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TCC203 FRACTURING EQUIPMENT CORRESPONDENCE COURSE
EDC – Tomball, Version 1.01 Revised: March 2005
BJ Services Tomball EDC- Training Department
Copyright 2005, by BJ Services. All Rights reserved. No part of this manual may be reproduced in any form or by any means (including electronic storage and retrieval or translation into a foreign language) without prior agreement and written consent from BJ Services as governed by United States and international copyright laws
Training Department BJ Services 11211 FM 2920 Tomball TX 77375 Printing History: First Edition – November 2004 Credits : Training Department : Tim Ramsey, Training Engineer; Luis Duque, Training Engineer; Jim Wilke Manager Engineering Training Group; Ken Kenner Manager Corporate Training
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INDEX Subject
Page
Introduction
5
Fluid Pumps Frac Pump 1000 HHP Frac Pump 1100 HHP Frac Pump 1300 HHP Frac Pump 1400 HHP Frac Pump 149A Frac Pump 1600A –TM Frac Pump 1700 HHP Gorilla Frac Pump Kodiak Frac Pump Model SFP 1200 Rhino Frac Pump Gator Frac Pump
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Hydration Units Hydration Unit 30 bbl Hydration Unit 60 bbl
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Mixer
22 Frac Blender 125 BPM Frac Blender 2060 TM Frac Blender 30 BPM Frac Blender 40 BPM Frac Blender 50 BPM Frac Blender 70 BPM
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Frac Blender 80 BPM Model SFB 40 Sand Storage Sand King 2 TFS-300SD Sand Dump
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Stimulation Vessels
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Monitoring and Miscellaneous Equipment Treatment Vans Wireless LAN Monitoring BJ Services Wireless Chemical Additive Unit LFC Transport Unit UEC-II Remote control Fracman Remote Control
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Frac Equipment ___________________________________________________________________________________
Introduction This article was developed with the intention to be a guide for the correspondence course TCC203, which forms part of the T-CAP training plan in BJ Services Company. It presents an overview of fracturing equipment necessary to perform a fracturing operation either on land or offshore. Fracturing is a core service line, generating approximately 40% of BJ Services revenue over last the three years. A fracturing operation covers a wide range of applications; from convention water base Frac fluids, to oil base, foam (Nitrogen, Carbon Dioxide or Binary), as well as frac treatments with methanol. Over time the treatments have become more technologically demanding, due to high reservoir temperatures, pressures or water sensitive formations. Accordingly BJ Services has developed new technologies to meet the new challenges. Examples include, Polymer-Free water based fluids, oil based fracturing fluids designed for reservoir temperatures higher than 250o F, equipment rated for treating pressures as high as 20,000 psi (137.9 MPa) and pump rates as high as 125 BPM (19.8 m3). Generally speaking, fracturing equipment is comprised of the following: 1. Fluid Pumps 2. Hydration Units 3. Mixers 4. Chemical Additive Units 5. Sand Storage 6. Stimulation Vessels 7. Monitoring Technical articles of these components can be found on either BJ Services web page: http://www.bjservices.com/website/index.nsf/P&S?openframeset Or through Power Center: https://powercenter.bjservices.com/intranet/TechnologyToolbox/pif.nsf/SLbyRegio n?OpenView&SL=Fracturing
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FLUID PUMPS The fluid pump is the component of the frac fleet designed to deliver fluid into a well for fracturing or acidizing. The units are classified by their hydraulic horsepower (HHP), as well as by their design, i.e. either trailer mounted or skid mounted. The following list highlights BJ Services fracturing pumps: 1. Frac Pump 1000 HHP 2. Frac Pump 1100 HHP 3. Frac Pump 1300 HHP 4. Frac Pump 1400 HHP 5. Frac Pump 149A 6. Frac Pump 1600A HHP 7. Frac Pump 1700 HHP 8. Gorilla Frac Pump. 9. Kodiak Frac Pump 10. SFP 1200 11. Rhino Frac Pump 12. Gator Frac Pump 1. MFP 1000-BL Mobile Frac pump, 1000 Body load. The MFP 1000-BL is a truck mounted frac pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 1,000 HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower. Major Components • Engine: Detroit Diesel 12V14 rated at 1,350 BHP • Transmission: Allison 8962 • Pump: CWS Triplex with 4" to 5.75" Fluid Ends • Chassis is an 8x4 Heavy Duty truck Instruments and Controls • BJ Services Universal Engine Controller II
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2. MFP 1100-TL Mobile Frac pump 1100 Trailer Mounted The MFP 1100-TM is a trailer mounted frac pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 1,100 hhp, at pressures up to 15,000 psi. This unit is configured with (2) engines, transmissions and triplex pumps. The deck engine drives the fan for the radiator. Independent operation with each power train is possible. The rate capacity is based on the plunger size used in the fluid ends. The unit carries enough fuel for 4 hours pumping at maximum horsepower. Major Components • Engines: Detroit Diesel 16V71T/A rated at 700 BHP • Transmission: Allison 6061 • Pump: RR 1000 Triplex with 4" to 5.5" Fluid Ends • Trailer is a Heavy Duty, Two Rail Design Instruments and Controls • BJ Services Universal Engine Controller II 3. MFP 1300-TM Mobile Frac Pump 1300 Trailer Mounted The MFP 1300-TM is a trailer mounted frac pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 1,300 HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower Major Components • Engines: Detroit Diesel 16V149TI rated at 1,600 BHP • Transmission: Allison 8962 • Pump: CWS Triplex with 4" to 5.75" Fluid Ends • Trailer is a Heavy Duty, Two Rail Design Instruments and Controls • BJ Services Universal Engine Controller II
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4. MFP 1400-TM Mobile Frac Pump 1400 trailer mounted The MFP 1400-TM is a trailer mounted frac pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 1,400 hhp, at pressures up to 15,000 psi. This unit is configured with (2) engines, transmissions and triplex pumps. The deck engine drives the fan for the radiator. Independent operation with each power train is possible. The rate capacity is based on the plunger size used in the fluid ends. The unit carries enough fuel for 4 hours pumping at maximum horsepower
Major Components • Engines: Detroit Diesel 16V92T/A rated at 900 BHP • Transmission: Allison 6061 • Pump: RR 1000 Triplex with 4" to 5.5" Fluid Ends • Trailer is a Heavy Duty, Two Rail Design Instruments and Controls • BJ Services Universal Engine Controller II 5. 149A High Pressure Fracturing Unit The 149A high-pressure fracturing unit is mounted on a semi-trailer and is capable of pumping stimulation fluids at pressures up to 17,500 psi (121 MPa), or rates up to 32.8 BPM (5.21 m3/min) depending on plunger size and well pressure requirements. High-pressure fluid delivery is made through a triplex pump, which is rated for up to 1,800 BHP input. The 149A will provide up to 1,525 HHP, and has a turbocharged engine. The unit is operated remotely from a control console, which can be located at a distance up to 125-ft (38 m). The operator can select the optimum shift point to maximize hydraulic horsepower as required by well conditions. If required, an emergency kill system can be remotely engaged which will cut off air and fuel supply to the engine. A pressure limiting system can be preset to any maximum pressure to ensure that over-pressuring does not occur. Heavy-duty hydraulic starters and ether injection systems ensure reliable starting in cold weather.
