ttc203 frac equipment manual version 1

BJ Services Tomball EDC- Training Department

EDC – Tomball, Version 1.01 Revised: March 2005

TCC203 FRACTURING EQUIPMENTCORRESPONDENCE COURSE


EDC – Tomball, Version 1.01 Revised: March 2005 2

Copyright 2005, by BJ Services. All Rights reserved. No part of this manual may be reproduced in any form orby any means (including electronic storage and retrieval or translation into a foreign language) without prioragreement and written consent from BJ Services as governed by United States and international copyright laws

Training DepartmentBJ Services11211 FM 2920Tomball 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



INDEX

Subject Page

Introduction 5

Fluid Pumps 6Frac Pump 1000 HHPFrac Pump 1100 HHPFrac Pump 1300 HHPFrac Pump 1400 HHPFrac Pump 149AFrac Pump 1600A –TM Frac Pump 1700 HHPGorilla Frac PumpKodiak Frac PumpModel SFP 1200Rhino Frac PumpGator Frac Pump

Hydration Units 19Hydration Unit 30 bblHydration Unit 60 bbl

Mixer 22Frac Blender 125 BPMFrac Blender 2060 TMFrac Blender 30 BPMFrac Blender 40 BPMFrac Blender 50 BPMFrac Blender 70 BPM



Frac Blender 80 BPMModel SFB 40

Sand Storage 32Sand King 2TFS-300SD Sand Dump

Stimulation Vessels 33

Monitoring and Miscellaneous Equipment 34Treatment VansWireless LAN MonitoringBJ Services WirelessChemical Additive UnitLFC Transport UnitUEC-II Remote controlFracman Remote Control



Frac Equipment___________________________________________________________________________________

IntroductionThis article was developed with the intention to be a guide for the correspondencecourse TCC203, which forms part of the T-CAP training plan in BJ ServicesCompany. It presents an overview of fracturing equipment necessary to perform afracturing operation either on land or offshore.

Fracturing is a core service line, generating approximately 40% of BJ Servicesrevenue over last the three years. A fracturing operation covers a wide range ofapplications; from convention water base Frac fluids, to oil base, foam (Nitrogen,Carbon Dioxide or Binary), as well as frac treatments with methanol. Over time thetreatments have become more technologically demanding, due to high reservoirtemperatures, pressures or water sensitive formations. Accordingly BJ Services hasdeveloped new technologies to meet the new challenges. Examples include,Polymer-Free water based fluids, oil based fracturing fluids designed for reservoirtemperatures higher than 250o F, equipment rated for treating pressures as high as20,000 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 Pumps2. Hydration Units3. Mixers4. Chemical Additive Units5. Sand Storage6. Stimulation Vessels7. Monitoring

Technical articles of these components can be found on either BJ Services webpage:http://www.bjservices.com/website/index.nsf/P&S?openframeset

Or through Power Center:https://powercenter.bjservices.com/intranet/TechnologyToolbox/pif.nsf/SLbyRegion?OpenView&SL=Fracturing

http://www.bjservices.com/website/index.nsf/P&S?openframeset

https://powercenter.bjservices.com/intranet/TechnologyToolbox/pif.nsf/SLbyRegion?OpenView&SL=Fracturing



FLUID PUMPS

The fluid pump is the component of the frac fleet designed to deliver fluid into awell for fracturing or acidizing. The units are classified by their hydraulichorsepower (HHP), as well as by their design, i.e. either trailer mounted or skidmounted. The following list highlights BJ Services fracturing pumps:

1. Frac Pump 1000 HHP2. Frac Pump 1100 HHP3. Frac Pump 1300 HHP4. Frac Pump 1400 HHP5. Frac Pump 149A6. Frac Pump 1600A HHP 7. Frac Pump 1700 HHP8. Gorilla Frac Pump.9. Kodiak Frac Pump10. SFP 120011. Rhino Frac Pump12. 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 awell for fracturing or acidizing. The unit will deliver 1,000 HHP, at pressures up to15,000 psi. The rate capacity is based on the plunger size used in the fluid end. Theunit 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



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 awell for fracturing or acidizing. The unit will deliver 1,100 hhp, at pressures up to15,000 psi. This unit is configured with (2) engines, transmissions and triplexpumps. The deck engine drives the fan for the radiator. Independent operation witheach power train is possible. The rate capacity is based on the plunger size used inthe fluid ends. The unit carries enough fuel for 4 hours pumping at maximumhorsepower.

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


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 awell for fracturing or acidizing. The unit will deliver 1,300 HHP, at pressures up to15,000 psi. The rate capacity is based on the plunger size used in the fluid end. Theunit 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




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 awell for fracturing or acidizing. The unit will deliver 1,400 hhp, at pressures up to15,000 psi. This unit is configured with (2) engines, transmissions and triplexpumps. The deck engine drives the fan for the radiator. Independent operation witheach power train is possible. The rate capacity is based on the plunger size used inthe fluid ends. The unit carries enough fuel for 4 hours pumping at maximumhorsepower

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


5. 149A High Pressure Fracturing Unit

The 149A high-pressure fracturing unit is mounted on a semi-trailer and is capableof pumping stimulation fluids at pressures up to 17,500 psi (121 MPa), or rates upto 32.8 BPM (5.21 m3/min) depending on plunger size and well pressurerequirements. High-pressure fluid delivery is made through a triplex pump, whichis rated for up to 1,800 BHP input. The 149A will provide up to 1,525 HHP, andhas a turbocharged engine.

