hopper of DA1. The convey-
ing rates of the augers in the tank are constant. The feed rate discharging from DA1 varies
according to the concentration and volume of gel required. The amount of dry gel spilling into
the hopper is such that it consistently overfills the hopper.
3. Dry gel not fed into the mixer overflows the hopper and falls to the bottom of the tank.
4. To facilitate the movement of dry gel to the bottom auger, the tank is equipped with rotary
vibrators. These vibrators shake the tank hopper, breaking the dry gel free of the walls,
allowing it to flow into the horizontal auger. The vibrators have two speeds. If the dry gel does
not flow as it should, the vibrators can be operated at the higher speed to facilitate movement
of the dry gel.

Fill Capacities
• The maximum operational capacity of the tank for most gels is 7,500 lb (6500 lb. for WG-39).
• The bulk tank is also equipped with four load cells that isolate the tank from its mounting. The
primary function of these load cells is to inventory the tank’s contents.

Feeder Calibration Check


The load cells have one additional function. As the dry gel is metered from the tank by the DA1 feeder,
the load cells can be used to continuously check the calibration of the feeder during operation.

For the calibration check to be valid, no one can be in contact with the tank during operation.
Instructions for the operation and calibration of the load cells are provided in Chapter A—Load Cell
Operation.

For additional information regarding operation of the bulk tank, see the Bulk Tank Manual Control
(Page 2-16) section of Chapter 2. Figure 1.8 and Figure 1.9 show detailed views of the bulk tank and
feeder assembly.

October 2013 Unit Overview 1-9


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.8—Bulk tank.

Figure 1.9—Feeder assembly (located inside the bulk tank).

1-10 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Cyclone System
The bulk tank has a cyclone separator that is used when pneumatically filling. When maintained and
operated properly, the cyclone will separate the dust particles from the pneumatic fill line and clean air
will be exhausted into the filter located on the bulk tank. For additional information regarding
operation of the bulk tank, see the Bulk Tank Manual Control (Page 2-16) of Chapter 2.

Liquid Additive (LA) System


The LA system (Figure 1.10 through Figure 1.13) on the eADP blender trailer includes:

• Four LA pumps—two lobe pumps and two progressive cavity pumps.


• Four Micro Motion® T-Series flowmeters.
• Three chemical transfer pumps.
• Three 40-gal holding tanks equipped with level sensors that automatically turn on and off the
chemical transfer pumps. This will help ensure that the fluid being delivered from the
chemical transfer pumps will not overflow the upright tanks or starve the LA pumps by
running the tanks empty (Figure 1.13).
• Hose and manifolding for bucket tests, recirculation with LA pumps, and injection into the
suction and discharge sides of the unit.

Each LA pump can be supplied from an off-unit source. Additionally, three pumps can be supplied
from one of the 40-gal tanks on the unit. These pumps then meter, based on rate information from a
tachometer drive or Micro Motion® T-Series mass flowmeter. The entire LA system can be air purged
and drained with fittings provided.

The fourth liquid additive circuit is not connected to an onboard holding vessel and must be supplied
from a storage vessel not on the unit.

Figure 1.10 is a schematic of the transfer pumps that fill the vertical uprights. Figure 1.11 is a
schematic of the LA system that shows how the vertical uprights supply fluid to the LA pumps and
where the fluid can be pumped to on the eADP unit. Figure 1.12 shows the single LA circuit without
an onboard tank. For additional information regarding operation of the LA system, see the LA Pump,
DA Feeder, and Transfer Pump Manual Operation (Page 2-31) section of Chapter 2.

October 2013 Unit Overview 1-11


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.10—LA system—chemical transfer pumps.

1-12 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 1.11—LA system—schematic of three of the four LA pumps (LA 2,3, and 4).

Figure 1.12—LA system—schematic of the fourth LA pump (LA 5).

October 2013 Unit Overview 1-13


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.13—LA system—tank level sensors.

Flowmeters
The T-Series meters are straight-tube flowmeters. The straight-tube design is self-draining, compact,
and reduces plugging. The wetted parts of the mass flowmeters are constructed from titanium for
excellent corrosion resistance. Titanium is not susceptible to chloride cracking as stainless steel is. The
flowmeters are sized to match the flow rates of the supplied LA pumps.

Viscometer
The eADP unit is equipped with a Brookfield viscometer that is pin-mounted on the walkway. Ensure
the viscometer is in the down position for roading and is in the upright position for operations. For
more information on the viscometer, refer to operation and calibration manual SAP No. 101431495.

1-14 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Power Package—Deck Engine


The eADP unit power package (Figure 1.14) consists of the following components:

• Caterpillar® C-13 engine (520-HP; 1,800 rev/min).


• Four-pad gearbox (1.30 increaser).
• Hydraulic pumps.
• Hydraulic reservoir (70 gal).
• Radiator assembly.
• Hydraulic coolers.
• Two battery sets with isolator.
• Work platforms.

Figure 1.15 and Figure 1.16 provides information on the location of basic equipment related to the
engine package. For additional information regarding operation of the power package/deck engine, see
the Power Package: Deck Engine (Page 2-35) section of Chapter 2.

Figure 1.14—Power package/deck engine.

October 2013 Unit Overview 1-15


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.15—Service/maintenance points of eADP blender engine passenger side


(some components hidden for clarity).

1-16 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 1.16—Service/maintenance points of eADP blender engine driver side


(some components hidden for clarity).

Hydraulic Power System


The rotating equipment and actuators on the eADP blender trailer are hydraulically powered. At full
throttle, the deck engine spins at 1,800 rev/min. This is then stepped up to 2,340 rev/min by the
gearbox. Four pads on the gearbox support and supply power to six pumps. Figure 1.17 shows how
these pumps are installed on the gearbox. These pumps in turn power the operating equipment on the
eADP blender trailer. Table 1.2 provides the pump types and sizes and the systems they power.

For additional information regarding operation of the hydraulic power system, see the Hydraulic
Power System (Page 2-35) section of Chapter 2.

October 2013 Unit Overview 1-17


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 1.17—Six hydraulic pumps on the eADP blender.

Table 1.2—Six Pumps of the eADP Hydraulic Power System

Pump Motor Component

Sundstrand 100cc Parker 1500 cc Suction pump


101345235 101442730 100059396

Sundstrand 75cc Parker 93cc Concentrate pump


101278456 101615664 101441970

Sundstrand 130 cc Parker 125cc Mixer pump


101278457 101613572 101433138

Parker 145cc LA 2,3,4,5,6, and 7; DA1, vibrators, actuators,


Parallel Curcuit
101694464 control valves, hydraulic cooler fans

Parker 280cc -
101330162 Elevating conveyor
Parker 75cc Parker 405cc - (SS1 in ACE control system)
101651799 10430383 Horizontal conveyor (SS2 in ACE control
Nichols 59cc - system conditioning flight in DA1 hopper (DA2)
102164811

Geartek 98cc Provides low pressure flow to the charge and


Charge and cooling
102053986 cooling loop

1-18 Unit Overview October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Control House/Lift Table


The eADP blender trailer is equipped with a control house that has 25K BTU cooling and 45K BTU
heating capabilities. The compressor is hydraulically driven, and the A/C unit is 24 VDC. Because of
the high walkway height, the house MUST be lifted into operating position and lowered for roading.
This is performed using a 24-VDC hydraulic lift table. When the door on the house is in the “closed”
position, the hand held controller can be used to lift and lower the control house. Also, a limit switch is
used in conjunction with the hand held controller to automatically stop the house at the proper
operating height when being raised into position. A hand pump can be used to manually raise and
lower the control house in the event the hand held controller is unable to. This is the only time the
manual pump should be used.

October 2013 Unit Overview 1-19


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

1-20 Unit Overview October 2013


Chapter

2
Operation and Maintenance

Introduction
The eADP™ blender trailer incorporates the necessary sensors and feedback systems to make full use
of the capabilities of the current ACE™ control system. Additionally, all components on the trailer are
backed with manual overrides. All automatic control systems are located in the control house, while
the hydraulic manual overrides are located on the operator's platform near the hydration tank.

Manual Controls
Truly independent manual control of the eADP blender trailer does not exist. Functionally, many of the
systems can be run without sensor feedback information; but, should the computer fail totally, it is not
advisable to attempt to operate the unit on-the-fly wholly in manual operation. Many of the mixer
functions are concentration-dependent, but there are no computer-independent meters to read the rev/
min of the LAs, mixer, DA feeder, or water pumps. Given the dependence of the unit on computer
control for seamless operation, it is still possible to batch tanks with the unit using the manual controls,
but should only be performed in emergency situations when the controls cannot be used through the
ACE control system.

Engine Startup and Operation


The deck engine has both electric and hydraulic start. It is also equipped with a Webasto heater to
facilitate cold weather startup (see the Cold Weather Startup section).

The engine can be started electrically from the control house using the following steps.

1. Switch the toggle marked “Engine Start/Stop” to the START position and hold until the engine
catches. At that point, the engine should idle freely at 700 rev/min.
2. Allow the engine to idle until the coolant temperature reaches 86°C (186°F).
3. The Caterpillar® C-13 engine is fully electronically controlled. The engine can be throttled up
using the ACE controller or by employing the manual toggle switch. In normal operation, the
engine will turn at 1,800 rev/min.

October 2013 Operation and Maintenance 2-1


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Cold Weather Startup


A cold weather startup procedure might be required at temperatures below -18°C (0°F). Cold weather
startup can be assisted using a Webasto heater by following the steps presented below.