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Major Components Engines: Detroit Diesel 16V149T rated at 1,800 BHP • Transmission: Allison 9686 • Pump: Triplex with 3.75" to 7.5" Fluid Ends Instruments and Controls • BJ Services Universal Engine Controller II
Figure 1
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6. MFP 1600A-TM Mobile Frac Pump 1600 trailer mounted The MFP 1600A-TM is a trailer mounted Frac Pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 1,600 HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower
Major Components Engines: Detroit Diesel 16V149TIB rated at 1,600 BHP • Transmission: Allison 9686 • Pump: CWS Triplex with 4" to 5.75" Fluid Ends • Trailer is a Heavy Duty, Two Rail Design Instruments and Controls • BJ Services Universal Engine Controller II 7. MFP 1700-TM Mobile Frac Pump 1700, Trailer Mounted The MFP 1700-TM is a trailer mounted Frac Pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 1,700 HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower. The unit can be configured with either a Triplex Pump or a Quintaplex Pump (T/Q). Major Components • Engine: Detroit Diesel 16V149 DDEC II rated at 1,900 BHP • Transmission: Twin Disc 6503 • Pump: CWS Triplex with 4" to 5.75" Fluid Ends • Trailer is a Heavy Duty, Two Rail Design Instruments and Controls • BJ Services Universal Engine Controller II EDC – Tomball, Version 1.01 Revised: March 2005
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8. MFP 2700 TM - Gorilla The MFP 2700-TM "GORILLA" is a trailer mounted Frac Pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 2,700 HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower Major Components • • • •
Engine: Detroit Diesel 16V4000 rated at 3,000 BHP Transmission: Twin Disc 8500 Pump: Triplex with 4" to 5.75" Fluid Ends Trailer is a Heavy Duty, Two Rail Design
Instruments and Controls BJ Services Universal Engine Controller II
Figure 2
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9. MFP 2000 BL - Kodiak Mobile Frac pump 2000 HHP, body load The MFP 2000-BL "KODIAK" is a truck mounted Frac Pump designed to deliver fluid into a well for fracturing or acidizing. The unit will deliver 2,000 hhp, at pressures up to 15,000 psi.
Figure 3
The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower. Major Components • • • •
Engine: Detroit Diesel 12V4000 rated at 2,250 BHP Transmission: Allison S9800 Pump: CWS Triplex with 4" to 5.75" Fluid Ends Chassis is an 8 x 4 Heavy Duty truck
Instruments and Controls BJ Services Universal Engine Controller II
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10. SFP 1200- Skid Frac Pump The SFP 1,200 is a skid-mounted Frac Pump designed to deliver fluid into a well for fracturing, acidizing and sand control. The unit will deliver 1200 HHP at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower Major Components • Engine: Detroit Diesel 12V149 rated at 1,350 BHP • Transmission: Allison 8962 • Pump: CWS Triplex with 4" to 5.75" Fluid Ends Instruments and Controls • BJ Services Universal Engine Controller II • Remote control for 100 ft • Over-Pressure shutdown system 11. Rhino TM Mobile Frac pump trailer mounted The MFP 1700-TM "RHINO" is a trailer mounted Frac Pump designed to deliver fluid into a well for Fracturing or Acidizing. The unit will deliver 1,700 HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger size used in the fluid end. The unit carries enough fuel for 4 hours pumping at maximum horsepower. The unit can be configured with either a Triplex or a Quintaplex pump. If it does have a triplex pump, them the Unit is identified Rhino T, and if the pump on it is a quintalplex its model is Rhino Q Major Components Engine: Detroit Diesel 16V149 DDEC II rated at 1,900 BHP Transmission: Twin Disc 6503 Pump: CWS Triplex with 4" to 5.75" Fluid Ends Trailer is a Heavy Duty Two Rail Design Instruments and Controls BJ Services Universal Engine Controller II EDC – Tomball, Version 1.01 Revised: March 2005
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Figure 4 Rhino
T
Figure 5 Rhino
Q
12. Gator Frac Pump Trailer The Gator Frac pump main components are: • • • •
2 1250 BHP Caterpillar 3412 DI SAT Diesel Engines 2 Geoquip LC-1200-BJ Triplex Plunger Pumps 5.5 : 1 Planetary gear reducers Allison DP8962 power shift transmission with TC1070 torque converters
The Gator will develop working pressures up to 15,000 PSI, with actual performance depending on fluid ends and plunger size selected. The engines and the transmission utilize electronic controls compatible with BJ Services Universal Engine Controller (UEC-II). The UEC-II controls and monitors engine functions and transmission shifting. Each pumping assembly operates independently, and either will remain functional should the other pump assembly be shutdown. The power end lube pumps, packing lube pump, and radiator fan are operated by hydraulic power supplied from the required Hydraulic-Ill tractor. The available plunger size is 4”, 5” and 5-3/4”.
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The Gator Frac Pump Trailer, when mated with a general-purpose tractor, is a selfcontained 2100 hydraulic horsepower (HHP) pumping unit designed for oil and gas fracturing services. Integral on-board back-up systems, higher available horsepower, add to the flexibility of this unit. Using twin pumps allows higher rates to be achieved than with a single pump Frac unit. The Gator Frac unit is designed to pump different types of fracturing fluids and generate the desired frac operating pressures. Fluid is supplied (supercharged) from the blender through a manifold system. Fluids from the blender may be plain water, acids or gelled fluids used to carry sand or other proppant.