The unit is operated remotely from a control console, which can be located at adistance up to 125-ft (38 m). The operator can select the optimum shift point tomaximize hydraulic horsepower as required by well conditions. If required, anemergency kill system can be remotely engaged which will cut off air and fuelsupply to the engine. A pressure limiting system can be preset to any maximumpressure to ensure that over-pressuring does not occur. Heavy-duty hydraulicstarters and ether injection systems ensure reliable starting in cold weather.



Major Components

Engines: Detroit Diesel 16V149T rated at 1,800 BHP• Transmission: Allison 9686• Pump: Triplex with 3.75" to 7.5" Fluid Ends


Figure 1



6. MFP 1600A-TM

Mobile Frac Pump 1600 trailer mounted

The MFP 1600A-TM is a trailer mounted Frac Pump designed to deliver fluid intoa well for fracturing or acidizing. The unit will deliver 1,600 HHP, at pressures upto 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


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 awell for fracturing or acidizing. The unit will deliver 1,700 HHP, at pressures up to15,000 psi. The rate capacity is based on the plunger size used in the fluid end. Theunit carries enough fuel for 4 hours pumping at maximum horsepower. The unitcan 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




8. MFP 2700 TM - Gorilla

The MFP 2700-TM "GORILLA" is a trailer mounted Frac Pump designed todeliver fluid into a well for fracturing or acidizing. The unit will deliver 2,700HHP, at pressures up to 15,000 psi. The rate capacity is based on the plunger sizeused in the fluid end. The unit carries enough fuel for 4 hours pumping atmaximum 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 ControlsBJ Services Universal Engine Controller II

Figure 2



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 deliverfluid into a well for fracturing or acidizing. The unit will deliver 2,000 hhp, atpressures up to 15,000 psi.

Figure 3

The rate capacity is based on the plunger size used in the fluid end. The unit carriesenough 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




10. SFP 1200- Skid Frac Pump

The SFP 1,200 is a skid-mounted Frac Pump designed to deliver fluid into a wellfor fracturing, acidizing and sand control. The unit will deliver 1200 HHP atpressures up to 15,000 psi. The rate capacity is based on the plunger size used inthe fluid end. The unit carries enough fuel for 4 hours pumping at maximumhorsepower

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 deliverfluid into a well for Fracturing or Acidizing. The unit will deliver 1,700 HHP, atpressures up to 15,000 psi. The rate capacity is based on the plunger size used inthe fluid end. The unit carries enough fuel for 4 hours pumping at maximumhorsepower. The unit can be configured with either a Triplex or a Quintaplexpump. If it does have a triplex pump, them the Unit is identified Rhino T, and ifthe pump on it is a quintalplex its model is Rhino Q

Major ComponentsEngine: Detroit Diesel 16V149 DDEC II rated at 1,900 BHPTransmission: Twin Disc 6503Pump: CWS Triplex with 4" to 5.75" Fluid EndsTrailer is a Heavy Duty Two Rail Design




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 actualperformance depending on fluid ends and plunger size selected. The engines andthe transmission utilize electronic controls compatible with BJ Services UniversalEngine Controller (UEC-II). The UEC-II controls and monitors engine functionsand transmission shifting. Each pumping assembly operates independently, andeither will remain functional should the other pump assembly be shutdown.The power end lube pumps, packing lube pump, and radiator fan are operated byhydraulic power supplied from the required Hydraulic-Ill tractor.

The available plunger size is 4”, 5” and 5-3/4”.



The Gator Frac Pump Trailer, when mated with a general-purpose tractor, is a self-contained 2100 hydraulic horsepower (HHP) pumping unit designed for oil and gasfracturing services.Integral on-board back-up systems, higher available horsepower, add to theflexibility of this unit. Using twin pumps allows higher rates to be achieved thanwith a single pump Frac unit.

The Gator Frac unit is designed to pump different types of fracturing fluids andgenerate the desired frac operating pressures. Fluid is supplied (supercharged) fromthe blender through a manifold system. Fluids from the blender may be plainwater, acids or gelled fluids used to carry sand or other proppant.

Figure 6



FRAC PUMP CLASSIFICATIONPump Model ENGINE TRANSMISSION PUMP TYPE HHP / PRESSURE

(PSI)RATES(BPM)