1. Switch the toggle for the engine heater to the ON position. The green light indicating that the
Webasto heater has power should come on.
2. After 30 seconds, the combustion air fan on the heater and the Webasto fuel pump should
come on. The Webasto heater circulates coolant in the block, heating the coolant, and thereby
the block, with a fired heat exchanger.
3. It is not necessary to heat the coolant to operating temperature before starting the engine, but a
reasonable amount of time must be allowed for the engine to come to sufficient temperature.

Typically, in a properly maintained engine, the engine should start when the coolant reaches a
temperature of approximately 4°C (40°F)

Hydraulic Startup
If the charge on the battery is low or has insufficient power to start the deck engine in extreme
temperature conditions, the hydraulic start can be used. This procedure requires a hydraulic tractor.

1. Using the quick-connect couplings on the front of the trailer, connect the hydraulic power
supply on the tractor to the eADP blender trailer.
2. Engage the PTO on the tractor to supply power to the hydraulic starter motor.
3. On the control stand, set the “Start Select” switch to HYDRAULIC START. The engine start
switch can then be activated as normal.

Manifold Operation
Concentrate
1. The unit draws in clean water from the driver-side manifold. The drawn water is pressurized
by the suction pump and sent to the mixer.
2. The mixer combines dry gel with the water to produce a concentrated gelled fluid.
3. The concentrated gelled fluid is sent to the hydration tank at the driver-side inlet. The concen-
trate then flows through the hydration vessel and is drawn off by the concentrate metering sys-
tem.
4. The concentrate is pumped to the suction manifold of the blender.
5. Concurrent with this process, the downhole blender draws clean fluid through the suction
crossover.

This process can be used to provide fully hydrated gel at higher rates without the use of a work tank.

2-2 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Conventional Operation
1. The unit draws in clean water from the driver-side manifold. The drawn water is pressurized
by the suction pump and sent to the mixer.
2. The mixer combines dry gel with water in the ratio that will be pumped downhole.
3. The gel flows through the hydration tank or to a work tank.
4. The blender draws the fluid from the hydration vessel.

Batching Tanks
1. Some steps for conventional operation can be performed using the instructions previously
presented; however, gelled fluid is usually pumped to a much larger tank to be sent to the
downhole blender from.
2. Open and close the proper valves to draw in clean fluid and discharge out the proper manifold
to the tank. The suction pump can be run at a maximum of 55 psi to push off to an external
tank. Ensure the LA7 set point is 10 psi and can be verified when pumping by the manual
gauge located near the mixer.
3. Pump the gelled fluid into batch tank to be used later. DO NOT try to roll the frac tank with
gelled fluid or try to add dry gel to a gelled fluid to try and change the viscosity of the gel
already pumped into the tank.

Suction Pump
The mixer function depends on the suction pump to provide sufficient backpressure across a wide
range of flow rates. Figure 2.1 shows the performance envelope of the suction pump.

Figure 2.1—Performance envelope for the suction pump.

October 2013 Operation and Maintenance 2-3


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Lubrication/Maintenance
The bearings in the power end of the suction pump are oil-lubricated. A site glass indicates the
appropriate oil level. Fill with 15W-40, as necessary.

Mixer Operation
Unless manual operation is required because of a mechanical failure, operation of the eADP blender
mixer is automated. However, the mixer has a mechanical seal that is sensitive to extended dry
operation.

IMPORTANT Never run the mixer dry for more than a few seconds.

Before operating the mixer, wet the seal using one of the following three methods.

• The wash-down hose adjacent to the mixer can be used. To use this hose, pressure must be
supplied by the suction pump.
• If the water level in the frac tanks is sufficiently high, water can be gravity-flooded from the
frac tanks through the suction header to the mixer.
• The manifold can be charged with the suction pump and then used to charge the mixer.

IMPORTANT The mixer will only hold back water pressure when turning at high rev/min.

Mixer Operating Guidelines


Table 2.1 provides operating parameters for the eADP blender mixer. A list of guidelines for operating
the mixer follows the table.

Parameters

Table 2.1—Mixer Operating Parameters

Parameter Range

Preferred mixer rev/min, rev/min *1,600 to 1,800

Preferred typical pressure range, psi 30 to 50

Water required to convey gel to the mixer, bbl/min 5 (or more)

Minimum gelling rate, bbl/min 5


* Mixer rev/min begins at 1,600 rev/min and ramps up to 1,800 rev/min at a rate of 3
rev/min per pound per gallon of DA1 concentration increase.

2-4 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Operating Guidelines
Although the function of the mixer does not usually require manual input, the following guidelines
should be kept in mind to help ensure ease of operation.

The amount of water being delivered to the wetting ring is very important and should be consistent.
This can be difficult if the suction pump runs at various boost pressures, as this will change the amount
of flow delivered to the wetting ring. This problem was controlled on older ADP blenders using ball
valves on the supply lines to the wetting rings. The setting for each ball valve was unique to the
pressure the suction pump supplied. If the suction pump boost pressure changed, the ball valves would
require being changed as well. The only way to determine if the proper amount of flow was being
achieved was by performing a visual check. This involved removing the chute attached to the mixer
and DA, removing the weight ring with the chute adapter, and removing the rubber isolator to visually
observe the clean water running at the set point. The suction pump would then be set and the ball
valves adjusted to achieve proper flow.

On the eADP blender, Valve 12 is automatically controlled by means of ACE control system software
to open and close automatically to supply the proper amount of flow to the wetting ring (similar to a
tub level valve, and is being used as LA7 in the ACE control system). This is performed by using a
pressure transducer just downstream of Valve 12 (Figure 2.2), an actuator with feedback on Valve 12,
(Figure 2.3), and a hydraulic positioning valve (similar to tub level valve, Figure 2.4). By entering a
desired pressure set point using the ACE control system (Figure 2.5) to be delivered to the mixer, the
software controls the components necessary to maintain that pressure being delivered to the wetting
ring. This input value should be 10 psi. Despite the pressure the suction pump is run, Valve 12 will be
throttled and automatically open and closed to the proper position to maintain the 10-psi set point
being delivered to the mixer. This system can be disabled and Valve 12 can be opened and closed
manually by using the manual control joystick on the positioning valve (Figure 2.4).

NOTE Manually controlling this valve is not advised and only should be performed if the
valve cannot be run in auto mode.

Figure 2.2—Pressure transducer and gauge used to control Valve 12.

October 2013 Operation and Maintenance 2-5


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.3—Valve 12 shown with actuator with feedback.

Figure 2.4—Positioning valve with manual override.

2-6 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 2.5—ACE control system GUI for mixer inlet pressure.

NOTE Flow rate to the wetting ring limits the minimum downhole rate. Once the downhole
rate falls below that of the wetting ring flow rate, gelled fluid will loop in the wetting
ring and be returned to the mixer.

Gel Quality
Gel quality, aside from proper gel loading, is largely a function of good dispersion during the mixing
process. The wetting ring should quickly convey dry gel to the impeller where it is then dispersed into
the fluid stream.

Gel Quality Troubleshooting


Table 2.2 lists some problems that can occur with gel quality along with probable solutions.

October 2013 Operation and Maintenance 2-7


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Table 2.2—Gel Quality Troubleshooting

Problem Cause Suggestions/Possible Solutions

The wetting ring was run with dry Verify the mixer inlet pressure set
Formation of “gel areas, resulting in gel accumulating point is 10 psi and this pressure can
balls” or fish eyes and partially hydrating before entering be observed from the manual gauge
the fluid stream. located near the mixer.
Observe the wetting ring without its
cover on to determine the problem.
The wetting ring is not being cleaned. Check the wetting ring strainer. To
Mixer has dry gel This should be performed after every clear the strainer, manually operate
and hydrated gel stage using the hose located on the the ball valve (Figure 2.6)
stuck to the walls of bulk tank. Water is supplied to the
the wetting ring hose when the suction pump is The unit was run too slowly. Unit must
running. be run more than 5 bbl/min.

Dry gel was added to gelled fluid.


Never add dry gel to a gelled fluid.

Figure 2.6—Wetting ring strainer.

2-8 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Hydration Tank Operation


The hydration tank provides a true first-in/first-out residence time for the gel before it proceeds to the
blender. This technology, in concert with the ability to meter concentrate, enables the eADP trailer to
provide a hydrated gel for fracturing on-the-fly without an independent work tank.

Listed below are the operating parameters for the eADP blender hydration tank.

• Maximum working volume—75 bbl


• Maximum fill volume—83 bbl

Important features and guidelines for the hydration tank include the following.

• Gelled fluid enters the tank through Valve 5 in Figure 2.7. Then, it is circulated around the
weirs and is drawn out of the tank through Valve 9.
• The level in the hydration tank is governed by feedback from the level probe. During
operation, care must be taken to ensure the fluid level is below the level probe emitter (Figure
2.8). If the fluid level is too high, the level probe will cease to function properly until the fluid
level drops.
• There are three return lines on the hydration tank labeled: “Strainer Flush,” “Viscometer,” and
“Conc. Pump” (Figure 2.9). The viscometer return and concentrate return can be used as loca-
tions to retrieve gelled samples.

IMPORTANT Never haul the trailer with fluid in the tank.

Figure 2.7—eADP blender manifold.

October 2013 Operation and Maintenance 2-9


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.8—Level probe emitter.

Figure 2.9—Strainer flush, viscometer, and conc. pump return lines on the hydration tank.

2-10 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Concentrate System
The eADP blender concentrate system is attached to the passenger side of the trailer below the
hydration tank.