Figure 6
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FRAC PUMP CLASSIFICATION Pump Model FRAC PUMP 1000 HHP FRAC PUMP 1100 HHP FRAC PUMP 1300 HHP FRAC PUMP 1400 HHP FRAC PUMP 149A FRAC PUMP 1600A -TM FRAC PUMP 1700 HHP GORILLA FRAC PUMP KODIAK FRAC PUMP MODEL SFP 1200 RHINO FRAC PUMP GATOR
ENGINE
TRANSMISSION
PUMP TYPE
HHP / PRESSURE (PSI)
RATES (BPM)
DD 12V149,1350 BHP
ALLISON 8962
CWS TRIPLEX 4-5.75 FLUID ENDS
1000 / 15,000 PSI
22
2-DD 16V71 T/A,700 BHP
ALLISON 6061
RR 100O TRIPLEX 4-5.5 FE
1100 /15,000 psi
32
DD 16V 149TI, 1600 BHP
ALLISON 8962
CWS TRIPLEX 4-5.75 F E
1300 / 15,000 PSI
22
2-DD 16V92T/A, 900 BHP
ALLISON 6061
RR 100O TRIPLEX 4-5.5 FE
1400 / 15,000 PSI
32
DD 16V 149T, 1800 BHP
ALLISON CLT 9686
TRIPLEX 3.75-7.5 FE
1500 / 17,500 PSI
32.8
DD 16V 149TIB,1600 BHP
ALLISON 9686
CWS TRIPLEX 4-5.75 F E
1300 / 15,000 PSI
22
DD 16V 149DDEC II,1900 BHP
TWIN DISC 6503
CWS TRIPLEX 4-5.75 F E
1700 / 15,000 PSI
22
DD 16V4000, 3000 BHP
TWIN DISC 8500
TRIPLEX 4-5.75 FLUID ENDS
2700/ 20,000 PSI
22
DD 12V4000, 2250 BHP
ALLISON S800
CWS TRIPLEX 4-5.75 F E
2000 / 15,000 psi
22
DD 12V149, 1350 BHP
ALLISON 8962
TRIPLEX 4-5.75 FLUID ENDS
1200 /15,000 PSI
22
DD 16V149 DDECII,1900 BHP
TWIN DISC 6503
TRIPLEX 4-6.5 FLUID ENDS QWS2500 QUINTALEX
1700 / 15,000 PSI
22
2 CATERPILLAR 3412 DISAT
ALLISON DP 8962
TRIPLEX 4-5.75 FLUID ENDS
2100 / 15,000 PSI
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FRAC PUMP CLASSIFICATION - METRIC Pump Model FRAC PUMP 1000 HHP FRAC PUMP 1100 HHP FRAC PUMP 1300 HHP FRAC PUMP 1400 HHP FRAC PUMP 149A FRAC PUMP 1600A -TM FRAC PUMP 1700 HHP GORILLA FRAC PUMP KODIAK FRAC PUMP MODEL SFP 1200 RHINO FRAC PUMP GATOR
ENGINE
TRANSMISSION
PUMP TYPE
HHP / PRESSURE (MPa)
RATES (M3/minute)
DD 12V149,1350 BHP
ALLISON 8962
CWS TRIPLEX 4-5.75 FLUID ENDS
1000 / 103.4
3.5
2-DD 16V71 T/A,700 BHP
ALLISON 6061
RR 100O TRIPLEX 4-5.5 FE
1100 / 103.4
5
DD 16V 149TI, 1600 BHP
ALLISON 8962
CWS TRIPLEX 4-5.75 F E
1300 / 103.4
3.5
2-DD 16V92T/A, 900 BHP
ALLISON 6061
RR 100O TRIPLEX 4-5.5 FE
1400 / 103.4
5
DD 16V 149T, 1800 BHP
ALLISON CLT 9686
TRIPLEX 3.75-7.5 FE
1500 / 120.6
5.2
DD 16V 149TIB,1600 BHP
ALLISON 9686
CWS TRIPLEX 4-5.75 F E
1300 / 103.4
3.5
DD 16V 149DDEC II,1900 BHP
TWIN DISC 6503
CWS TRIPLEX 4-5.75 F E
1700 / 103.4
3.5
DD 16V4000, 3000 BHP
TWIN DISC 8500
TRIPLEX 4-5.75 FLUID ENDS
2700/ 103.4
3.5
DD 12V4000, 2250 BHP
ALLISON S800
CWS TRIPLEX 4-5.75 F E
2000 / 103.4
3.5
DD 12V149, 1350 BHP
ALLISON 8962
TRIPLEX 4-5.75 FLUID ENDS
1200 / 103.4
3.5
DD 16V149 DDECII,1900 BHP
TWIN DISC 6503
TRIPLEX 4-6.5 FLUID ENDS QWS2500 QUINTALEX
1700 / 103.4
3.5
2 CATERPILLAR 3412 DISAT
ALLISON DP 8962
TRIPLEX 4-5.75 FLUID ENDS
2100 / 103.4
3.2
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HYDRATION UNITS Performance parameters of the hydration unit are based on the requirement of a "three minute" residence time to be provided for the liquid Frac concentrate (LFC) and for hydration of fracturing fluids. It provides the necessary volume and mixing shear to ensure complete hydration of the polymer before adding proppant or crosslinker. Four separate compartments allow the residence time to be controlled. The slurried polymer is added to the water at the inlet and is sheared through a static mixer. The resulting gel is passed into the first compartment, where the hydration process begins. The second and third compartments are equipped with power agitators to provide vigorous mixing. The final compartment contains the fluid for discharge to the blender. An in-line gel analyzer provides constant data regarding viscosity, temperature and pH. The LFC Control Module allows either manual or fully automatic operation of the LFC system and the seven liquid additive pumps. All parameters regarding fluids i.e., flow rates, totals etc can be sent to the BJ Well Treatment Analyzer, which then can be recorded and/or displayed, if desired. Operational parameters can be changed remotely from a computer for more rapid and complete control. The Universal Control Module can add additives by rate and in proportion to other rate (ratio mode). As an added feature of fluid inventory and control, mass flow meters can be easily installed and interfaced with this unit. Hydration Units are classified on their maximum delivering rate capacity The following are BJ Services Hydration unit’s models: 1.
Model MHU 30-TM
Mobile Hydration Unit Trailer Mounted: The MHU3-0-TM is a trailer mounted unit designed to carry Liquid Frac Concentrate (LFC) and provide residence time for the hydration of fracturing fluids. This unit will deliver the fluids to the frac blender at rates ranging from 5 to 30 bpm (0.8-4.8 m3). The unit is configured with a 100-bbl (15.9 m3) tank that has two compartments. The LFC is injected into the fluid via a static mixer and then flows over and under weirs for blending. Hydraulic powered agitators supply additional mixing energy. The 100-bbl tank gives over 3 minutes hydration time EDC – Tomball, Version 1.01 Revised: March 2005
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for the fluids. The piping allows the blender to "bypass" the MHU and take fluid directly from the Frac tanks. The unit is capable of carrying 2,000-gal (7.5m3) of LFC. An on board pump and Mass Flow Meter (MFM) provides accurate metering of the gel concentrate. The unit has an automatic tub level control system as well as continuous monitoring of the viscosity and pH levels. The power is supplied by an onboard diesel engine. The closed loop hydraulic pumps provide the power for the suction centrifugal pump, KCL pump system and the LFC metering pump. The Liquid Additive System (LAS) pump and tub level systems are powered by hydraulics that utilizes servo controls. Major Components • Chassis: Heavy duty trailer • Deck Engines: (1) Detroit Diesel 8V92T • LFC Pump: 2 to 40 gpm (7.6-151 Liters) • (1)MFM • On board tank for LFC • (4) compartment tanks, 200 bbl (31.8m3) capacity • Twentieth Century Suction Centrifugal pump (2) • Mission Suction Centrifugal Pump for KCL (2)
Instruments and Control BJ Services Pendant Control • Automatic and Manual LFC Pump Control • Automatic or Manual Tub level control • Ratio control based on unit suction rate • Fixed Flow Control • Mechanical pump speed sensors for backup • In-line Viscosity Meter and pH Meter
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2. Model MHU 60-BL(Formally known as CMG Hydration Unit)