FRAC PUMP 1000 HHPDD 12V149,1350 BHP ALLISON 8962 CWS TRIPLEX 4-5.75 FLUID

ENDS1000 / 15,000 PSI 22

FRAC PUMP 1100 HHP2-DD 16V71 T/A,700 BHP ALLISON 6061 RR 100O TRIPLEX 4-5.5 FE 1100 /15,000 psi 32

FRAC PUMP 1300 HHPDD 16V 149TI, 1600 BHP ALLISON 8962 CWS TRIPLEX 4-5.75 F E 1300 / 15,000 PSI 22

FRAC PUMP 1400 HHP2-DD 16V92T/A, 900 BHP ALLISON 6061 RR 100O TRIPLEX 4-5.5 FE 1400 / 15,000 PSI 32

FRAC PUMP 149ADD 16V 149T, 1800 BHP ALLISON CLT 9686 TRIPLEX 3.75-7.5 FE 1500 / 17,500 PSI 32.8

FRAC PUMP 1600A -TMDD 16V 149TIB,1600 BHP ALLISON 9686 CWS TRIPLEX 4-5.75 F E 1300 / 15,000 PSI 22

FRAC PUMP 1700 HHPDD 16V 149DDEC II,1900 BHP TWIN DISC 6503 CWS TRIPLEX 4-5.75 F E 1700 / 15,000 PSI 22

GORILLA FRAC PUMPDD 16V4000, 3000 BHP TWIN DISC 8500 TRIPLEX 4-5.75 FLUID ENDS 2700/ 20,000 PSI 22

KODIAK FRAC PUMPDD 12V4000, 2250 BHP ALLISON S800 CWS TRIPLEX 4-5.75 F E 2000 / 15,000 psi 22

MODEL SFP 1200DD 12V149, 1350 BHP ALLISON 8962 TRIPLEX 4-5.75 FLUID ENDS 1200 /15,000 PSI 22

RHINO FRAC PUMPDD 16V149 DDECII,1900 BHP TWIN DISC 6503 TRIPLEX 4-6.5 FLUID ENDS

QWS2500 QUINTALEX1700 / 15,000 PSI 22

GATOR2 CATERPILLAR 3412 DISAT ALLISON DP 8962 TRIPLEX 4-5.75 FLUID ENDS 2100 / 15,000 PSI 20



FRAC PUMP CLASSIFICATION - METRICPump Model ENGINE TRANSMISSION PUMP TYPE HHP / PRESSURE

(MPa)RATES

(M3/minute)

FRAC PUMP 1000 HHPDD 12V149,1350 BHP ALLISON 8962 CWS TRIPLEX 4-5.75 FLUID

ENDS1000 / 103.4 3.5

FRAC PUMP 1100 HHP2-DD 16V71 T/A,700 BHP ALLISON 6061 RR 100O TRIPLEX 4-5.5 FE 1100 / 103.4 5

FRAC PUMP 1300 HHPDD 16V 149TI, 1600 BHP ALLISON 8962 CWS TRIPLEX 4-5.75 F E 1300 / 103.4 3.5

FRAC PUMP 1400 HHP2-DD 16V92T/A, 900 BHP ALLISON 6061 RR 100O TRIPLEX 4-5.5 FE 1400 / 103.4 5

FRAC PUMP 149ADD 16V 149T, 1800 BHP ALLISON CLT 9686 TRIPLEX 3.75-7.5 FE 1500 / 120.6 5.2

FRAC PUMP 1600A -TMDD 16V 149TIB,1600 BHP ALLISON 9686 CWS TRIPLEX 4-5.75 F E 1300 / 103.4 3.5

FRAC PUMP 1700 HHPDD 16V 149DDEC II,1900 BHP TWIN DISC 6503 CWS TRIPLEX 4-5.75 F E 1700 / 103.4 3.5

GORILLA FRAC PUMPDD 16V4000, 3000 BHP TWIN DISC 8500 TRIPLEX 4-5.75 FLUID ENDS 2700/ 103.4 3.5

KODIAK FRAC PUMPDD 12V4000, 2250 BHP ALLISON S800 CWS TRIPLEX 4-5.75 F E 2000 / 103.4 3.5

MODEL SFP 1200DD 12V149, 1350 BHP ALLISON 8962 TRIPLEX 4-5.75 FLUID ENDS 1200 / 103.4 3.5

RHINO FRAC PUMPDD 16V149 DDECII,1900 BHP TWIN DISC 6503 TRIPLEX 4-6.5 FLUID ENDS

QWS2500 QUINTALEX1700 / 103.4 3.5

GATOR2 CATERPILLAR 3412 DISAT ALLISON DP 8962 TRIPLEX 4-5.75 FLUID ENDS 2100 / 103.4 3.2



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 mixingshear to ensure complete hydration of the polymer before adding proppant orcrosslinker. 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 astatic mixer. The resulting gel is passed into the first compartment, where thehydration process begins. The second and third compartments are equipped withpower agitators to provide vigorous mixing. The final compartment contains thefluid for discharge to the blender. An in-line gel analyzer provides constant dataregarding viscosity, temperature and pH.

The LFC Control Module allows either manual or fully automatic operation of theLFC system and the seven liquid additive pumps. All parameters regarding fluidsi.e., flow rates, totals etc can be sent to the BJ Well Treatment Analyzer, whichthen can be recorded and/or displayed, if desired. Operational parameters can bechanged remotely from a computer for more rapid and complete control. TheUniversal 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 easilyinstalled 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 FracConcentrate (LFC) and provide residence time for the hydration of fracturingfluids. This unit will deliver the fluids to the frac blender at rates ranging from 5 to30 bpm (0.8-4.8 m3). The unit is configured with a 100-bbl (15.9 m3) tank that hastwo compartments. The LFC is injected into the fluid via a static mixer and thenflows over and under weirs for blending. Hydraulic powered agitators supplyadditional mixing energy. The 100-bbl tank gives over 3 minutes hydration time



for the fluids. The piping allows the blender to "bypass" the MHU and take fluiddirectly from the Frac tanks.