When concentrate is being made within the hydration tank, the concentrate system behaves like a
liquid additive system by metering concentrated gel to the suction header of the downhole blender. The
downhole blender then makes up the difference between the supplied concentrate and the total clean by
pulling in water from the frac tanks. The function of the concentrate system is automatically controlled
unless there is an electronic failure. In the event of a failure, the system can be run using the overrides
for the control valve and the concentrate pump. The performance of the pump is shown in Figure 2.10.

Figure 2.10—Performance of the concentrate system.

Gel Calculator
The gel calculator is a tool that can be used to help set the parameters on the eADP blender to make a
predicted gel when using the concentrate system. Figure 2.11 and Figure 2.12 show how to open the
gel calculator within the ACE control system. As mentioned previously, the maximum values that
should be followed within the gel calculator are as follows.

• Under normal operations, the concentrate viscosity should not exceed 250 cp.
• LA rates must be between 420 and 1,000 gal/min (gpm) (preferably at 1,000 gal/min).
• DA rates must not exceed 126 lb/min.
• A good rule of thumb is that holding time should be at least two minutes. (Verify this holding
time meets or exceeds the hydration time necessary tested by QA).

October 2013 Operation and Maintenance 2-11


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.11—Locating eADP blender manifold to find gel calculator.

Figure 2.12—Selecting the gel calculator from the eADP blender manifold.

Figure 2.13 shows an example of acceptable parameters input into the gel calculator.

Values for this example are as follows:

• Gel type.
• Temperature.
• Downhole clean rates.
• Downhole gel viscosity.

2-12 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

From those inputted parameters, the gel calculator calculates everything else. Careful attention should
be paid to a few different boxes. Ensure LA rates (concentrate pump) are between 420 and 1,000 gal/
min (preferably 1,000 gal/min), the DA rates are less than 126 lb/min, and the holding time is greater
than two minutes. Also, the gel calculator will calculate what the DA setpoint and LA1 setpoint would
be for the parameters input. If all the calculated boxes are acceptable and do not exceed any of the
minimum/maximum values mentioned, the “Set Setpoint” button and selecting “ENTER” will allow
these setpoint values to for DA and LA1to be entered automatically.

CAUTION This is just a good starting point, actual downhole viscosity can vary slightly; the gel
calculator's calculated values and LA1 setpoint might need to be tweaked. A good
rule of thumb is that a 10-gal/min difference in the LA1 concentration Setpoint will
make a 1-cp viscosity difference.

Figure 2.13—Example on how to use the gel calculator.

October 2013 Operation and Maintenance 2-13


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Bulk Tank Manual Control


The bulk tank serves as the onboard bulk-handling equipment and also the mechanism for metering gel
to the mixer. The bulk tank should not be filled with more than 7,500 lb of gel. When making a gelled
fluid, the dry gel material in the tank is conveyed from the horizontal auger charging the vertical auger
and overfilling the hopper of the DA1 feeder, providing a constant head of material for the metering
screw. The movement of dry gel in the tank is facilitated by the vibrators.

There are two ways to perform manual operations of the bulk tank controls. The first is using the
electric controls located inside the control house on the control stand. The second way is using
hydraulic controls located outside the control house on the hand rails. Table 2.3 shows the name of the
switch, its function, and its use. Figure 2.14 shows the pilot pressure block that allows for the hydraulic
controls. (The gel tank vibrator hydraulic controls are located on the 15-station actuator block).

Table 2.3—Switch Functions

Switch Function Use

Switches between forward and reverse


Lift auger FWD/REV
to help free a stuck auger.

Switches between forward and reverse


Bottom auger FWD/REV
to help free a stuck auger.

MAN HIGH/ Kicks the vibrators to a higher rev/min to


Gel tank vibrate
MAN LOW aid dry gel flow.

Switches between forward and reverse


DA1 FWD/REV
to help free the DA, if stuck.

Switches between forward and reverse


DA2 FWD/REF
on conditioning flight (DA2) to empty the DA hopper.

2-14 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 2.14—Manual hydraulic controls for bulk tank operation.

Handling Dry Gel Safely


Guar dry gel should be treated as a hazardous substance. When emptying the tank or filling the tank
with a super sack, wear proper personal protective equipment (PPE), including coveralls, eye
protection, gloves and a respirator. Health effects and treatment for exposure can be found in the
appropriate material safety data sheet (MSDS).

CAUTION Guar has a slight flammability risk.

WARNING Never place ignition mechanisms in the tank interior. Ignition mechanisms include
sparking devices as well as open flames. If ignition occurs, the tank is provided with
a rupture disc to help prevent damage.

WARNING During operation, no person should ever be on the tank.

October 2013 Operation and Maintenance 2-15


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Filling the Bulk Tank


The bulk tank is designed to be filled either by dumping dry gel from a bag or by blowing to the tank
pneumatically. Before filling the tank, read the section “Handling Dry Gel Safely.”

Filling the Tank by Super Sack


1. Load dry gel through the manway hatch on the front driver side of the tank. The hatch is
approximately 13.5 ft vertically.
2. Position the bags over the open manway and dump with a crane or a fork truck (if one is
available with sufficient range).

When Filling
1. Open the hatch and lay down the hand rail on the driver side.
2. Position the bag over the hatch and open.

NOTE While filling, the collapsed hand rail acts as a guard to limit the danger of the pinch
point presented by the bag.

Filling the Tank Pneumatically


The tank can also be filled pneumatically if a bulk transport vessel is available. A 660 trailer or
Fruehauf transport can blow material to the unit through the fill line located at the back of the tank.

The following steps in Table 2.4 are taken from the work method found at the blender web page titled
“Pneumatically Loading Gel on the ADP Blender.” These steps should be performed exactly as written
to help ensure the safety of all personnel. The URL is listed below:

http://halworld.corp.halliburton.com/HES/Hesps/hespspe/hespspe_fracacid/
hespspe_fracacid_eqblender/hespspe_fracacid_eqblender_drygel.asp

Table 2.4—Steps for Pneumatically Loading Gel on the ADP Blender

Step Action Comment

Turn on the cyclone pump on the ADP


1. —
blender.
Ensure the wheel valve on the top of the Do not over-tighten, as damage to gearbox
2.
ADP blender bulk tank is closed. can occur.

Open the butterfly valve on the rear of the


3. Located on the passenger top rear of the tank.
ADP bulk tank.

Connect the bulk trailer to the ADP blender


4. —
bulk gel tank.
Engage the PTO on the bulk tractor and idle
5. —
the engine to approximately 2,000 rev/min.

Pressurize the tank on the bulk trailer to 5 to The pressure may need to be increased due
6.
7 psi. to distance from the unit.

2-16 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Table 2.4—Steps for Pneumatically Loading Gel on the ADP Blender

Step Action Comment

This aerates the gel to prevent the fill line from


7. Open the bypass valve on the bulk trailer.
packing off.
Select the compartment on the bulk trailer
that you will remove gel from and open the Compartment needs to be at least half full of
8.
valve on the bottom of the compartment gel if possible.
halfway.

Watch the tank level readout on the ADP


9. Should load at about 500 to 1000 lb/min.
blender until the desired fill level is reached.

Shut the valve on the bottom of the


10. compartment and keep the bypass valve This allows the fill line to be purged of all gel.
open for 5 to 10 seconds.

Shut the bypass valve on the bulk trailer and Tank pressure should be at 0 psi before
11.
open the vent line to release the pressure. unhooking the hoses.
Shut down the blower and return the bulk
12. —
tractor engine to idle.

Turn off the cyclone pump on the ADP Should run for about 5 minutes after
13.
blender. operation.

Listed next is more content found at the blender web page, explaining how the diaphragm pump, wheel
valve, and cyclone detailed previously works. All of the images and content can be found at the
following URL:
http://halworld.corp.halliburton.com/internal/PS/pe/contents/Procedures_and_Manuals/web/
ADP_Dust_Separation_System.pdf.

Although the images are for older ADP blenders and not the eADP blender, the content is still valid
and should be followed.

ADP™ (Dry Gel) Blender Dust Separation System


The ADP automatic dry polymer blender is designed with a cyclone separator inside the dry gel tank.
When maintained and operated properly, this cyclone will efficiently remove the dust from the air
steam that is used to convey the dry gel from the transport trailer to the ADP blender dry gel tank.
Understanding how the system functions will help to eliminate dusting problems on location and
correct issues when they occur.

How the System Works


Air and dry gel from the transport trailer enter the rear of the ADP blender dry gel tank. Most of the
dry gel falls out of the air stream and settles at the bottom of the tank. The remaining air and dust enter
the cyclone where the air and dust are separated. The dust is collected in a container on the bottom of
the cyclone and the air exits out the top. Before the air returns to the outside of the tank, it passes
through a backup filter. The dust that collects in the bottom of the cyclone is removed by the
diaphragm pump on the walkway and returned back to the dry gel tank (Figure 2.15).

October 2013 Operation and Maintenance 2-17


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.15—Diagram of how ADP blender system works.

Why Dry Gel Can Exist on Location


The cyclone is the key component in the removal of dust. If air does not pass through the cyclone
correctly, the air and dust will not separate and dust will be carried out the air exhaust.

The dry gel must be removed from the collection bin on the bottom of the cyclone. If the diaphragm
pump on the walkway is on and operating correctly, the pump will continually remove the dust that is
collected in the bottom of the cyclone. If the pump is not on or not functioning, dust will build up over
time (one to two dry gel tank fillings) and the cyclone cannot effectively remove the dust. It is
important to start the diaphragm pump before blowing dry gel into the tank and when the cyclone dust
bin is empty. Starting the pump when the dust bin is full can plug off the pump.