Mobile Hydration Unit Body Load the MHU60-BL is a truck mounted unit designed to carry Liquid Frac Concentrate (LFC) and provide residence time for the hydration of fracturing fluids. This unit will deliver the fluids to the Frac Blender at rates ranging from 5 to 60 bpm (0.8-9.5m3). The unit is configured with a 180-bbl (28.6m3) tank that has four compartments. The LFC is injected into the fluid via a static mixer and then is recirculated through centrifugal pumps for blending. The unit also carries 1,300 gallons (4.9m3) of LFC. An on board pump and Mass Flow Meter (MFM) provides accurate metering of the gel concentrate. The unit has an Automatic tub level control system as well as continuous monitoring of the viscosity and pH levels. The piping allows the blender to "bypass" the MHU and take fluid directly from the Frac tanks. Power is supplied by the chassis engine via a PTO that drives the hydraulic pumps. The circulating centrifugal pumps are powered by closed loop hydraulic systems. The LAS pump and tub level systems are powered by hydraulics that utilizes servo controls. Major Components • Chassis: Heavy duty 8x4 with 500 BHP engine LFC Pumps: rated from 2 to 40 gpm (7.6-151 Liters) • MFM • On board tank for LFC (4) compartment tanks, 180-bbl capacity. Instruments and Controls BJ Services Pendant Control • • • • • •
Automatic and Manual LFC Pump Control Automatic or Manual Tub Level Control Ratio control based on unit suction rate Fixed Flow Control Mechanical pump speed sensors for backup In line Viscosity Meter and pH Meter
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Figure 7, Hydration Unit
BLENDER UNITS The Blender is literary the heart of a fracturing job – fracturing products are mixed before being pumped in to the well. The function of the blender is threefold: • To pull fluid out of the storage tanks • To mix the correct amount of propping agent • To deliver the sand-filled slurry to the fracturing pumps suctions at a low pressure (usually at 60 psi or less)
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1. Model MFB 30-BL Mobile Frac Blender CONDOR Body Load The MFB 30-BL is a truck mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 40 bpm (with water). The unit is configured with a patented CONDOR closed tub for mixing proppants with the frac fluids. The tub design utilizes a spinning impeller at the top of the tub to inject sand into the pressurized tub. The impeller is hydraulically driven. The suction pump is mechanically driven. Only one centrifugal pump is used. The chassis engine supplies the power for the blender. Major Components Chassis: Heavy Duty chassis, 6x4 configuration, with 450 BHP engine Tub: CONDOR Style, 1 bbl Active Capacity Sand Screws: (2) at 12" nominal diameter, hydraulically driven, mounted at 45° (2) Liquid Additive Systems Instruments and Controls BJ Services Automatic Controls · Automatic and Manual Sand Screw Control · Automatic and Manual Liquid Additive Systems · Programming of Job Stages, with Automatic or Manual Staging · Stage and Job Totals, Turbine Flow Meters
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2. Mobile Frac Blender 40 Body Load The MFB 40-BL is a truck mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 60 bpm (with water). The unit is configured with a "vertically configured" open tub for mixing proppants with the frac fluids. The tub design utilizes the flow of the fluid into the tub and directs that flow around the tub interior for efficient mixing with the proppants. A hydraulically driven agitator provides added mixing energy. The suction pump is mechanically driven and the discharge centrifugal pump is driven mechanically by the chassis engine. The chassis engine provides power for the hydraulic functions as well as the discharge centrifugal pump. Major Components Chassis: Heavy Duty chassis, 6x4 configuration, with 360 BHP engine Tub: Horizontal Tub, with Agitator; 10 bbl Active Capacity Sand Screws: (3) at 10" nominal diameter, hydraulically driven, mounted at 60°. (1) Liquid Additive System
Instruments and Controls BJ Services Automatic Controls · Automatic and Manual Tub Level Screw Control · Automatic and Manual Sand Screw Control. Turbine Flow Meter (6")
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3. Mobile Frac Blender 50 Trailer Mount The MFB 50-TM is a trailer mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 65 bpm (with water). The unit is configured with a horizontally configured open tub for mixing proppants with the frac fluids. The patented HYDROPACE tub design utilizes the flow of the fluid into the tub and directs that flow into a spiral movement for efficient mixing with the proppants. A hydraulically driven agitator provides added mixing energy. The suction pump is hydraulically driven, as is the discharge centrifugal pump. The deck engine provides the power for all the hydraulic functions. Major Components Trailer: Heavy Duty Two Rail Design Deck Engine: Detroit Diesel 16V71T, rated at 700 BHP Tub: Horizontal Tub, with Agitator; 8 bbl Active Capacity Sand Screws: (2) at 14" nominal diameter, hydraulically driven. They act as feed screws for the (2) 14" diameter Metering Screws (2) Liquid Additive Systems (1) Dry Additive System Feeders Instruments and Controls BJ Services Op-Amp Controls · Automatic Tub Level Control · Automatic Feed and Metering Sand Screw Control · Turbine flow meters (8")
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4. Mobile Frac Blender 2060 Trailer Mount The MFB 2060-TM is a trailer mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 60 bpm (with water). The unit is configured with a patented CONDOR closed tub for mixing proppants with the frac fluids. The tub design utilizes a spinning impeller at the top of the tub to inject sand into the pressurized tub. The impeller is hydraulically driven. The suction pump is hydraulically driven. There is a boost centrifugal pump, hydraulically driven, mounted on the unit. This allows higher supercharge pressures to the frac pumps. A single deck engine supplies the power for the blender. The unit is designed to allow suction or discharge on either side. Major Components Trailer: Heavy Duty Two Rail Trailer with Air Ride suspensions Deck Engine: Detroit Diesel Series 60, 14 Lt engine at 660 BHP Tub: CONDOR Style, 1 bbl Active Capacity Sand Screws: (3) at 14" nominal diameter, hydraulically driven, mounted at 45° (3) Liquid Additive Systems with Mass Flow Meters optional (2) Dry Additive System Feeders Instruments and Controls BJ Services MCM 2000 Automatic Controls · Automatic Discharge Pressure Control · Automatic and Manual Sand Screw Control · Automatic and Manual LAS and DAS · Programming of Job Stages, with Automatic or Manual Staging · Stage and Job Totals · Turbine Flow Meters (6" and 3") and Magnetic Flow Meters (6")