The unit is capable of carrying 2,000-gal (7.5m3) of LFC. An on board pump andMass Flow Meter (MFM) provides accurate metering of the gel concentrate. Theunit has an automatic tub level control system as well as continuous monitoring ofthe viscosity and pH levels.The power is supplied by an onboard diesel engine. The closed loop hydraulicpumps provide the power for the suction centrifugal pump, KCL pump system andthe LFC metering pump. The Liquid Additive System (LAS) pump and tub levelsystems 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



2. Model MHU 60-BL(Formally known as CMG Hydration Unit)

Mobile Hydration Unit Body Loadthe MHU60-BL is a truck mounted unit designed to carry Liquid FracConcentrate (LFC) and provide residence time for the hydration offracturing fluids. This unit will deliver the fluids to the Frac Blender at ratesranging 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 fluidvia a static mixer and then is recirculated through centrifugal pumps forblending.The unit also carries 1,300 gallons (4.9m3) of LFC. An on board pump andMass Flow Meter (MFM) provides accurate metering of the gel concentrate.The unit has an Automatic tub level control system as well as continuousmonitoring of the viscosity and pH levels.The piping allows the blender to "bypass" the MHU and take fluid directlyfrom the Frac tanks.Power is supplied by the chassis engine via a PTO that drives the hydraulicpumps. The circulating centrifugal pumps are powered by closed loophydraulic systems. The LAS pump and tub level systems are powered byhydraulics 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 ControlsBJ 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



Figure 7, Hydration Unit

BLENDER UNITS

The Blender is literary the heart of a fracturing job – fracturing products aremixed before being pumped in to the well. The function of the blender isthreefold:

• 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)



1. Model MFB 30-BL

Mobile Frac Blender CONDOR Body Load

The MFB 30-BL is a truck mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 40 bpm (with water). The unit isconfigured with a patented CONDOR closed tub for mixing proppants withthe frac fluids. The tub design utilizes a spinning impeller at the top of thetub to inject sand into the pressurized tub. The impeller is hydraulicallydriven.

The suction pump is mechanically driven. Only one centrifugal pump isused. 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 ScrewControl · Automatic and Manual Liquid Additive Systems · Programming ofJob Stages, with Automatic or Manual Staging · Stage and Job Totals,Turbine Flow Meters



2. Mobile Frac Blender 40 Body Load

The MFB 40-BL is a truck mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 60 bpm (with water). The unit isconfigured with a "vertically configured" open tub for mixing proppantswith the frac fluids. The tub design utilizes the flow of the fluid into the tuband directs that flow around the tub interior for efficient mixing with theproppants. A hydraulically driven agitator provides added mixing energy.

The suction pump is mechanically driven and the discharge centrifugalpump is driven mechanically by the chassis engine. The chassis engineprovides power for the hydraulic functions as well as the dischargecentrifugal pump.

Major Components


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


BJ Services Automatic Controls · Automatic and Manual Tub Level ScrewControl · Automatic and Manual Sand Screw Control. Turbine Flow Meter(6")



3. Mobile Frac Blender 50 Trailer Mount

The MFB 50-TM is a trailer mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 65 bpm (with water). The unit isconfigured with a horizontally configured open tub for mixing proppantswith the frac fluids. The patented HYDROPACE tub design utilizes the flowof the fluid into the tub and directs that flow into a spiral movement forefficient mixing with the proppants. A hydraulically driven agitator providesadded mixing energy. The suction pump is hydraulically driven, as is thedischarge centrifugal pump. The deck engine provides the power for all thehydraulic functions.

Major Components

Trailer: Heavy Duty Two Rail Design

Deck Engine: Detroit Diesel 16V71T, rated at 700 BHP


Sand Screws: (2) at 14" nominal diameter, hydraulically driven. They act as feedscrews for the (2) 14" diameter

Metering Screws


(1) Dry Additive System Feeders


BJ Services Op-Amp Controls · Automatic Tub Level Control · AutomaticFeed and Metering Sand Screw Control · Turbine flow meters (8")



4. Mobile Frac Blender 2060 Trailer Mount

The MFB 2060-TM is a trailer mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 60 bpm (with water). The unit isconfigured with a patented CONDOR closed tub for mixing proppants withthe frac fluids. The tub design utilizes a spinning impeller at the top of thetub to inject sand into the pressurized tub. The impeller is hydraulicallydriven. The suction pump is hydraulically driven. There is a boostcentrifugal pump, hydraulically driven, mounted on the unit. This allowshigher supercharge pressures to the frac pumps. A single deck enginesupplies the power for the blender. The unit is designed to allow suction ordischarge 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



BJ Services MCM 2000 Automatic Controls · Automatic Discharge PressureControl · Automatic and Manual Sand Screw Control · Automatic andManual LAS and DAS · Programming of Job Stages, with Automatic orManual Staging · Stage and Job Totals · Turbine Flow Meters (6" and 3")and Magnetic Flow Meters (6")



5. Mobile Frac Blender 70 Trailer Mounted

The MFB 70-TM is a trailer mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 70 bpm (with water). The unit isconfigured with a vertically configured open tub for mixing proppants withthe frac fluids. The tub design utilizes tub jet rings for efficient mixing withthe proppants. A hydraulically driven agitator provides added mixingenergy. 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


(3) Liquid Additive Systems with Mass Flow Meters



BJ Services MCM 2000 Control · Automatic and Manual Tub Level Control· Automatic and Manual Sand Screw Control · Automatic and ManualLiquid Additive System and Dry Additive System Control · Programming ofJob Stages, with Automatic or Manual Staging · Stage and Job Totals.Turbine flow Meters (8. and 4") and Magnetic Flow Meters (8")



6. Mobile Frac Blender 80 Trailer Mounted

The MFB 80-TM is a trailer mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 80 bpm (with water). The unit isconfigured with a horizontally configured open tub for mixing proppantswith the frac fluids. The tub design utilizes the flow of the fluid into the tuband directs that flow into a spiral movement for efficient mixing with theproppants. 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



(3) Liquid Additive Systems with Mass Flow Meters



BJ Services MCM 2000 Control Automatic and Manual Tub Level Control ·Automatic and Manual Sand Screw Control · Automatic and Manual LiquidAdditive System and Dry Additive System Control · Programming of JobStages, with Automatic or Manual Staging · Stage and Job Totals. Turbineflow Meters (8. and 4") and Magnetic Flow Meters (8")



7. Mobile Frac Blender 125 Body Load

The MFB 125-BL is a truck mounted Frac Blender designed to mix anddeliver fluids for fracturing or acidizing. This unit will deliver the fluids tothe downhole pumps at rates as high as 125 bpm (with water). The unit isconfigured with a "horizontally configured" open tub for mixing proppantswith the Frac fluids. The patented HYDROPACE tub design utilizes theflow of the fluid into the tub and directs that flow into a spiral movement forefficient mixing with the proppants. A hydraulically driven agitator providesadded mixing energy.