The butterfly valve on the bottom of the cyclone should always be closed when blowing dry gel into
tank. Leaving the valve open allows air to short circuit the cyclone and the dust is not removed from
the air. It is recommended that the valve be closed all times and the diaphragm pump used to remove
the dust from the bottom of the cyclone. If the diaphragm pump is not working, the valve on the
bottom of the cyclone can be opened to dump the dust back into the tank. On stage jobs where dry gel
is continually loaded into the dry gel tank, the dry gel level may never fall below the valve. If the dry
gel level is above the bottom of the cyclone, it does no good to open the valve. If the valve must be
opened to dump the dust from the cyclone, running the tank vibrators can help the dust through the
valve and running the horizontal and vertical augers will help move the dry gel to the rear of the tank to
lower the dry gel level below the valve.

2-18 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Why Gel Might Come From the Relief Valve


The eADP blender tank has two safety devices to protect against over pressuring and rupturing the
tank. One is a blowout panel at the rear of the tank and the other is a relief valve at the front near the
handrail. Under no circumstances should these safety devices be removed or bypassed. If air is coming
out of the relief valve, there is too much restriction in the dust separation system. The cause of this
restriction is often a clogged filter on the exhaust of the cyclone. When functioning correctly, the
cyclone and the diaphragm pump will efficiently remove most of the dust from the air and the filter is
used only as a backup. The filter will become clogged very quickly when the cyclone is not
functioning properly. It is better to have no filter installed than a filter that is clogged and not allowing
the proper air flow through the cyclone.

All Steps were Followed and Dry Gel Still Exists on Location
Ensure the valve on the bottom of the cyclone is closing properly. Overtightening the wheel valve
actuator on top of the tanks can damage the actuator. Remove the rubber elbow on top of the cyclone
and verify the valve is closing by shining a light down the cyclone to visually inspect the valve or
placing a rod or strap stick down the cyclone to verify that the valve is closed. Turning the wheel left
should close the valve. Disregard any markings on the wheel; there is a stainless steel plate below the
wheel showing the correct direction to close the valve.

Ensure dry gel is being removed from the cyclone. Check the diaphragm pump for proper operation.
The hoses going to and from the diaphragm pump should not be packed off with dry gel. The hoses can
be removed by disconnecting the camloks on top of the cyclone. If dry gel is packed in the hose, run
the pump with the hoses disconnected or reverse the hoses and use the pump to clear the dry gel. If the
hoses are reversed, take care to hook the hoses up properly so that dry gel is being pumped from the
cyclone dust bin to the tank during filling operations.

If the hoses are cleared and the pump will still not remove the dry gel from the cyclone, use the air
purge line to fluff the dry gel in the bottom of the cyclone.

If the diaphragm pump is still not functioning properly, dust must be removed by opening the cyclone
valve. The dry gel in the tank must be below the valve level for dust to empty from the cyclone. Ensure
to close the cyclone valve every time after the valve is opened. Get the diaphragm pump repaired at the
first opportunity.

Check cyclone for damage. Cracks in the cyclone can allow air to short circuit the proper path and the
cyclone may not separate the air and dust. The cyclone can be quickly inspected by shining a bright
light in the cyclone outlet and looking in the dry gel tank for any light coming through cracks in the
cyclone. Remove the cyclone from the tank and inspect for cracks or gaps in the welds. Check the
cyclone valve for proper sealing and operation. Figure 2.16 through Figure 2.18 illustrate component
details.

October 2013 Operation and Maintenance 2-19


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.16—Component details.

2-20 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 2.17—Component details.

October 2013 Operation and Maintenance 2-21


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.18—Component details.

2-22 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

CAUTION Filling and blow down to the tank should not exceed 2-psi backpressure. At 3 psi, the
tank valve located on the driver side front of the tank will open and vent to prevent
destruction of the rupture disk, which will happen at 5 psi. The tank itself has been
pressure-tested to 5 psi without failure.

Diagnosing and Fixing a Seized Auger


1. Start the engine and check the operation of the tank.
2. The augers should be turned on in FORWARD. If the augers are turning, it should be observed
through the DA1 tab in the ACE control system software (Figure 2.19).
3. If the ACE control system software window shows that the augers are not turning, check the
gauges located outside the house. The maximum output of the auger load sense circuit is 3,000
psi. If 3,000 psi is indicated on the gauges, the augers are locked and not turning. An inline
sequencing valve causes a torque spike in the augers as they are first turned on. If the tank
does not immediately begin rolling:

• Flip the switch on and off, resulting in multiple torque spikes. This might be enough to free
them. If this does not work, bump the vibrators to high. This can be performed inside the
house by the toggle switch located on the console, or this can be performed with hydraulic
controls located outside the house.
• Attempt to operate the horizontal auger in reverse. Often, the auger might not turn in one
direction but can free up when bumped in the opposite direction.
• Use a mallet to hammer the auger housing while simultaneously attempting to start the con-
veyors.
• Open the air purge lines located on the horizontal and vertical auger housings. See Figure
2.20. This can help break up the packed gel and allow the augers to turn.

Figure 2.19—ACE control system GUI.

October 2013 Operation and Maintenance 2-23


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.20—Purge lines for auger housings.

Removing Dry Gel from the Bulk Tank


Dry gel inside the bulk tank can be removed two different ways. The first way is to empty the dry gel
into a super sack; the other is to blow the dry gel into a Fruehauf trailer.

To empty into Super Sack


1. With the eADP blender unit running, turn on the augers and vibrators only.
2. Position a super sack under the output manifold to receive the overflow from the tank. Open
butterfly valve on unloading manifold (Figure 2.21) to begin unloading gel into super sack.
3. When all the dry gel is nearly removed from the tank, run “DA2/Conditioning Flight” in
reverse (momentary switch located on console in control house) to empty the DA1 feeder hop-
per.
4. Close the butterfly valve on the unloading manifold and turn off augers and vibrators. Shut
down the unit.

2-24 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 2.21—Emptying into super sack from the output manifold.

To Empty into a Fruehauf Trailer


1. With the eADP blender unit running, turn on the augers and vibrators only.
2. Refer to Figure 2.22 for rigging up hose connections. Open the butterfly valve on unloading
manifold.
3. Run the Fruehauf trailer as one would to load the unit for pressure and rate from the blower.
However, only air will be delivered to the eADP blender unit, with no product in the supply air
stream.
4. Open the butterfly valve at the unloading manifold. This will allow dry gel to be gravity fed
out of the tank and into the unloading manifold to be blown back into the Fruehauf trailer.
5. When all the dry gel is nearly removed from the tank, run the “DA2/Conditioning Flight” in
reverse (momentary switch located on console in control house) to empty the DA1 feeder hop-
per.
6. Close the butterfly valve on the unloading manifold and turn off augers and vibrators. Shut
down the unit.

October 2013 Operation and Maintenance 2-25


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.22—Unloading the eADP blender dry gel back into the Fruehauf trailer pneumatically.

Liquid Additive Pumps


Figure 2.5 lists the makes/models and flow rates of the four LA pumps.

Table 2.5—eADP Blender LA Pumps

Flow Rate (gal/min)


Make Model
Low High

Waukesha Model 6 0.3 4.0

Waukesha Model 18 1.0 13.0

Roper 733025 GHV 0.2 3.1

Roper 73201 GHV 0.8 10.3

2-26 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Flowmeters
The T-Series meters are straight-tube flowmeters (Figure 2.23). The straight-tube design is self-
draining, compact, and reduces plugging. The wetted parts of the mass flowmeters are constructed
from titanium for excellent corrosion resistance. Titanium is not susceptible to chloride cracking, as
stainless steel is. The flowmeters are sized to match the flow rates of the supplied LA pumps. Refer to
Table 2.6 for flow rates.

Figure 2.23—T-Series flowmeters.

Table 2.6—Flow Rates for T-Series Flowmeters

Flow Rate, gal/min


Make Model
Minimum Maximum

Micro Motion® T050 0.2 17


T075 0.7 60

October 2013 Operation and Maintenance 2-27


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Bucket Test Manifold


After leaving the flowmeter, additive is pumped to the manifold located on the walkway near the
control house. At the manifold, a series of valves can be adjusted to either bucket-test, meter to
suction, or meter to the discharge. Also, on the manifold, is a valve that can be opened to allow the LA
pump to recirculate the vertical upright tank. The fourth liquid additive manifold (LA 5) circuit is not
connected to an onboard holding vessel and must be supplied from a storage vessel not on the unit. The
entire LA system can be air-purged and drained with the fittings provided.

Figure 2.24—Bucket test manifolds.

2-28 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

LA Pump, DA Feeder, and Transfer Pump Manual


Operation
All liquid additives, DA1, and transfer pumps can be controlled using electric over hydraulic controls,
located inside the control house (Figure 2.25), or manually at the hydraulic manifold mounted on the
walkway (Figure 2.26). The following can also be performed.

To begin manual control of DA1 or the LA pumps electrically, perform the following steps.

1. Ensure the toggle switch is in the ON position.


2. Adjust the rate of the function by turning the manual control knob:

– CW to increase.
– CCW to decrease.

Figure 2.25—Electric overrides for DA1 and LA pumps.

To begin manual control of DA1 or the LA pumps hydraulically, perform the following steps.

1. Turn the “Auto/Manual” lever to the MANUAL position.


2. Adjust the rate of the function by turning the manual control knob:

– CCW to increase.
– CW to decrease.