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5. Mobile Frac Blender 70 Trailer Mounted The MFB 70-TM is a trailer mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 70 bpm (with water). The unit is configured with a vertically configured open tub for mixing proppants with the frac fluids. The tub design utilizes tub jet rings for efficient mixing with the proppants. A hydraulically driven agitator provides added mixing energy. There is a Tub Bypass System. Major Components Trailer: Heavy Duty Two Rail design Deck Engine (1): Detroit Diesel 8V92T at 450 BHP Deck Engine (2): Detroit Diesel 8V92T at 450 BHP Tub: Vertical Tub, with Agitator; 12 bbl Active Capacity Sand Screws: (3) at 14" nominal diameter, hydraulically driven, mounted at 45°. (3) Liquid Additive Systems with Mass Flow Meters (2) Dry Additive System Feeders Instruments and Controls BJ Services MCM 2000 Control · Automatic and Manual Tub Level Control · Automatic and Manual Sand Screw Control · Automatic and Manual Liquid Additive System and Dry Additive System Control · Programming of Job Stages, with Automatic or Manual Staging · Stage and Job Totals. Turbine flow Meters (8. and 4") and Magnetic Flow Meters (8")
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BJ Services Tomball EDC- Training Department
6. Mobile Frac Blender 80 Trailer Mounted The MFB 80-TM is a trailer mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 80 bpm (with water). The unit is configured with a horizontally configured open tub for mixing proppants with the frac fluids. The tub design utilizes the flow of the fluid into the tub and directs that flow into a spiral movement for efficient mixing with the proppants. A hydraulically driven agitator provides added mixing energy. There is a Tub Bypass System. Major Components Trailer: Heavy Duty Two Rail design Deck Engine (1): Cummins rated at 500 BHP Deck Engine (2): Cummins rated at 600 BHP Tub: Horizontal Tub, with Agitator; 10 bbl Active Capacity Sand Screws: (3) at 14" nominal diameter, hydraulically driven, mounted at 45°. (3) Liquid Additive Systems with Mass Flow Meters (2) Dry Additive System Feeders Instruments and Controls BJ Services MCM 2000 Control Automatic and Manual Tub Level Control · Automatic and Manual Sand Screw Control · Automatic and Manual Liquid Additive System and Dry Additive System Control · Programming of Job Stages, with Automatic or Manual Staging · Stage and Job Totals. Turbine flow Meters (8. and 4") and Magnetic Flow Meters (8")
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BJ Services Tomball EDC- Training Department
7. Mobile Frac Blender 125 Body Load The MFB 125-BL is a truck mounted Frac Blender designed to mix and deliver fluids for fracturing or acidizing. This unit will deliver the fluids to the downhole pumps at rates as high as 125 bpm (with water). The unit is configured with a "horizontally configured" open tub for mixing proppants with the Frac fluids. The patented HYDROPACE tub design utilizes the flow of the fluid into the tub and directs that flow into a spiral movement for efficient mixing with the proppants. A hydraulically driven agitator provides added mixing energy. The suction pump is hydraulically driven and the discharge centrifugal pump is driven by the chassis engine. The deck engine provides power for the hydraulic functions. Major Components Chassis: Heavy Duty chassis, 8x4 configuration, with 500 BHP engine Tub: Horizontal Tub, with Agitator; 8 bbl Active Capacity Sand Screws: (3) at 14" nominal diameter, hydraulically driven (3) Liquid Additive Systems (2) Dry Additive System Feeders Deck engine: Detroit Diesel 6V92T rated at 360 BHP Instruments and Controls BJ Services Automatic Tub Level Control · BJ Services Automatic Sand Screw Control. Turbine Flow Meters and Magnetic Flow Meters
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BJ Services Tomball EDC- Training Department
BLENDER PERFORMANCE Blender Model Sand Density Rate - Water MFB 30-BL MFB 40-BL MFB 50-TM MFB 2060-TM MFB 70-TM MFB 80-TM MFB 125-BL SFB 40 (Cyclone ll.)
psa
BPM
Maximum Rate Gelled Fluids BPM
Sand Rate Min-Max LB/min
Liquid Additive System Gallons per Minute
Dry Additive System Lbs per Minute
20
1-40
30
100-15,000
Up to 15 gpm
NA
20
2-60
40
100-10,000
Up to 15 gpm
NA
20
5-65
50
300-20,000
Up to 15 gpm
Up to 60 Lbs./min
20
1-60
40
200-25,000
Up to 15 gpm
Up to 60 Lbs./min
15
5-70
60
300-23,000
Up to 15 gpm
Up to 60 Lbs./min
15
5-80
60
300-25,000
Up to 15 gpm
Up to 60 Lbs./min
20
5-125
100
300-25,000
Up to 15 gpm
Up to 60 Lbs./min
20
1-40
0.5-30
100-10,000
Up to 10 gpm
NA
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BJ Services Tomball EDC- Training Department
BLENDER PERFORMANCE - METRIC Rate - Water Blender Model Sand Density 3 3
MFB 30-BL MFB 40-BL MFB 50-TM MFB 2060-TM MFB 70-TM MFB 80-TM MFB 125-BL SFB 40 (Cyclone ll.)
Kg/m
M /min
Maximum Rate Gelled Fluids M3/min
Sand Rate Min-Max Kg/min
Liquid Additive System Liters per Minute
Dry Additive System Kgs per Minute
2396
.16 – 6.3
4.8
45 – 6,803
Up to 57 lpm
NA
2396
.31 – 9.5
6.4
45 – 4,536
Up to 57 lpm
NA
2396
.8 – 10.3
7.9
136 – 9,072
Up to 57 lpm
Up to 27.2 kgs./min
2396
.16 – 9.5
6.4
90.7 – 11,340
Up to 57 lpm
Up to 27.2 kgs./min
1797
.8 – 11.1
9.5
136 – 10,432
Up to 57 lpm
Up to 27.2 kgs./min
1797
.8 – 12.7
9.5
136 – 11,340
Up to 57 lpm
Up to 27.2 kgs./min
2396
.8 – 19.8
15.9
136 – 11,340
Up to 57 lpm
Up to 27.2 kgs./min
2396
.16 – 6.3
4.8
45 – 4,536
Up to 38 lpm
NA
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BJ Services Tomball EDC- Training Department
SAND STORAGE UNITS 1. Sand Kings BJ Services’ Sand King Mobile Field Storage Bin and Conveyor Systems eliminate the need to move and unload numerous individual bulk transports on location during jobs and provide a uniform and continuous delivery of proppant to the blender. The Sand Kings are powered by Detroit diesel engines. BJ offers two models, the CB2500 and the CB4000 with 250,000 Lbs. (113,636 kg) and 400,000 Lbs. (181,818 kg) capacities, respectively. The sand is gravity-fed through a hydraulically operated slide and gate valve onto a self-contained conveyor system and transported on a belt to the blender’s sand hopper.
Figure 8, Sand King
2. Sand Belt Conveyor The BJ Sand Belt Conveyor is utilized on stimulation treatments requiring large amounts of proppant. It allows up to eight (8) Sand Kings to be spotted for delivery. Adjustable gates give the option of proppant delivery to the left, right or to both sides simultaneously. The unit has two 36”in. (91cm) belts, each powered by its own Detroit diesel 3-53N engine. Each belt has a proppant capacity of up to 30,000 Lbs./min (13,636 kg/min). All systems are hydraulically powered and include a hydraulic landing gear assembly to raise and lower the tractor end of the unit. EDC – Tomball, Version 1.01 Revised: March 2005
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BJ Services Tomball EDC- Training Department
3. TFS-300SD Bodyload Sand Dump The TFS-300SD Sand Dump is capable of hauling and storing up to 300 ft3 (8.5 m3) of proppant. The dump bed, divide into two compartments for storage of different proppants, is raised for unloading during the stimulation treatment. Hydraulic power is delivered from the chassis engine / transmission.
