ACE Blender Operator Manual Chapter 1 – Introduction

CHAPTER 1 INTRODUCTION TO THE ACE

CONTROLLER AND GUI DISPLAY CHAPTER 1 INTRODUCTION TO THE ACE CONTROLLER AND GUI DISPLAY................... 1-1

1.1 BASICS ...................................................................................................................................... 1-2 1.1.1 Definition of Blender Terms ................................................................................................ 1-2 1.1.2 Control Loops and the Electronics ...................................................................................... 1-4 1.1.3 Display Monitor / Control functions.................................................................................... 1-5

1.2 SPECIFICATIONS ........................................................................................................................ 1-6

It is fruitless to attempt to indoctrinate a superannuated canine with innovative maneuvers.

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ACE Blender Operator Manual Chapter 1 – Introduction

1.1 Basics 1.1.1 Definition of Blender Terms Clean rate – also called suction rate, clean side, and master rate. Clean rate is defined as the rate at which fluid is delivered to the blender’s tub by the suction pump. Clean rate is the main variable involved in good control for chemical and sand delivery to the well bore. All of the additives are slaved to the clean rate; meaning additive rate follows the clean rate. In some instances, we have slaved chemicals to the sand rate, but the sand rate is still slaved to the clean rate. Clean rate is typically measured in Barrels per Minute (barrel being 42 gallons). A blender operator should always monitor clean rate and insure the clean rate is stable and not fluctuating.

Dirty rate –also called slurry rate, dirty side and discharge. Dirty rate is defined as the rate at which the fluid is taken from the blender tub and boosted by the discharge pump to the high pressure pumps. Dirty rate is usually measured in BPM, same as clean. During Pad or before sand is brought on the blender operator should insure the dirty rate and clean rate are matched up. If the Clean rate is 30bpm then the dirty should be close to 30bpm with the tub at set point and maintaining a constant level. This check insures both clean and dirty flow meters are working and that the end of job volumes will be correct. After sand is started in the tub the clean rate will decrease due to the sand acting as clean volume in the tub. As more sand is delivered to the tub it takes less clean rate to maintain adequate tub level. Suction pressure – The pressure in PSI (pounds per square inch) that is maintained on the suction manifold. Discharge pressure – also called “Boost”. Discharge pressure is defined as the pressure in PSI that is maintained on the discharge manifold. Discharge pressure is needed to insure proper high pressure pump operation and accurate Densometer operation relative to the high-pressure pump operation and accurate Densometer operation. Boost – Boost is defined as the pressurized fluid that is being pumped from the blender to the high pressure pumps. High pressure pumps – Fluid pumps such as Grizzly, HT2000, and HT400 that pump sand laden fluids at high pressure. Tub level – The level of fluid that is in the blender tub. Tub level is very critical to many different variables. The main variable being having enough fluid in the tub to insure the pumps do not suck air. Tub level set point is usually 70% to 75%. Prior to the job the blender should check for a 0% (+/-2%) tub level reading with an empty tub and a 105% reading when the float is pulled to the top (+/-5%). Setting the top value to 105% allows the controller time to stop the tub from overflowing.

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ACE Blender Operator Manual Chapter 1 – Introduction

Agitation – The stirring of the fluids in the blender tub with the agitator or paddles mounted in the tub. Densometer – A radioactive sensor that reads the weight of fluid as is passes through the sensor. Liquid and Dry additives – Controlled chemical delivery systems used to alter the Fracturing fluid to job specifications.

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ACE Blender Operator Manual Chapter 1 – Introduction

1.1.2 Control Loops and the Electronics

Control of the delivery devices on the blender is accomplished by electrical signals, from the ACE controller, sent to the “control valves” via modules mounted on the unit, commonly called device modules. The SDS device modules are all hooked through a wiring scheme known as SDS BUS (Smart Distributed System). Simply stated, the modules are connected through common wiring to the controller, which in this case is the computer. The modules receive instructions to output signals or requests for information relating to the inputs. These SDS device modules send commands to Hydraulic valves. The hydraulic valves are electric over hydraulic in operation and are designed to change actuator position or pump speed by controlling the direction and the amount of hydraulic fluid flow to the pumps or actuators. The pump or actuators are what physically move the fluids, chemicals and sand. An electrical signal from the sensors (pressure, rate, ph, viscosity), referred to as “feedback”, monitors the speed or position. This term “feedback” is nothing more than a word for the signal being returned to the controlling computer to inform it as to the current status of a device. The feedback is an important element in a control loop. 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. Once they are equal the command is held until the feedback differs from the set point. This type of control system is defined as a Closed Loop Control. At application start up all of the devices are set to Forced Closed Loop that is the control system will not deviate from the Closed Loop until instructed by the operator.

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ACE Blender Operator Manual Chapter 1 – Introduction

1.1.3 Display Monitor / Control functions

The ACE control system can be used as a (remote) display. The control and monitoring of the units on location can then be done through the ACE control Graphical User Interface (GUI) and then data would be received and sent out via network connections. For example, some of the stations in the INSITE Technical Command Center (TCC) are GUI’s only. As such, the ACE control system can replace the PCI in the PSW/PCI TCC.

The ACE control window can be used to launch other GUIs; selecting one of the menu items for that particular unit type does this. For example to start a pump GUI select Pump on the menu then Pump truck.

The instructions for using the Pump GUI can be found in the ACE Pump Operator Reference Manual, part number 101268133 or downloaded from the ACE Web site. The instructions for using the Instrument Data Gathering System (IDGS) which is listed under the Instrument unit menu can be found in the IDGS Manual part number 101310021 or downloaded from the ACE Web site. The instructions for using the Sand GUI can be located in the ACE Sand System Manual, which can be downloaded from the ACE Web site. Some functions of the ACE Control System are limited to what computer the GUI display is running on. Thus some functions are not sent to other units and are local to that computer only; refer to the list below for those functions.

• Job Plan information • Local Only tab – refer to chapter 3 • Selected Additive Pump chosen, selected chemical chosen • Operator entered Additive names, valve names • Display Setup – number of additives, units • Unique ACE items – viscosity control, pH control, cross linker control, selected

Master rate from other blender units • Manifold selection • Edited Group Commands

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ACE Blender Operator Manual Chapter 1 – Introduction

1.2 Specifications The ACE Controller Blender supports the following

• Built in error checking for job data entry • Auto Job Manager • Same look and feel as Pump, Sand and Instrumentation Control systems • Premier control system in the TCC INSITE system • 14 Liquid Additives • 3 Dry Additives • 3 Sand Screws • Tub Mixing System • Auto Tuning • Group Commands to bring selected devices off or to set to auto mode. • Control local as well as remote blenders; ARC, ACE, FACTORY LINK ACE • Direct support of HMP fluid process • Display is expandable for larger resolution displays • Supports both standard D1FH and SDS DIFH valves • Bucket Test Calculator • Auto tuning for PID algorithms • Ability to run as a controller or as remote display to control/monitor • JLAN, Token Ring and Ethernet compatible • Operates on Windows NT 4.0, WINDOWS 2000 and WINDOWS XP • Uses Halliburton Standard SDS and Can devices • Color displays • English or Metric units • Model mode for job simulation or training

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NOTES

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