The suction pump is hydraulically driven and the discharge centrifugal pumpis driven by the chassis engine. The deck engine provides power for thehydraulic functions.

Major Components



Sand Screws: (3) at 14" nominal diameter, hydraulically driven



Deck engine: Detroit Diesel 6V92Trated at 360 BHP


BJ Services Automatic Tub Level Control · BJ Services Automatic SandScrew Control. Turbine Flow Meters and Magnetic Flow Meters



BLENDER PERFORMANCE

Blender Model Sand Densitypsa

Rate - WaterBPM

Maximum Rate Gelled Fluids

BPM

Sand RateMin-MaxLB/min

Liquid Additive SystemGallons per Minute

Dry Additive SystemLbs per Minute

MFB 30-BL20 1-40 30 100-15,000 Up to 15 gpm NA

MFB 40-BL20 2-60 40 100-10,000 Up to 15 gpm NA

MFB 50-TM20 5-65 50 300-20,000 Up to 15 gpm Up to 60 Lbs./min




MFB 125-BL20 5-125 100 300-25,000 Up to 15 gpm Up to 60 Lbs./min

SFB 40(Cyclone ll.)

20 1-40 0.5-30 100-10,000 Up to 10 gpm NA



BLENDER PERFORMANCE - METRIC

Blender Model Sand DensityKg/m3

Rate - WaterM3/min

Maximum Rate Gelled Fluids

M3/min

Sand RateMin-MaxKg/min

Liquid Additive SystemLiters per Minute

Dry Additive SystemKgs per Minute

MFB 30-BL2396 .16 – 6.3 4.8 45 – 6,803 Up to 57 lpm NA

MFB 40-BL2396 .31 – 9.5 6.4 45 – 4,536 Up to 57 lpm NA

MFB 50-TM2396 .8 – 10.3 7.9 136 – 9,072 Up to 57 lpm Up to 27.2 kgs./min

MFB 2060-TM2396 .16 – 9.5 6.4 90.7 – 11,340 Up to 57 lpm Up to 27.2 kgs./min



MFB 125-BL2396 .8 – 19.8 15.9 136 – 11,340 Up to 57 lpm Up to 27.2 kgs./min

SFB 40(Cyclone ll.)

2396 .16 – 6.3 4.8 45 – 4,536 Up to 38 lpm NA



SAND STORAGE UNITS

1. Sand Kings

BJ Services’ Sand King Mobile Field Storage Bin and Conveyor Systemseliminate the need to move and unload numerous individual bulk transportson location during jobs and provide a uniform and continuous delivery ofproppant to the blender. The Sand Kings are powered by Detroit dieselengines. BJ offers two models, the CB2500 and the CB4000 with 250,000Lbs. (113,636 kg) and 400,000 Lbs. (181,818 kg) capacities, respectively.The sand is gravity-fed through a hydraulically operated slide and gate valveonto a self-contained conveyor system and transported on a belt to theblender’s sand hopper.

Figure 8, Sand King

2. Sand Belt Conveyor

The BJ Sand Belt Conveyor is utilized on stimulation treatments requiringlarge amounts of proppant. It allows up to eight (8) Sand Kings to be spottedfor 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 aproppant capacity of up to 30,000 Lbs./min (13,636 kg/min). All systems arehydraulically powered and include a hydraulic landing gear assembly toraise and lower the tractor end of the unit.



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 forstorage of different proppants, is raised for unloading during the stimulationtreatment. Hydraulic power is delivered from the chassis engine /transmission.

STIMULATION VESSELS

BJ Services operates the largest fleet of stimulation vessels in Latin Americaand offers the second-largest dedicated fleet of stimulation vessels in theindustry, with operations in the North Sea, the Gulf of Mexico, LatinAmerica and offshore Africa. Using fracturing barges and skid mountedunits aboard workboats, BJ provides stimulation services from the inlandwaters 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/0/15BA4C43CD6C7C9F86256F1D00535DD4/$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

http://www.bjservices.com/website/ps.nsf/0/15BA4C43CD6C7C9F86256F1D00535DD4/$file/Deepwater+Stimulation+Vessels-Gulf+of+Mexico.pdf

https://powercenter.bjservices.com/86256A3E00482B4A/$All?SearchView&SearchFuzzy=TRUE&Query=%20Vessels

P R O D U C T I O N

2004 World survey of marine stimulaton vessels

Region of operation Statistics Above deck Below deck

Contractor and

1

2

5

6

1 RC Baker • 224 54 4,000 10.5 28,000 12,000 530 10,000 2,000 250,000 n/a 4,000 750,000 6,040 11,600 16 2 HR Hughes • 270 56 3,420 12.5 20,000 12,000 880 8,000 10,000 1,000,000 n/a 6,600 1,200,000 6,600 11,600 20