STIMULATION VESSELS BJ Services operates the largest fleet of stimulation vessels in Latin America and offers the second-largest dedicated fleet of stimulation vessels in the industry, with operations in the North Sea, the Gulf of Mexico, Latin America and offshore Africa. Using fracturing barges and skid mounted units aboard workboats, BJ provides stimulation services from the inland waters of Louisiana to Lake Maracaibo and Southeast Asia. BJ Web site link for Gulf of Mexico Stimulation Vessels: http://www.bjservices.com/website/ps.nsf/0/15BA4C43CD6C7C9F86256F1 D00535DD4/$file/Deepwater+Stimulation+Vessels-Gulf+of+Mexico.pdf Power Center link for BJ Stimulation Vessels: https://powercenter.bjservices.com/86256A3E00482B4A/$All?SearchView &SearchFuzzy=TRUE&Query=Challenger,%20Vessels
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PRODUCTION
2004 World survey of marine stimulaton vessels
• •
224 270
M/V Blue Angel M/V Blue Ray M/V Blue Shark M/V Challenger M/V Discovery Hippo 8 M/V Seamar III 9 M/V Vestfonn
•
275 265 260 240 240 172 205 270
• • • • • • •
10
11 12 13 14
Schlumberger 15 16 17 18 19 20
Bigorange 18 Bigorange 25 DeepStim DeepStim II DeepStim III Galaxie
Notes:
28,000 20,000
12,000 12,000
530 880
10,000 8,000
2,000 10,000
250,000 1,000,000
n/a n/a
4,000 6,600
750,000 1,200,000
6,040 6,600
11,600 16 11,600 20
Yes Yes
61 60 56 56 56 40 50.5 60
9,600 14 6,780 12 5,400 13 3,200 10.5 3,200 10.5 5,550 12 3,240 12 6,480 12
60,000 13,000 40,000 12,000 12,000 10,000 40,000 180,000
9,850 12600 gal 32,800 14,000 14,000 1,100 13,270 3,150
None 350 None 400 400 None 1,700 n/a
None 20,000 None 12,000 12,000 None None 22,000
None 4,250 None 2,000 2,000 2,000 None n/a
500,000 425,000 425,000 200,000 200,000 145,000 308,700 n/a
57,000 n/a None
n/a None 6,650
1,200 10,450 500 4,200 6,040 None None n/a
1,800,000 1,080,000 1,025,000 1,032,000 827,000 No 308,700 1,205,000
4,000 3,500 10 Yes 10,800 7,915 25 Yes 2,380 1,720 10 Yes 4,200 8,913 15 Yes 6,040 11,348 15 Yes 1,900 No n/a No 1,700 2,380 15 No 10,875 7,143 60 Note 2
Don Weinheimer, 10200 Bellaire, Houston, TX 77020; phone: (281) 575-3994; email:
[email protected]
Halliburton Energy Services Cape Hawke Falcon Tide Gulf Stim Halliburton 220 Halliburton 301 Skandi Fjord Stim Star Stim Star II Stim Star III War Admiral
4,000 10.5 3,420 12.5
Greg Salerno, 5500 Northwest Central Drive, Houston, TX 77092; (713) 895-5459; email:
[email protected]
BJ Services US/Gulf of Mexico 3 4 5 6 7
54 56
Gel on the fly capability?
Mike Naquin, 654 N. Sam Houston Pky, Suite 400, Houston, TX 77060; phone: (713) 625-6600; email:
[email protected]
1 RC Baker 2 HR Hughes
Filter capability (bbl/min)
Baker Oil Tools
Water (bbl)
Frac (bbl)
Tankage
Proppant (cu ft or lb)
Gel / completion fluid (bbl)
Proppant (lb)
Additives (gal)
Below deck
Bulk (cu ft)
Gas (gal)
Gel / completion fluid (bbl)
Additive (gal or lb)
Cruising speed (kts)
Total beam (ft)
Total length (ft)
Middle East
South America
West Africa
Photo #
Gulf of Mexico North Sea
Contractor and Vessel Name
Above deck
Acid (gal)
Statistics
Main engine horsepower (hp)
Region of operation
• • • • • • • • • •
200 258 237 210 210 288 274 240 260 220
56 49 48 42 42 61 56 56 56 44
4,200 12 **67,288 3,000 10 **256,000 3,000 12 ***** 2,640 12 80,000 2,450 10 129,000 7,200 14 180,000 3,420 14.2 **60,000 3,420 14.2 ***** 5,400 14.2 ***** 4,000 12 20,000
11,400 10,000 8,000 4,000 4,400 12,000 12,100 8,000 10,000 8,000
None None None None None None 620 None None None
50,000 n/a ****** 15,000 12,000 42,000 n/a ****** ****** 25,000
None None None None None None None None None None
None 69,000 None 240,000 n/a 2,450 2,100 cu ft None 2,320 60,000 None 1,425 None None 1,570 1,730,000 136,000 19,760 6,680 cu ft 0 4,850 6,680 cu ft None 6,040 8,350 cu ft None 10,230 210,000 n/a 2,200
59 44 56 56 44 44
5,000 3,600 3,420 3,420 3,200 3,900
10,000 11,000 8,250 8,250 8,250 7,750
None 380 870 860 810 240
24,000 10,000 4,000 3,050
1,150 3,600 2,000 2,000 2,000 2,000
1,200,000 14,800 50,000 n/a 200,000 0 200,000 0 200,000 200,000 0
None None 6,000 cu ft None None 2,500 8,075 cu ft 8,075 cu ft 10,500 cu ft 8,000
2,200 5,085 n/a 2,450 2,588 n/a 2,320 2,976 10 1,425 5,300 50 n/a 2,625 30 23,810 7,140 100 4,850 4,850 75 5,465 10,486 75 8,870 6,740 75 2,200 4,000 10
n/a Yes Yes Yes Yes Yes Yes Yes Yes Yes
5,500 1,200 4,800 6,600 4,140 240
Yes Yes Yes Yes Yes Yes
[email protected] • • • • • •
1) 2 off Drexel 3” line 2) 4,500 gal of LFC 3) 4”/ 3”/ 2.75”
243 217 260 270 239 220
12 10 12 12 12 11
240,000 120,000 8,400 8,400 12,600 45,000
4) DGPS/Satloc 5) Two 1,200 hp bow thrusters: 1 fixed, 1 dropdown
4,000
2-stern thrusters 600 hp 6) 1,000 hp tunnel and 1,200 hp dropdown
15,400 n/a 12,200 14,700 6,400 6,400
7) 350 hp tunnel and 1,200 hp dropdown
1
3
5
7
9
2
4
6
8
10
74 Offshore June 2004 • www.offshore-mag.com
5,500 1,200 4,800 6,600 4,140 2,750
5,500 1,200 4,800 6,600 4,140 5,800
60 8 70 70 35 25
PRODUCTION General Notes:
Worldwide offshore marine vessels capable of self-propulsion
• “Data not provided” indicated by blank cells • Pump types common to all vessels in survey are quintiplex and triplex positive displacement pumps with Coflexip high pressure line(s) • Pump “Number” includes all pumps available • Pump “Max Rate” includes all pumps available • Pump “Max Pressure” is highest rating of all pumps on rigs Pumping equipment
15 15
Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes No Yes
Yes Yes Yes Yes Yes No Yes Yes