October 2013 Operation and Maintenance 2-29


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.26—Hydraulic manifold for DA1, LAs, and CT pumps.

The additive functions require the operator to reference system feedback on the ACE control system
computer. The operation of these functions, except the transfer pumps, is given in Table 2.7.

2-30 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Table 2.7—Additive Function Operations

Step *Operation

1 Turn the Man/Off/Auto lever of the desired function to the MAN position.
2 Begin turning the control knob CCW while observing the ACE control system computer display.

3 Adjust the rate of the function to the desired setting, as required.

4 Return the Man/Off/Auto lever to the AUTO position when manual operation is complete.
*The control knob can have up to two turns of dead band at the beginning of operation and at maximum speed.

The transfer pumps are operated in similar fashion to the LA pumps; however, there is no feedback
method. Flow must be judged visually by the rate at which the holding tanks fill.

In addition to the ACE control system feedback on the dry additive feeder, there is also a weight loss
feedback.

In the CAN module box, a controller (black box located inside enclosure) gathers weight information
from the load cells that support the bulk tank. Should the computer fail, on-the-fly processes will most
likely have to be abandoned; however, it might still be possible to batch tanks using the load cell
readout. Simply add the required amount of gel to the frac tank as given by the load cell controller.
Load cell operation and calibration is provided in Appendix A—Load Cell Operation.

Viscometer
The eADP blender unit is equipped with a Brookfield viscometer skid (SAP No. 101513143). The
manual SAP No. for The viscometer is SAP No. 101431495.

Transporting the Skid


In transport, the skid must be laid down in the horizontal position and secured down.

Operating the Viscometer


To use the viscometer during an operation, perform the following steps.

1. Raise viscometer to the vertical position.


2. Open the ball valves at the discharge of the concentrate pump that supplies gel to the viscom-
eter pump and on the hydration tank near the control house labeled “Viscometer.”
3. Toggle switch labeled “Viscometer Power.” (Ensure the viscometer is powered up by opening
the enclosure mounted on the top of the viscometer. If no power is observed, toggle the
switches at the viscometer to power the unit.
4. Fluid should be supplied to the unit at a rate of 3 gal/min.

Figure 2.27 shows both orientations of the viscometer.

October 2013 Operation and Maintenance 2-31


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.27—Viscometer orientations.

If the unit is connected to the eADP blender trailer, the following process will occur.

• Hydrated fluid will be supplied from the discharge side of the hydration tank to the
progressive cavity pump, MONOFLO CB012AC1V8.
• Fluid is delivered from the pump to the viscometer.
• After passing through the viscometer, the fluid returns to the hydration tank.

CAUTION Never run the viscometer pump dry.

The viscometer pump is a progressive cavity pump. At the end of a job, the hydration tank and/or the
discharge header will be evacuated of fluid. At this point, it is critical to shut off the pump supplying
the Brookfield viscometer. The stator can rapidly overheat and begin destroying the pump, resulting in
costly repairs.

Power Package—Deck Engine


Before each job, throttle the deck engine up to 1,800 rev/min using the ACE control system computer
or the manual override. For maintenance intervals, service information, and fill capacities, refer to the
manufacturer’s equipment manuals.

Hydraulic Power System


The hydraulic power system includes five independent circuits, each powered by a pump and one
charge/cooling loop supplied by a pump.

• The centrifugal pumps and mixer are driven by three dedicated hydrostatic drives, or
hydrostats. The hydrostats are hydraulic pumps that adjust their output flow and pressure as
required to maintain a given speed.

2-32 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

• The rev/min of the suction pump and concentrate pump can vary based on pressure and flow
requirements of a specific job entered into the ACE control system. The mixer operates at a
variable speed that starts at 1,600 rev/min and ramps up to 1,900 rev/min at a rate of 3 rev/min
(1 lb/gal) of DA1 increase. Feedback is through a magnetic pickup mounted on the coupler
between the motor and the centrifugal pumps.

NOTE A check valve between the supply and return to the mixer motor prevents the inertia
of the mixer from turning the motor into a pump.

• The conveying augers of the bulk tank are supplied with pressure and flow by the load sense
circuit. The augers operate at fixed speeds set at the spool valve located adjacent to the tank on
the mixer/suction pump mount. Inline, between the spool valve and the auger motors, are
sequencing valves set at 2,500 psi. When the augers are switched on (manually or by the ACE
controller), the sequencing valve limits flow until the pump is delivering 2,500 psi. The
sequencing valve then allows this pressure spike to the horizontal auger motor, causing a kick
in the torque delivered by this motor for startup. Pressure then drops to running pressure. This
process repeats immediately with the vertical auger.
• The remaining pump supplies pressure to the parallel circuit. This pump supplies a constant
pressure of 3,000 psi to the valve bank located on the walkway near the control house. This
bank divides flow between the dry additive feeder, the liquid additive pumps, the viscometer
pump, the transfer pump, the tub level valves, and the on/off hydraulic actuators controlling
the flow in the manifold.
• The remaining hydraulic pump provides hydraulic oil for cooling the entire system through
the two hydraulic coolers. The cooled oil from this circuit is also used to slightly pressurize
the suctions of the other pumps in the system.

Suction Pump, Concentrate Pump, and Mixer


The hydraulic manual controls for the centrifugal pumps and mixer are common to the same hydraulic
manifold. Fluid for the manual controls must be routed away from the automatic hydraulic valve using
a single lever. Figure 2.28 shows the locations of the knob and lever. Figure 2.29 shows the electric
over hydraulic manual controls. To adjust the rate of the function, turn the manual control knob in the
following directions.

• Clockwise (CW) to increase the rev/min.


• Counterclockwise (CCW) to decrease the rev/min.

October 2013 Operation and Maintenance 2-33


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 2.28—Hydraulic manual controls for the centrifugal pumps and mixer.

2-34 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 2.29—Electric over hydraulic controls for centrifugal pumps.

The suction and concentrate pumps require a feedback mechanism.

• If the computer is functioning, the ACE controller can be used, as detailed in Table 2.8.
• If the computer is not functioning but the unit has power, the pumps can be set at the desired
output using the mechanical gauges for suction and concentrate pressure as well as the Rose-
mount displays on the control stand to calibrate flowrate. Use of the controls is the same as
that given in Table 2.8.

Mixer operation does not require the same feedback. Flow control of the mixer motor has been limited
to 1,800 rev/min. The control should be set to manual and the dial should be turned to maximum flow.
This should result in a hydraulic pressure of 3,500 psi on the mixer motor.
Table 2.8—Manual Operation of the Concentrate and Suction Pump using
ACE Controller Feedback

Step *Operation

1 Turn the Man/Off/Auto lever of the desired function to the MAN position.

2 Begin turning the control knob CW while observing the ACE control system computer display.

3 Adjust the pressure of the function to the desired setting, as required.

4 Return the Man/Off/Auto lever to the AUTO position when manual operation is completed.
*The control knob might have up to two turns of dead band at the beginning of operation and at maximum speed.

October 2013 Operation and Maintenance 2-35


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Automatic and Manual Tub Level Control


Flow rate on the eADP blender trailer is established by tub level position at the discharge of the mixer.
The suction pump will provide a fixed pressure, and the tub level valve will open sufficiently to allow
flow through. If the unit is making concentrate to the hydration tank, the tub level valve will open or
close in response to the level of fluid in the tank. If the level drops rapidly, the valve will open quickly,
causing a spike in flow to the tank. If the level is relatively constant, the valve will “dither” about a
point, allowing consistent flow to the tank. If the tub level valve is not linked to the hydration tank, it
can be controlled manually using the following steps.

NOTE Manual control should only be performed in emergencies.

1. To bypass the automatic tub level control, close the two ball valves on the hydraulic tub level
valve assembly. This will isolate the proportional directional control valves from the circuit.
2. After the ball valves are closed, use the lever on the manual stack to control the tub level actu-
ator.
3. When flow is through the hydration tanks, adjust the level valve to maintain a constant tub
level relative to the rate fluid is pumped from the hydration tank.

Figure 2.30—Tub level control valve stack with manual override.

2-36 Operation and Maintenance October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Manual Valve Banks


The hydraulic components that function at a fixed-flow rate or fixed position are equipped with
manual overrides located on the walkway near the control house (Figure 2.31). These manual
overrides are four-way hydraulic direction-control valves. Internal to these valves are spools that direct
the flow to one side or the other of the affected hydraulic component. The spools can be shifted
electrically or mechanically using the manual override knobs.

To operate the components manually, push the override knob in all the way and turn it clockwise one-
quarter turn. This procedure will shift the spool and it will remain in a locked position. The hydraulic
manual overrides on the walkway can be used to actuate butterfly valves located in the manifold,
control direction of augers for bottom and lift, DA1 and DA2 (conditioning flight located in DA1
hopper), and control tank vibrator level (high or low).

Figure 2.31—Manual valve bank controls.

The last valve located on this assembly is “AC Compressor.” This provides hydraulic fluid to the
motor that turns the compressor for the air conditioner located on the control house. A pressure
compensated flow control valve is located downstream of this valve bank to regulate the amount of
flow delivered to the motor. The compressor motor should be set to turn at approximately 2,000
rev/min.

October 2013 Operation and Maintenance 2-37


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

2-38 Operation and Maintenance October 2013


Chapter

3
ACE™ Control System Controller
Functions

Introduction
This chapter contains an introduction to the ACE™ control system for blender-type units. Refer to the
Dry Gel Blender Controller and GUI Manual for detailed operating instructions. This manual is
available on the HalWorld website and as a hard copy (SAP No. 101310018).