Greg Salerno, 5500 Northwest Central Drive, Houston, TX 3 M/V Blue Angel • 275 61 9,600 14 60,000 9,850 None None None 500,000 57,000 1,200 1,800,000 4,000 3,500 10

• 265 60 6,780 12 13,000 12600 gal 350 20,000 4,250 425,000 n/a 10,450 1,080,000 10,800 7,915 25 • 260 56 5,400 13 40,000 32,800 None None None 425,000 None 500 1,025,000 2,380 1,720 10

• 240 56 3,200 10.5 12,000 14,000 400 12,000 2,000 200,000 4,200 1,032,000 4,200 8,913 15 • 240 56 3,200 10.5 12,000 14,000 400 12,000 2,000 200,000 6,040 827,000 6,040 11,348 15

Hippo • 172 40 5,550 12 10,000 1,100 None None 2,000 145,000 n/a None No 1,900 No n/a No • 205 50.5 3,240 12 40,000 13,270 1,700 None None 308,700 None None 308,700 1,700 2,380 15 No

• 270 60 6,480 12 180,000 3,150 n/a 22,000 n/a 6,650 n/a 1,205,000 10,875 7,143 60 Note 2

Cape Hawke • 200 56 4,200 12 **67,288 11,400 None 50,000 None None 69,000 None None 2,200 5,085 n/a n/a • 258 49 3,000 10 **256,000 10,000 None n/a None 240,000 n/a 2,450 None 2,450 2,588 n/a

Gulf Stim • 237 48 3,000 12 ***** 8,000 None ****** None 2,100 cu ft None 2,320 6,000 cu ft 2,320 2,976 10 Halliburton 220 • 210 42 2,640 12 80,000 4,000 None 15,000 None 60,000 None 1,425 None 1,425 5,300 50 Halliburton 301 • 210 42 2,450 10 129,000 4,400 None 12,000 None None None 1,570 None n/a 2,625 30

• 288 61 7,200 14 180,000 12,000 None 42,000 None 1,730,000 136,000 19,760 2,500 23,810 7,140 100 • 274 56 3,420 14.2 **60,000 12,100 620 n/a None 6,680 cu ft 0 4,850 8,075 cu ft 4,850 4,850 75

Stim Star II • 240 56 3,420 14.2 ***** 8,000 None ****** None 6,680 cu ft None 6,040 8,075 cu ft 5,465 10,486 75 • 260 56 5,400 14.2 ***** 10,000 None ****** None 8,350 cu ft None 10,230 10,500 cu ft 8,870 6,740 75

• 220 44 4,000 12 20,000 8,000 None 25,000 None 210,000 n/a 2,200 8,000 2,200 4,000 10

[email protected] • 243 59 5,000 12 240,000 10,000 None 24,000 1,150 1,200,000 14,800 5,500 15,400 5,500 5,500 60

• 217 44 3,600 10 120,000 11,000 380 10,000 3,600 50,000 n/a 1,200 n/a 1,200 1,200 8 • 260 56 3,420 12 8,400 8,250 870 4,000 2,000 200,000 0 4,800 12,200 4,800 4,800 70 • 270 56 3,420 12 8,400 8,250 860 3,050 2,000 200,000 0 6,600 14,700 6,600 6,600 70 • 239 44 3,200 12 12,600 8,250 810 2,000 200,000 4,140 6,400 4,140 4,140 35

• 220 44 3,900 11 45,000 7,750 240 4,000 2,000 200,000 0 2,750 6,400 240 5,800 25

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(gal

)

Addi

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Gel /

com

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fluid

(bbl

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Gas

(gal

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Bulk

(cu

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Prop

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(lb)

Addi

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(gal

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Gel /

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fluid

(bbl

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Prop

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Frac

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3

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74 June 2004 •

7

8

9

10

Notes: 1) 2 off Drexel 3” line 2) 4,500 gal of LFC 3) 4”/ 3”/ 2.75”

4) DGPS/Satloc

1 fixed, 1 dropdown

2-stern thrusters 600 hp

1,200 hp dropdown 1,200 hp dropdown

Tankage

Vessel Name

Baker Oil Tools Mike Naquin, 654 N. Sam Houston Pky, Suite 400, Houston, TX 77060; phone: (713) 625-6600; email: [email protected] Yes Yes

BJ Services US/Gulf of Mexico 77092; (713) 895-5459; email: [email protected] Yes

4 M/V Blue Ray Yes 5 M/V Blue Shark Yes 6 M/V Challenger Yes 7 M/V Discovery Yes

8 M/V Seamar III 9 M/V Vestfonn n/a

Halliburton Energy Services Don Weinheimer, 10200 Bellaire, Houston, TX 77020; phone: (281) 575-3994; email: [email protected]

10 Falcon Tide Yes Yes Yes Yes

11 Skandi Fjord Yes 12 Stim Star Yes

Yes 13 Stim Star III Yes 14 War Admiral Yes

Schlumberger 15 Bigorange 18 Yes 16 Bigorange 25 Yes 17 DeepStim Yes 18 DeepStim II Yes 19 DeepStim III Yes 20 Galaxie Yes

Wes

t Afri

ca

Tota

l len

gth

(ft)

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l bea

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Wat

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bl)

Offshore www.offshore-mag.com

5) Two 1,200 hp bow thrusters: 6) 1,000 hp tunnel and 7) 350 hp tunnel and

General Notes:

quintiplex and triplex positive displacement pumps with Coflexip high pressure line(s)

pumps on rigs

P R O D U C T I O N

Mixing equipment Navigational equipment Safety equipment Pumping equipment

pump capability (frac pumps)