3, 4 3, 4 3, 4 3 3 3 3 Note 3
380 350 380 300 400 200 200 600
15,000 15,000 15,000 15000 15000 10,000 10,000 10,000
9 7 6 5 5 4 3 8
12,000 12,500 !! 8,600 8,400 ! 8,400 ! 5,200 3,550 13,400
60 75 60 45 45 50 30 60
15,000 15,000 15,000 15,000 15,000 15,000 10,000 10,000
8,400 4,200 8,400 2,100 2,100 n/a 2,100 2,730
12,000 12,500 8,600 8,400 8,400 5,200 3,550 13,400
Yes Simrad SDP01 Yes Nautronics ATS11 402 Yes Robertson No n/a Yes Nautronics ASK 4001 Yes Kongsberg 703 Yes Simrad/Kongsberg SDP21,Class 2 Yes Simrad/Kongsberg SDP11,Class I Yes Simrad/Konesberg SDP21,Class II Yes Robertson
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
3 4 3 3 3 4 3&4 3&4 3&4 3
80 400 300 110 320 400 450 400 400 300
15,000 10,000 10,000 10,000 15,000 15,000 15,000 15,000 15,000 15,000
4 5 5 10 8 6 7 6 8 5
6,750 7,500 8,000 6,000 4,800 10,400 10,150 17,500 21,500 8,500
35 50 32 100 70 100 75 64 64 35
15,000 11,500 15,000 15,000 11,200 15,000 15,000 15,000 15,000 15,000
2,940 2,940 3ea 2,100 5,000 2,100 5,040 7ea 2,500 7ea 2,500 7ea 3,100 5,000
6,750 7,500 8,000 6,000 4,800 10,400 10,150 17,500 21,500 8,500
Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes
Yes Yes Yes Yes Yes Yes
3 3 3 3 3 4
480 400 2 x 300 2 x 300 1 x 300 1 x 300
15,000 15,000 22,500 22,500 22,500 10,000
9 3 8 8 5 5
12,600 6,400 16,850 21,450 12,850 8,500
70 60 50 50 25 40
12,500 10,000 15,000 15,000 15,000 15,000
2,100 2,100 2,100 3,360
12,600 6,400 16,850 21,450 12,850 8,500
Dynamic positioning type
Thrusters (hp)
32,000 36,000 32,000 17,000 17,000 14,000 10,000 22,000
50 75 50 45 45 30 25 60
Yes Yes Yes Yes Yes Yes No Yes
4,200 3600 (5) 4,800 Yes *** (6) Yes *** (7) 280 600 3,200
35 50 25 100 70 60 50 50 75 50
n/a n/a n/a n/a n/a 48 200 n/a n/a n/a
35 50 n/a 100 70 60 30 n/a n/a 20
n/a 20,000 11,000 n/a n/a 20,000 20,000 20,000 20,000 20,000
35 50 18 n/a n/a 60 50 50 60 50
Yes Yes Yes No No Yes Yes Yes Yes Yes
1,200 1,800 2 ea 1,000 280 650 3,300 1,200/1,000 1,000/400 2-1,000/1-1,200 680
70 80 70 70 35 50
5,500 150 4,800 6,600 4,140 240
60 70 30 30 25 40
60,000 18,000 18,000 18,000 18,000 18,000
70 25 50 50 25 40
Yes No Yes Yes Yes Yes
7,100 750 1,550 2,200 2,200 700
** *** n/a
Acid storage below deck Navigational thrusters are of Azimuthal type Not applicable
Kongsberg ADP 702 Robopos/Tautwire Konsberg/Simrad Konsberg/Simrad Konsberg/Simrad Konsberg/Simrad
****** Use MPT's as needed for CO2 and N2 !! Hp expandable to 16,500 hhp ! Hp expandable to 10,400 hhp
**** Hp expandable to 11,000 hhp ***** Use 5,400 gal MPT’s, no permanent storage
11
13
15
17
19
12
14
16
18
20
www.offshore-mag.com • June 2004 Offshore 75
27,000 hhp
Yes Yes Yes Yes Yes Yes Yes Note 1
200 50 444 25 200 50 400 8 400 8 No n/a 120 30 238 60
24,000 hhp
DP-2 DNV Certified Bier DP-2 ABS Certified DP-2 ABS Certified DGPS-SAT DGPS-SAT n/a n/a Simrad SDP21/DP2
120 120 120 60 60 50 50 60
21,000 hhp
Yes Yes Yes Yes Yes No No yes
Rudy de Grood, 654 N. Sam Houston Pky, Suite 400, Houston, TX 77060; phone (713) 625-6443; email:
[email protected] 60 110 2 x 60 180
18,000 hhp
9,800 12,500
9,000 hhp
2,100 2,100
6,000 hhp
15,000 15,000
3,000 hhp
9,800**** 50 12,500 60
Max. rate (b/m)
5 7
Total hydraulic horsepower (hhp)
15,000 15,000
Number
2 x 350 2 x 350
Line pressure capability (psi)
2x3 3&4
Treatment line length (ft)
Yes Yes
Treatment line size (in.)
Yes Yes
QA/QC lab on vessel?
Yes Yes
Quick disconnect work w/ power loss?
Yes Yes
One button operation shutdown?
DGPS-SATLOC + RF/DGPS Kongsberg/Simrad-SATLOC
Hose reel quick disconnect?
Yes Yes
Dynamic positioning
700*** 1,200/1,000***
Frac on the fly capability? Yes Yes
Frac (bbl/min) 50 60
Proppant (lb/min) 16,000 2 x 18,000
15,000 hhp
Total operating pump capability (frac pumps)
Below deck pump capability (gpm)
Safety equipment
Max. pressure (psi)
Navigational equipment
Acid (bbl/min)
Batch (bbl)
Blenders (bbl/min)
Mixing equipment
12,000 hhp
Victor Schmidt, Exploration Edtior
BJ Services Tomball EDC- Training Department
MONITORING & MISCELLANEOUS EQUIPMENT Monitoring, recording and fracturing control equipment is crucial to job performance. For this reason, BJ uses the most advanced instruments in the field to monitor job progress. Among them being: • Universal Engine Controller, UEC-II • 125 Blender Controller • Hydration Unit Control System • Trailer Mount Chemical Additive Control System • FLV-1400 • FLV-350 • HTV-350 • STV-1400 • STV-2600 • IsoLink Wireless LAN • Wireless Wellhead Unit • MicroPlex Battery • Microplex Monitor • VisiPlex Monitor • Stimulation Vessel Integrated Control System •
Gas Hazardous Area Isoplex Data Acquisition Unit
The BJ Services Wireless LAN System replaces well site LAN cabling with radio links allowing for zero time deployment at the wellsite of treatment data communication. The units directly replace BJ LAN cables or may be used interchangeable with LAN cables. Since cabling is not used, the problems with maintaining conventional cables are eliminated and the reliability of the signals are improved. EDC – Tomball, Version 1.01 Revised: March 2005
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BJ Services Tomball EDC- Training Department
Features and Benefits • Operates in extremely harsh environments with immunity from interference. • Eliminates the need to run LAN cables between units and the time it takes to lay, retrieve, clean and store these cables. • Supports wireless data transmission between 3305 and remote computers via the computer serial port.