ACE™ Control System Basics


Electrical over mechanical hydraulic devices on the eADP™ blender trailer are operated by electrical
signals sent from the ACE control system controller to the control valves through modules mounted on
the unit, known as device modules. The smart distributed system (SDS) device modules are
interconnected through a wiring scheme known as SDS BUS. The modules are connected through
common wiring to the controller (computer) and function as follows:

• The modules receive instructions to output signals or requests for information related to the
input.
• The SDS device modules send commands to the hydraulic valves.
• The hydraulic valves change actuator position or motor speed by controlling the pressure and
the amount of hydraulic fluid flow to the motors or actuators.
• The centrifugal and positive displacement liquid pumps, dry additive feeder, and actuators
physically move the fluids and chemicals.

Figure 3.1 shows the ACE control system control screen for the eADP blender unit; this display is
specific to the eADP blender unit.

October 2013 ACE™ Control System Controller Functions 3-1


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 3.1—eADP blender mixing unit controls system.

Closed-loop Control
The ACE control system is a closed-loop control. At application startup, all devices are set to
FORCED CLOSED LOOP, which means that the control system will not deviate from the closed loop
until instructed by the operator. The closed-loop system functions as follows:

• An electrical signal from the sensors (pressure, rate, pH, viscosity), referred to as feedback,
monitors speed or position. Feedback is the signal returned to the controlling computer
regarding the current status of a device.
• The operator enters a set point and the controller commands the devices to deliver.
• The controller monitors the feedback and continues to command until the set point equals the
feedback. When equal, the command is held until the feedback differs from the set point.

Knowledge gained with Halliburton’s other systems has benefited ACE control system operator and
maintenance personnel. As a result, the main display features 100% of the unit-critical information for
the blender, and secondary information is typically only one-level deep. The ACE control system
controller has built-in error-checking pertaining to the operator-entry set points. The system also has
three types of operator input: touch screen, keyboard, and mouse. The control system is easily
configurable; common components and interface functions were used from the pump and instrument
control systems. Training times are also faster because many operators will be familiar with the user
interface. The ACE controller system can be configured both as a controller and as a remote display for
control and monitoring of the blender. The TechCommand® center (TCC) uses the ACE system
controller as the primary interface to control and monitor all equipment on the jobsite. The ACE
system controller replaces the PCI in the TCC. The auto-job manager used in the TCC is the same one
used on the blender.

3-2 ACE™ Control System Controller Functions October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

eADP™ Blender Interface


Although the ACE control system is configurable based on the unit specifications, the eADP blender
display as delivered will have the following main elements:

• LA1—The concentrate system located below the hydration tank on the passenger side. The
function of the concentrate system is to meter high-viscosity fluid to the blender header for
dilution as it passes through the blender suction pump. Concentrations are in gal/Mgal with
the ACE control system typically slaved to the blender clean rate to correctly adjust the
proportion of fluid being sent to the blender.
• LA2, LA3, LA4, and LA5—Positive displacement liquid additive pumps located beneath the
operator control stand. These pumps may draw additives from tanks located on or off the unit
and can pump these fluids to locations on the unit, suction/discharge, or to locations off the
unit such as the blender suction or discharge. Each pump can be set up for metering control by
means of a tach drive or a flowmeter. These pumps typically meter as some proportion of a
rate being fed to them from a flowmeter on or off the unit.
• LA6—The viscometer pump, typically set at a fixed-flow rate that supplies gel to a
viscometer. The only feedback is a tach pickup.
• LA7—Controls valve number 12 (mixer fluid inlet) automatically to maintain a desired input
pressure (should be 10 psi).
• DA1—The feeder located in the dry bulk tank. It delivers dry gel in lb/Mgal of a flow rate.
This flow rate can be supplied by an onboard flowmeter or by the flowmeter on the blender,
depending on the type of operation. Dry gel metering is on a volumetric basis. Each turn of the
screw delivers a volume of dry gel to the mixer. The density of this volume is dependent on
the type of dry gel, each dry gel having a specific calibration factor that is entered from the
rate calibration button.

The dry additive feeder employs an optical encoder. Calibration is in pulses/lb (pul/lb), and there are
600 pulses per motor revolution. The motor supplies power to a 20.62:1 reduction gear box on the
DA1 feeder. Each revolution of the DA1 feeder is 12,372 pulses of the optical encoder. The majority of
gels calibrate to roughly 8,965 pul/lb (1.38 lb/screw revolution). More specific calibration data might
be necessary, depending on job requirements.

An additional element of the ACE system specific to the eADP blender trailer is the bulk tank level
given from the Tanks tab in the lower-left corner of the screen. Tank 1 is the bulk tank. Level
information is supplied to the ACE controller from the four load cells supporting the bulk tank. The
accuracy of the cal factor can be compared to the true loss in weight by employing the bucket test
function for DA1.

Tanks 2, 3, and 4 represent the vertical LA uprights. If the CT pumps are set to “AUTO” at the
hydraulic control block, then these tanks can be selected for “Auto Fill” in the ACE control system.
This will control the hydraulic flow delivered to the chemical transfer pumps to control the tank levels
of the uprights using the sensors.

Manifold Interface
The eADP mixer/ACE control system software is also supplied with a manifold screen. This manifold
screen is a dynamic interface that displays information on valve position, tub level, control valve
position, manifold pressure, LA1 rate, DA1 rate, suction pressure, mixer flow rate, etc. The interface
can be used to control all the displayed functions.

October 2013 ACE™ Control System Controller Functions 3-3


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 3.2—Valve names and numbers.

Table 3.1—Valve Names and Numbers

Valve Valve
Valve Name Valve Name
No. No.

Hydration tank roll 1 Discharge manifold 8

Driver-side header isolation 2 Hydration tank exit 9

Driver-side master suction 3 passenger-side header isolation 10

Driver-side mixer discharge (batch mixing) 4 Passenger-side master suction 11

Hydration tank fill 5 Mixer inlet water (controlled by LA7 in “AUTO”) 12

Concentrate pump suction 6 Mixer discharge 13

Passenger-side mixer discharge (batch mixing) 7 DA1 outlet 14

NOTE The computer always comes on showing all valves in the closed position. If the
blender is being operated manually before turning on the computer and some of the
valves are left open, the manifold page will not be reflective of the true valve posi-
tion. Finally, the valves on the manifold page are numbered such that the switches on
the control stand have descriptive names. Figure 3.2 shows a screen shot from the
ACE control system computer of the manifold and corresponding valve positions.

3-4 ACE™ Control System Controller Functions October 2013


Chapter

4
Pre and Post-job Checklists

This chapter contains a reprint of Work Method WM-GL-HAL-PE-418, which contains pre and post-
job methods as well as other topics that should be known to operate the eADP™ blender.

October 2013 Pre and Post-job Checklists 4-1


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 1 of 13
15.APR.2013 1

1.0 Purpose:

To establish a consistent procedure for pre-job, operation, and post-job activities for the ADP Blender.

2.0 Scope:

Global Production Enhancement

3.0 Approach or Procedure

3.1. This document contains the following topics:

This document contains the following topics:


Contents
Topic See Page
Pre-Job Work Methods 1
Operation Work Methods 5
Maintenance Between Stages 9
Post-Job Work Methods 10
Troubleshooting 11
Appendix A 12

3.2. Pre-Job Work Methods

Hose Rig Up Use the following guidelines to rig up hoses before the job:
Guidelines
Guidelines
One 4” suction hose should be used for each 8 bpm of clean rate plus one
extra hose.
If mixing work tanks or batch mixing, one 4” discharge hose should be used
for each 10 bpm of clean rate plus one extra hose.
Additional hoses may be required for high viscosity or greater distance to the
blender and/or work tanks.
If mixing concentrate, three 4” discharge hoses should be rigged up from the
dry gel blender to the downhole blender and placed as close to the suction
pump as possible.
Don’t connect to actuated valves on the downhole blender. Connect to and
keep open manual valves to prevent slugs of concentrated gel.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 2 of 13
15.APR.2013 1

You may get a better visc sample off the blender if you alternate water and
gel lines. (i.e.: If you have 3 water and 3 gel lines, place 3 waters on bottom
ports and 3 gels on top ports).

Pre-Start Use the following guidelines prior to starting the ADP blender:
Guidelines
Guidelines
Confirm the fuel tank, the hydraulic tank, and engine fluid levels are full.
BEFORE starting computer, start the engine and allow it to reach 700 rpm
and voltmeter reach 28 volts. The same batteries that start the engine also
power the computer; therefore you risk browning out the computer if it is
started first.

Use the following guidelines prior to loading gel on the ADP blender:
Loading
Guidelines Guidelines
The Fruehauf with gel should be spotted as close to the ADP blender as
possible, and no farther than 60’, to improve offloading times. A dry, non-
damaged 4” hose should be run from the Fruehauf to the ADP blender.
Confirm mixer and strainer are clean
Check each auger (3) to make sure it is turning before loading the bulk tank
with gel
Check bulk tank scale to ensure it is working properly and confirm amount of
gel in the tank with the vibrators off. There are four scales, and each scale
accounts for 25% of the load so they each need to be working properly or the
total weight will be wrong. Stand on each corner of the tank and verify each
corner indicates within 10 lbs of the individual’s weight. If it does not
indicate the correct weight, contact an e-tech for calibration check.
Determine the amount of gel required for the next job and load more gel if
necessary. BEFORE loading gel, verify the wheel valve on the cyclone is
closed and turn on the diaphragm pump; this will minimize dusting.
Do not fill the bulk tank with more than 6500 lbs of WG39 or 7500 lbs for
all other gel types. Determine if more gel will be required during the job.