9,800 12,500

12,000 12,500 8,600 8,400 8,400 5,200

3,550 13,400

6,750 7,500 8,000 6,000 4,800 10,400 10,150 17,500 21,500 8,500

12,600 6,400 16,850 21,450 12,850 8,500

3,00

0 hh

p

6,00

0 hh

p

9,00

0 hh

p

12,0

00 h

hp

15,0

00 h

hp

18,0

00 h

hp

21,0

00 h

hp

24,0

00 h

hp

27,0

00 h

hp

60 110 15 16,000 50 700*** 2x3 2 x 350 15,000 5 9,800**** 50 15,000 2,100 2 x 60 180 15 2 x 18,000 60 3&4 2 x 350 15,000 7 12,500 60 15,000 2,100

120 200 50 32,000 50 4,200 DP-2 DNV Certified 3, 4 380 15,000 9 12,000 60 15,000 8,400 120 444 25 36,000 75 3600 (5) Bier DP-2 ABS Certified 3, 4 350 15,000 7 12,500 !! 75 15,000 4,200 120 200 50 32,000 50 4,800 DP-2 ABS Certified 3, 4 380 15,000 6 8,600 60 15,000 8,400 60 400 8 17,000 45 3 300 15000 5 8,400 ! 15,000 2,100 60 400 8 17,000 45 3 400 15000 5 8,400 ! 15,000 2,100 50 No n/a 14,000 30 280 No n/a No 3 200 10,000 4 5,200 50 15,000 n/a 50 120 30 10,000 25 No 600 No n/a 3 200 10,000 3 3,550 30 10,000 2,100 60 238 60 22,000 60 3,200 yes Simrad SDP21/DP2 Note 1 Note 3 600 10,000 8 13,400 60 10,000 2,730

35 n/a 35 1,200 Simrad SDP01 3 15,000 4 6,750 35 15,000 2,940 50 n/a 20,000 50 1,800 4 400 10,000 5 7,500 50 11,500 2,940 25 n/a 11,000 18 Robertson 3 300 10,000 5 8,000 32 15,000 3ea 2,100 100 n/a 100 n/a No 280 No n/a 3 110 10,000 10 6,000 100 15,000 5,000 70 n/a n/a 650 Nautronics ASK 4001 3 320 15,000 8 4,800 70 11,200 2,100 60 48 60 20,000 60 3,300 Kongsberg 703 4 400 15,000 6 10,400 100 15,000 5,040 50 200 30 20,000 50 1,200/1,000 Simrad/Kongsberg SDP21,Class 2 450 15,000 7 10,150 75 15,000 7ea 2,500 50 n/a 20,000 50 1,000/400 Simrad/Kongsberg SDP11,Class I 400 15,000 6 17,500 64 15,000 7ea 2,500 75 n/a 20,000 60 Simrad/Konesberg SDP21,Class II 3 & 4 400 15,000 8 21,500 64 15,000 7ea 3,100 50 n/a 20,000 50 680 3 300 15,000 5 8,500 35 15,000 5,000

70 5,500 60 60,000 70 7,100 Kongsberg ADP 702 3 480 15,000 9 12,600 70 12,500 80 150 70 18,000 25 No 750 3 400 15,000 3 6,400 60 10,000 70 4,800 30 18,000 50 1,550 Konsberg/Simrad 3 22,500 8 16,850 50 15,000 2,100 70 6,600 30 18,000 50 2,200 Konsberg/Simrad 3 22,500 8 21,450 50 15,000 2,100 35 4,140 25 18,000 25 2,200 Konsberg/Simrad 3 22,500 5 12,850 25 15,000 2,100 50 240 40 18,000 40 700 Konsberg/Simrad 4 10,000 5 8,500 40 15,000 3,360

Blen

ders

(bbl

/min

)

Batc

h (b

bl)

Acid

(bbl

/min

)

Prop

pant

(lb/

min

)

Frac

(bbl

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)

Frac

on

the

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?

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Num

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Belo

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capa

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• June 2004 75

11

12

13

14

15

16

17

18

19

20

** Acid storage below deck *** Navigational thrusters are of Azimuthal type n/a Not applicable

**** Hp expandable to 11,000 hhp *****

2 and N2 !! Hp expandable to 16,500 hhp ! Hp expandable to 10,400 hhp

• “Data not provided” indicated by blank cells • Pump types common to all vessels in survey are

• Pump “Number” includes all pumps available • Pump “Max Rate” includes all pumps available • Pump “Max Pressure” is highest rating of all

Total operating

Rudy de Grood, 654 N. Sam Houston Pky, Suite 400, Houston, TX 77060; phone (713) 625-6443; email: [email protected] Yes Yes DGPS-SATLOC + RF/DGPS Yes Yes Yes Yes Yes 1,200/1,000*** Yes Kongsberg/Simrad-SATLOC Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes *** (6) Yes DGPS-SAT Yes Yes Yes Yes 45 Yes Yes *** (7) Yes DGPS-SAT Yes Yes Yes Yes 45 Yes Yes Yes Yes

Yes Yes No Yes Yes Yes Yes Yes

35 n/a Yes Yes Yes Yes Yes Yes 80 50 Yes Yes Nautronics ATS11 402 Yes Yes Yes Yes n/a Yes 2 ea 1,000 Yes Yes Yes Yes Yes

n/a Yes Yes Yes Yes 70 n/a No Yes Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes 3 & 4

n/a Yes Yes Yes Yes Yes Yes 3 & 4 n/a Yes 2-1,000/1-1,200 Yes Yes Yes Yes Yes 20 Yes Yes Robertson Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes Yes Robopos/Tautwire Yes Yes Yes Yes

Yes Yes Yes Yes Yes Yes 2 x 300 Yes Yes Yes Yes Yes Yes 2 x 300 Yes Yes Yes Yes Yes Yes 1 x 300 Yes Yes Yes Yes Yes Yes 1 x 300

Trea

tmen

t lin

e si

ze (i

n.)