Figure 9. Wireless LAN
Figure 10. Wireless LAN
WIRELESS WELLHEAD UNIT The Wireless Wellhead Unit provides complete monitoring capabilities at the wellhead without the need for cables running back to the monitoring van. The unit incorporates the Microplex Monitor, companion battery pack and an IsoLink Wireless LAN module to form a complete integrated package. (See individual spec sheets for complete specifications) The Wireless Wellhead Unit is designed to operate with BJ's JobMaster system. The unit is approximately 5 1/2 feet high. Power Center link for BJ monitoring & miscellaneous equipment: https://powercenter.bjservices.com/__86256d48004debc5.nsf/WebByCatego ry?OpenView&Start=1&Count=30&Expand=1#1
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Flow Meters BJ uses a variety of devices to measure flow. They include: • Turbine Flow Meters - to measure fluids or slurries • Magnetic Flow Meters - to measure fluid, slurries, and N2 gas • Target Meters - to measure N2 gas • Mass Flow Meters - to measure fluid and slurries The first three measure volumetric flow and the latter, mass flow. Turbine Flow meters work best in low viscosity laminar flow. Target and Magnetic Meters perform well in laminar and turbulent flow patterns. The target meter is recommended for both gas and liquid service but not for slurries. Although Magnetic Meters are not designed for gas measurement, they generally work well in all fluid services. The Turbine Meter performance is most affected by changes in Fluid Properties. The largest measurement errors with volumetric flow meters occur at low rates. This demonstrates the importance of sizing the flow meter for the application. Meters with large diameters will have more measurement error at nominal flow rates than smaller diameter meters will. If the meter is too small for the desired rate, there will be a significant pressure drop across the meter. Types of meters to measure volumetric flow. • Turbine Flow Meter • Magnetic Flow Meter • Target Meter Turbines Flow Meters Turbine flow meters indicate flow rate and measure total throughput of a liquid line. The unit consists of a multiple-bladed rotor, or impeller, mounted within a pipe, perpendicular to the liquid flow. Most turbines use flow straighteners on both the inlet and discharge end of the meter to make the flow pattern more laminar. As liquid flows through the meter and over the rotor, the rotor turns at a speed that is directly proportional to the flow rate. A magnetic pickup senses the rotor blades as they pass and generates an electrical (sine wave) signal. The magnetic pickup is mounted outside the flow tube, and the electrical pulses from this pickup can be converted to proportional flow rate or counted and totaled in a remote monitor.
The Turbine Flow Meter is designed to measure the flow of liquids and gases in pipes to 2% inaccuracy. They are volumetric flow measuring devices and have been available since the late 1940s. The Turbine Flow Meter is a flow measurement “workhorse”, having proven itself over the years. In spite of the many new types of flow meters now in use, the Turbine is still a popular choice. Turbine Flow meters are very accurate for measuring clean fluids of low to medium viscosity. The turbine has a linear output. Turbines are available for virtually any pressure and for high and low temperature applications. Limitations are incompatibility with high viscosity or slurries. Gas turbines are designed for gas service only; not fluid. Turbines are used primarily for the following BJ applications: • On the suction side of blenders to measure clean rate • On the discharge side of blenders to measure slurry rate • Measure hydraulic fluid flow for the impeller, suction and discharge centrifugal pumps on blenders. • With CO2 manifolds to measure liquid CO2 rate • On Canadian nitrogen pumpers to measure gas rate • Measuring mix water rate on cement pumpers Mechanical Installation - Turbine Flow Meters
Magnetic Flow Meters The Magnetic Flow Meter (often called “Magmeter”) provides a free flow measurement which is unaffected by density, temperature, pressure or viscosity changes in the fluid. Advantages • No moving parts. • Unobstructed bore. • Can measure bi-directional flow. • Minimal pressure drop across meter. • Unaffected by turbulent flow patterns. • Linear output. • Good accuracy and range. Limitations • Maximum pressure is 4,500 psi. • Process fluid must be more conductive than 5 µSiemens/cm. (µ micro) • Unsuitable for oil based fluids or distilled water. Magnetic flow meters measure volumetric flow by monitoring the distortion of an induced magnetic field. The distortion is caused by the flow of a conductive fluid in the pipe. The advantages of this type of flow device are that there are no moving parts and nothing protruding into the flow. Viscosity and consistency also have no adverse effect on their performance, however particulate in the fluid such as sand can be a problem if the concentration of particulate becomes too high (>25% of volume). Mag meters can be used for bi-directional flow measurement. There is, however, one major disadvantage for our application in that the fluid to be measured must be electrically conductive (usually greater than 5 µSiemens per cubic centimeter). Pure substances, including many hydrocarbons and gases, tend to fall below the 5µS/cm threshold. Some typical fluids are listed in the table below:
Conductive Hydrochloric Acid Sodium Hydroxide Acetic Acid Potable Water
Non-Conductive 400,000 µS/cm 40,000 µS/cm 250 µS/cm 70 µS/cm
Glycol 0.3 µS/cm Kerosene 0.017 µS/cm Ethyl Alcohol 0.0013 µS/cm Xylene 0.000000001 µS/cm
Theory of Operation - Magnetic Flow Meters
Mass Flow Meters Flow Meters that measure mass directly using the properties of mass, as opposed to those that measure volume or velocity, were developed and commercialized in the 1980s. Other flow meter technologies are affected by changes in fluid density, viscosity, pressure and/or temperature. Mass is the amount of matter in an object. Mass Flow measurement is based on the laws of nature that prohibit a stream from accumulating or loosing mass. Therefore, Mass Flow measurements are independent of changes in temperature, or pressure. Meters that measure mass directly, in effect, weigh the fluid as it passes through the meter, yielding a highly accurate measurement that is virtually independent of varying process conditions that often occur. Because of this unique ability, it is possible to use a Coriolis Flow Meter on a wide variety
of chemicals without need for re-calibration or compensation to specific fluid parameters.
Several types of mass meters are available including radiation, angular momentum, Coriolis, heat transfer, and hot-wire probes type. BJ has standardized on the Coriolis style of mass meter. Coriolis Mass Flow Meters offer many advantages: • Multi-measurement including: – Mass Flow rate – Volumetric Flow rate – Density – Temperature • High accuracy (+/-0.1%) and repeatability, especially at low flow rates, which means improved product quality and reduced waste. • Installation is simplified because there are no flow conditioning nor straight pipe run requirements. • Low maintenance because there are no moving parts, and the system is non-intrusive. • Wide working range (turndown) of 10:1. • The mass meter provides an alternative to nuclear densimeters. Mass Flow - Density Determination Density is defined as mass per unit volume, or mass divided by volume. The volume of the fluid contained in the Flow Tubes remains constant. Then the only way mass can change is if density changes. Because of this relationship, the natural frequency of the Flow Tubes indicates not only the mass of the fluid contained, but also the density. The density of the process fluid can be derived from the frequency of oscillation of the sensor. As the density increases, the natural frequency of the system decreases. Micro Motion Coriolis Meters The Coriolis meter is more expensive than conventional turbine Flow Meters or encoder systems. However, when maintenance costs are examined, the Mass Flow Meter compares favorably with other methods of flow measurement.
BJ uses Micro Motion meters in a variety of applications: • R-Series Coriolis meters to measure chemical additive rates • D Series Coriolis meters to measure cement mass flow, volumetric flow and density • DH Series meters to measure N2 for foam cement jobs • DL Series meters to measure cement mass flow • Basis meters to measure chemical additive rates • Elite meters to measure chemical additive rates
Conclusion Some points of consideration when selecting a mass flow meter include: • Meter accuracy • Required signal outputs • Available mounting space • Sizing for fluid velocity • Process fluid properties • Instrument delivery and support • Cost
BJ Services Tomball EDC- Training Department
Acknowledgements:
References:
The authors would like to thank. Tomball’s Engineering Department:
BJ Services Applied Fracturingby Ken Kenner-1992 BJ Services Iron Manual BJ Operations and Maintenance Manuals for Fracturing Equipment BJ Services Equipment and Technology Magazine –1994 BJ Services Power Center and BJ Services Website Links. 2004 World Survey of Marine Stimulation Vessels
EDC – Tomball, Version 1.01 Revised: March 2005
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