Calibration Use the following guidelines to calibrate the ADP blender sensors:
Guidelines

Guidelines
Visually inspect t h a t Mag Flowmeter cables are connected properly.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 3 of 13
15.APR.2013 1

Verify slopes for suction pressure transducers:


• 9.38 psi/ma if using 150 psi transducer (standard)
• 18.75 psi/ma if using 300 psi transducer
Verify slopes for mag-meters:
• Slopes for 6” o r 8 ” mag-meters on the ADP are 100 p/gal.
Note: The FB4K and High Rate Blender mag-meters have a different
cal factor (10 p/gal). Do not get the calibration factors between the
ADP and downhole blender confused; they are different.
Check LA set points and cal factors for the appropriate LA pump:
• LA-2 thru LA-6 Micro Motion slopes should be 6000 p/gal.
• Confirm the Mag-meter slope on LA-1 (100 p/gal) and that it is set for
a 6” prop valve.
Check “Mixing Pump” slope. This should be set at 60. This is the mag pickup
for mixing pump and must be set correctly for correct RPM and mixing.
Check DA-1 set point and cal. factor. DA-1 (Acrison 5”) should be slaved to
the Dry Gel’s suction flowmeter. It should wake up slaved to the DGB. (If
not have the E-Tech fix the issue.)
LA-1 (6in Prop Valve) should be slaved to the suction side of the downhole
blender if mixing concentrate.

Check slope on tub level sensor. This should be around 6.5-6.8 and is
dependent on “Zero/Span” by the operator.
Bucket test each LA pump. Use the Bucket Test Mode for slaving the LA
pump. The ideal bucket test is at a rate above and a rate below expected job
rate.
Confirm LA pumps are slaved to the correct blender and plumbed to the
correct injection points.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 4 of 13
15.APR.2013 1

Function Use the following guidelines to function test the hydraulic actuated valves,
Testing augers, suction pump, concentrate pump, and mixer:
Guidelines
Guidelines
Test the valves:
• Visually verify that all hydraulic actuated butterfly valves open and
close from ACE. (Valves 12, 13, and 14 will not open until mixer is at
75% of set point rpm.)
• Visually verify the tub level valve calibration at 0, 50 and 100%
• Visually verify the LA1 valve calibration at 0, 50 and 100%
Test the augers with vibrators on:
• Bottom auger rotates ccw at shaft end, speed 60 rpm
• Vertical auger rotates cw at the shaft end 100 rpm
• Both augers should be able to run in reverse
• To test the Acrison feeder it should be empty. Do not turn it
backwards for testing. The flex hose has to be removed and 5 gal
bucket used to catch the powder to empty the Acrison. Powder can be
dumped back in tank after testing. 100rpm Max.
• After testing the Acrison feeder it should be refilled for the job.
Test suction pump.
• You must have water to the pump or mechanical seal will be
ruined.
• Use the manual up arrow in ACE and verify pump will turn.
• Use the manual control on the hydraulic valve block and verify the
pump will turn.
• Confirm the Manual and Auto pressure gauges are matching
• Do not run the pump longer than 60 seconds.
Test the concentrate pump.
• You must have water to the pump or mechanical seal will be
ruined.
• Close the 3 manual valves going to the blender.
• Confirm the Manual and Auto pressure gauges are matching
• Do not run the pump longer than 60 seconds.
Test mixer.
• You must have water to the pump or mechanical seal will be
ruined.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 5 of 13
15.APR.2013 1

• Without adding gel, run water through the mixer and confirm the rpm
reaches at least 1800 to 1900 rpm for old software. With newer
versions of software, the mixer should start at 1600 rpm and increase
3 rpm per lb/min.
• Do not run for more than 60 sec when testing.
• Verify mixer rpm is displayed in ACE.

3.3. Operation Work Methods


Operating Use the following guidelines to operate the dry gel blender:
Guidelines
Guidelines
Run the ADP Blender in Auto using the user defined variables.
• Never run the unit using the manual switches. Manual switches are for
emergency use only.
• Operators should be trained to set up DA1 in group commands but get
them used to using the DA1 Vickers valve to turn DA ON and OFF.
• The cal factor lbs/rev is different for each gel. Always make sure the
Acrison feeder has the cal/factor for the gel being run.

Design all jobs using the gel calculator on the unit and recheck with Q.C.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 6 of 13
15.APR.2013 1

• When using concentrate, the job should be designed for a discharge


rate to the blender of 900 to 1100 gpm and a max tank viscosity of
150 to 170 vis.
Leave DA-1 off until there is 5 to 8 bpm on the clean flowmeter. The
master gel valve will open once the mixer is at 75% of setpoint speed. Have
DA in auto and use Vickers valve to turn on and off.

Guidelines
Look into the top port on gel feeder (by removing rubber lid) to
confirm gel is being provided and confirm augers (3) are turning in the right
direction.
Vibrators should be on while mixing
Confirm all chemicals are going down visually and through straps from
chemical uprights and totes
Maintain tub level at approximately 75%
If mixing work tanks, start at 10 bpm and check viscosity before increasing
rate.
Have DA1 bucket test running to keep track of gel used and to calibrate the
DA feeder.
When mixing a work tank, bypass the hydration tank and use the
driver/passenger side discharge ports to gel tank. This would be valve 4 (driver

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 7 of 13
15.APR.2013 1

side) or valve 7 (passenger side). You can also use both to achieve the desired
rate.
• Use the “Fill Once” command in the tub level control screen to control
rate. Using this command allows the tub fill valve to read the suction
rate and not the tub level.
• You will also set the hydration tank up in the group commands for
“Fill Once”. DO NOT use the manual joysticks to control the tub fill
as this can lead to issues with the visc.
• Do not make more than 10 bpm changes at a time; take a sample after
each change in rate.

Check viscosity every 1,000 gals while mixing by samples and on the inline
viscometer
Keep the downhole blender’s suction pump at 30 psi to maximize the
mixing of the concentrated gel and the water.
Guidelines

Continuously check the amount of gel in the bulk tank and have the bucket
test screen open and running for the DA-1 feeder
The Bucket Test feature is a good indicator of how the gel is running but can
be overused during the job. Optimal is around 1% difference in the weight in
bulk tank and what the DA says it has run. If gel is at visc you may show
around a 5% difference. It’s recommended to not adjust anything in this case
since the bucket test does not take into account other factors that affect the
gel (base fluid, temp, hyd. time, etc.).

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 8 of 13
15.APR.2013 1

Never try to add gel to already hydrated gel as this can cause gel balls
and then plug up screen going to mixer.
Refill if necessary. Refer to “Instructions for Filling the ADP Blender While
Mixing” work method.
• Never let the gel get below 1500 lbs. in the bulk tank
• BEFORE loading gel, verify the wheel valve on the cyclone is closed
and turn on the diaphragm pump; this will minimize dusting.
• Always run the diaphragm pump when loading gel into the bulk tank
from the Fruehauf.
• Allow diaphragm pump to continue pumping 5 to 10 minutes after
loading before shutting it off. (NOTE: If pump is not turned on at
the onset of loading DO NOT turn on until load is complete or it may
clog up)
If mixing at very low rates, batch mix tubs at 10 bpm and let it drop.
Continue batch mixing until the discharge rate of the ADP is at least 10 bpm,
and then constant mixing can begin.
Guidelines
• When approaching flush, drop the tub level to 40%. (Remember you
can’t recover quickly from a low tub so “time this” so you will not
have to return to gel i.e. they decide to extend stage.)
• When going to water, turn off DA-1(using the Vickers valve) and let
the tub clean-up to water.
• While on water, open the strainer valve on the tub. If there is
restricted flow or no flow, the strainer may be plugged and requires
cleaning. Make sure the fluid coming out of the strainer is clear

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 9 of 13
15.APR.2013 1

before closing.
• NOTE: When running linear gel directly to blender valve 11
MUST BE CLOSED to prevent water from diluting the gel going to
the blender.

3.4. Maintenance Between Stages


Use the following guidelines to maintain the blender between stages:
Maintenance
Guidelines Guidelines
Clean the mixer
• Take the top cover off the mixing head to clean the wetting ring.
• Use a water hose from the suction pump or LA pump to spray the
mixer thoroughly until it is clean.
• Do not spray water thru the rubber cover that is above the Acrison
feeder this is the very top rubber cover.
• Make sure the water jet orifices are not plugged.
• Reassemble the cover.
Turn the DA-1 feeder to manual off from the hydraulic valve block when
shutting down. Do not leave in manual auto on the hydraulic override as the
feeder may creep and fill mixer with powder when 12 and 13 are opened.
SAFETY NOTE: Never put hands in the mixer to clean it unless proper
LOTO is utilized. (Follow WM-GL-HAL-PE-405 for LOTO instructions.)
Engine Regen
• Force a regen before starting the job. Ensure the regen process
completes (to 0% soot), which is indicated by the “Regen in Process”
lamp turning off.
• During the regen process, minimize changes to the engine speed and
load since changes could stop the regen process.
Roll the tub if linear gel is still in it and you are adding biocide. Otherwise,
the tank does not need to be recirculated. Do not roll thru mixer as it will
introduce large amounts of air into the gel causing problems with the LA-1
Mag Meter and will also clog the strainer and wetting ring jets.
Mix another tub if going to another stage and the viscosity is higher. DO
NOT attempt to increase viscosity by adding more powder. (If it is a
concentrate job and the vis is good no need to remix.)
There are several components that need grease at regular intervals:
some daily and some weekly,
• On the newer units the grease Zerts are on the back bumper of
the unit and are marked with service intervals.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 10 of 13
15.APR.2013 1

• These intervals will need to be more frequent when unit on 24hr


ops.

3.5. Post-Job Work Methods


Use the following guidelines to maintain the equipment after the job:
Post-Job
Guidelines Guidelines
Weigh the ADP unit after all modifications or additions (hoses, connections,
or tool boxes) are completed to determine payload available for transporting
gel in the bulk tank. Ensure that the weight of gel in the bulk tank does not
exceed this payload capacity before mobilizing the unit.
Clean up all LA pumps with water or LCA
Empty all uprights that had chemicals
Ensure all LA pumps and DAs are turned to off on the Vickers valve if not in
use
On the computer, exit out of Windows and shut down computer
using the correct procedure. Do not ever hard shut down computer.
Turn off all component switches and the main power switch
Complete pre-trip inspection before mobilizing the unit

Before the Use the following guidelines to maintain the dry gel blender before the next job:
Next Job
Guidelines Guidelines
Take apart and thoroughly clean the mixer and strainer
Wash the unit thoroughly to remove any gel build up
Clean dust filters after every 4 loadings.
Fuel Filters need to be changed at least every 5 days. The maintenance
department will decide if that needs to be done more frequently.
Follow grease guidelines on back of unit to grease daily and weekly
If excess dust was seen while loading or out of relief valve, have a
mechanic check the cyclone separator and diaphragm pump.
Report any problems to the maintenance group immediately
Refer to ADP Blender Tech Manual Table 5.1 – Post-Job Checklist

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 11 of 13
15.APR.2013 1

3.6. Troubleshooting
Use the following guidelines to troubleshoot the auger in the event that
Trouble- the augers stop:
shooting
Auger Issues Guidelines
Run the augers in reverse for a few minutes to adjust how the load
sits in the bulk tank. After doing this they should operate normally.
If the augers are locked up, the purge airlines in the auger housings
can be used to help break up the gel and free the augers.
If unit is accidently loaded above recommended volume and running
augers in reverse does not correct the problem, proceed with the
following steps:
• Follow WM-GL-HAL-PE-405 to LOTO the ADP unit
• Open the bulk tank hatch above DA
• Move gel away from lift auger and out of DA until the level
is even with top of DA hopper
• Ensure bulk tank guards are replaced before removing LOTO
locks or tags.
• Unload gel from the tank until tank contains less than 6500
lbs of WG39 or 7500 lbs for all other gel types.

SAFETY NOTE: Do not place anything near the opening of the


HSE
DA feeder when it is turning. This feeder opening is an extreme
safety hazard.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 12 of 13
15.APR.2013 1

Appendix A
The “Mix Concentrate” is to only be used if water going to the blender does not pass thru the
ADP. If water for blender is passing thru ADP modify ALL OFF so you do not shut off the
blender’s water supply.

Batch Mix

Mix Concentrate - no water to blender

Unless you have a good reason, never use the no change option (white box), see
examples above. Always use the check mark, red x, yellow or green valves when
making a group command, see example below.

Printed copies of this document are UNCONTROLLED


WORK METHOD
Title:
Halliburton Management System
ADP Blender
Document Number:
Region: Function/PSL:
WM-GL-HAL-PE-418
Global Process Assurance & Service Quality
Review/Revision Revision
Owner: Approved By: Job Review/Revision By: Page:
Date: No:
HEI Center PE GSQM HEI Center 13 of 13
15.APR.2013 1

Mix Concentrate - water going to blender from


ADP

Revision
Date Issued Summary of Key Revisions
No.

15.APR.2013 1 Original Release


To obtain a copy of a previous version of this document, please contact <FHOUPE-HMS>

Printed copies of this document are UNCONTROLLED


Chapter

5
Drawings

To help facilitate more accurate drawings for each unit, the following procedures should be followed.

1. Locate the unit number on the equipment tag located at the front of the trailer (Figure 5.1).
2. Enter that equipment number at the Halliburton equipment web page (Figure 5.2).
3. Click the “Magnifying Glass” icon (Figure 5.3).
4. From the right side of the screen, click on the “Documents” icon (Figure 5.3).
5. Open the Microsoft® Excel spreadsheet link description, “BOM 101999124 D EQUIPMENT
12180822.xlsx” shown in the example in Figure 5.4. This spreadsheet will display every part
used to assemble the eADP™ blender. The “Top Level Part” shown at the top of the Excel
spreadsheet will display the highest level bill of materials (BOM) used to build the eADP
blender, and this is called the “Specific Assembly.” This contains all the installations and
assemblies (stockable modules) as well as revision levels that were used to assemble the
eADP blender. Any installation drawings necessary can be found using this SAP number.
Navigate to CWI and type in this number to find the proper drawing required (Step 6). If an
actual replacement part is what is desired, it can be difficult to acquire using CWI starting at
the specific assembly and trying to drill down to a single component. The easiest way to locate
an individual SAP No. is to use the Excel spreadsheet mentioned. The best way to navigate
within this Excel spreadsheet (which contains thousands of lines of data) is to use the “Find”
toolbar feature. Pressing “Ctrl + F” will open the “Find” toolbar. Typing in a good, simple
description will help facilitate a productive Excel search in all the lines of data that make up
the spreadsheet. The column labeled “F” will display what the number represents (Part, Engr
Drawing, Documentation, etc.); this will help navigate what is located from the search. Keep
selecting “Enter” or “Find Next” until the desired search is located or Excel has displayed
everything from that search.

For example, if the 3/4-in. flow meter must be replaced, the best way to find this is to use the
Excel spreadsheet. Type “flow meter” into the “Find” toolbar and press “Enter.” This will start
displaying (in order) everything that has “flow meter” in the description. The first displayed
search shows “Document D00262513.” Pressing “Enter” again displays “Part 100003523,
NW, FLOW METER ASSEMBLY, 3/4 INCH…” Now that a good SAP No. has been found, it
can be ordered through the Halliburton Manufacturing Center or directly from the vendor.
Refer to the following steps below to do this.

October 2013 Drawings 5-1


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

6. Navigate to “Advanced Lookup” in CWI and type in the SAP No. in the “Search Text” field
referenced in Step 5 (SAP No. 100003523). Also, ensure “Part” is selected for “Type.” Click
“Search” (Figure 5.5).
7. If the correct revision letter is shown, click the SAP No. If the correct revision letter is not
shown under “Revisions,” (it is for this example), right-click the SAP No. and scroll down to
“Revisions.” While hovering over “Revisions,” click the revision letter that matches the letter
found in Step 6 (Figure 5.6).
8. This will pull up the Halliburton SAP No. that was setup and used to build the eADP blender
unit. This SAP number can now be used to order the flow meter through the Duncan
Manufacturing Center (DMC). In some instances, some parts might not have to be ordered
through DMC (mostly “buy” parts bought through DMC and not “make” parts manufactured
through DMC); and it might be cheaper/faster to order it directly from the supplier. Opening
this SAP number and contacting the “Organization” and ordering the “Manufacturer SAP
No.” will allow for this to be done.

Figure 5.1—Locating unit number (SAP No. 12180822 in this example).

5-2 Drawings October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 5.2—Halliburton equipment web page.

Figure 5.3—Magnifying glass icon from Halliburton equipment web page.

October 2013 Drawings 5-3


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure 5.4—Documents tab from Halliburton equipment web page.

Figure 5.5—Finding SAP No. and revision letter using “Documents” link.

5-4 Drawings October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Figure 5.6—Using advanced lookup in CWI.

October 2013 Drawings 5-5


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

5-6 Drawings October 2013


Chapter

A
Load Cell Operation

Setup and Calibration for the Load Cell


(SAP No.101432326)
The DGB load cell must be connected to the weight-indicator display on the operator console. The
following procedures describe how to set up and calibrate the load cell.

Connect to the Terminal


Connect to the load cell terminal using the following steps.

1. Using the HyperTerminal program on a user laptop, connect to the load cell terminal.
2. Configure the following parameters:
• Baud rate: 57,600.
• N,i,1.
• No flow control.
3. Power up the weight module and press the space bar. The terminal menu will display.

NOTE Every letter is upper case; the functions do not respond to lower-case letters
(Figure A.1).

4. Proceed to the next section to calibrate the load cell.

October 2013 Load Cell Operation A-1


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

Figure A.1—Every letter is upper case; the functions do not respond to lower-case letters.

A-2 Load Cell Operation October 2013


SAP No. 102236003 eADP™ Advanced Dry Polymer Blender Trailer Manual

Calibration Settings
To set up the parameters, Perform the steps listed in Table A.1.

IMPORTANT The tank must be empty before performing these steps.

Table A.1—Calibrating the Settings

No. Primary Step Secondary Step

1. Press the F key. Enter: 0

2. Press the M key to set the number of samples. Enter: 20

3. Press the N key to enter the step size. Set to: 30000
4. Press the O key. Turn on: 4MA

5. Press the P key. Enter: 3644

Set analog output scaling to: 165770


6. Press the Q key.
Nominal is 160000

If the tank is truly empty,


7. press D to capture the empty tank Enter: the tare weight
weight (D stores the “tare” weight).

Follow each menu to capture the empty tank


8. Press the A, B, and C keys.
weight to each

October 2013 Load Cell Operation A-3


eADP™ Advanced Dry Polymer Blender Trailer Manual SAP No. 102236003

A-4 Load Cell Operation October 2013

Verwandte Interessen