Trea

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(ft)

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l hyd

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powe

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www.offshore-mag.com Offshore

Use 5,400 gal MPT’s, no permanent storage ****** Use MPT's as needed for CO

Worldwide offshore marine vessels capable of self-propulsion

Victor Schmidt, Exploration Edtior



MONITORING & MISCELLANEOUS EQUIPMENT

Monitoring, recording and fracturing control equipment is crucial to jobperformance. For this reason, BJ uses the most advanced instruments in thefield 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 withradio links allowing for zero time deployment at the wellsite of treatmentdata communication. The units directly replace BJ LAN cables or may beused interchangeable with LAN cables. Since cabling is not used, theproblems with maintaining conventional cables are eliminated and thereliability of the signals are improved.



Features and Benefits• Operates in extremely harsh environments with immunity frominterference.

• Eliminates the need to run LAN cables between units and the time it takesto lay, retrieve, clean and store these cables.

• Supports wireless data transmission between 3305 and remote computersvia the computer serial port.

Figure 9. Wireless LAN Figure 10. Wireless LAN

WIRELESS WELLHEAD UNIT

The Wireless Wellhead Unit provides complete monitoring capabilities atthe wellhead without the need for cables running back to the monitoring van.The unit incorporates the Microplex Monitor, companion battery pack andan IsoLink Wireless LAN module to form a complete integrated package.(See individual spec sheets for complete specifications) The WirelessWellhead Unit is designed to operate with BJ's JobMaster system. The unitis approximately 5 1/2 feet high.

Power Center link for BJ monitoring & miscellaneous equipment:

https://powercenter.bjservices.com/__86256d48004debc5.nsf/WebByCategory?OpenView&Start=1&Count=30&Expand=1#1

https://powercenter.bjservices.com/__86256d48004debc5.nsf/WebByCategory?OpenView&Start=1&Count=30&Expand=1#1

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. TurbineFlow meters work best in low viscosity laminar flow. Target and MagneticMeters perform well in laminar and turbulent flow patterns. The target meteris recommended for both gas and liquid service but not for slurries.Although Magnetic Meters are not designed for gas measurement, theygenerally work well in all fluid services. The Turbine Meter performance ismost affected by changes in Fluid Properties.

The largest measurement errors with volumetric flow meters occur at lowrates. This demonstrates the importance of sizing the flow meter for theapplication. Meters with large diameters will have more measurement errorat nominal flow rates than smaller diameter meters will. If the meter is toosmall for the desired rate, there will be a significant pressure drop across themeter.

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 aliquid line. The unit consists of a multiple-bladed rotor, or impeller, mountedwithin a pipe, perpendicular to the liquid flow. Most turbines use flowstraighteners on both the inlet and discharge end of the meter to make theflow pattern more laminar. As liquid flows through the meter and over therotor, 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 anelectrical (sine wave) signal. The magnetic pickup is mounted outside theflow tube, and the electrical pulses from this pickup can be converted toproportional flow rate or counted and totaled in a remote monitor.

The Turbine Flow Meter is designed to measure the flow of liquids andgases in pipes to 2% inaccuracy. They are volumetric flow measuringdevices and have been available since the late 1940s. The Turbine FlowMeter is a flow measurement “workhorse”, having proven itself over theyears. In spite of the many new types of flow meters now in use, theTurbine is still a popular choice. Turbine Flow meters are very accurate formeasuring clean fluids of low to medium viscosity. The turbine has a linearoutput. Turbines are available for virtually any pressure and for high and lowtemperature applications. Limitations are incompatibility with high viscosityor 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 flowmeasurement which is unaffected by density, temperature, pressure orviscosity 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 distortionof an induced magnetic field. The distortion is caused by the flow of aconductive fluid in the pipe. The advantages of this type of flow device arethat 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 theconcentration of particulate becomes too high (>25% of volume). Magmeters can be used for bi-directional flow measurement.

There is, however, one major disadvantage for our application in that thefluid to be measured must be electrically conductive (usually greater than 5µSiemens per cubic centimeter). Pure substances, including manyhydrocarbons and gases, tend to fall below the 5µS/cm threshold. Sometypical fluids are listed in the table below:

Conductive Non-Conductive

Hydrochloric Acid 400,000 µS/cm Glycol 0.3 µS/cmSodium Hydroxide 40,000 µS/cm Kerosene 0.017 µS/cmAcetic Acid 250 µS/cm Ethyl Alcohol 0.0013 µS/cmPotable Water 70 µS/cm Xylene 0.000000001 µS/cm

Mass Flow Meters

Flow Meters that measure mass directly using the properties of mass, asopposed to those that measure volume or velocity, were developed andcommercialized in the 1980s. Other flow meter technologies are affected bychanges in fluid density, viscosity, pressure and/or temperature.

Mass is the amount of matter in an object. Mass Flow measurement is basedon the laws of nature that prohibit a stream from accumulating or loosingmass. Therefore, Mass Flow measurements are independent of changes intemperature, or pressure.

Meters that measure mass directly, in effect, weigh the fluid as it passesthrough the meter, yielding a highly accurate measurement that is virtuallyindependent of varying process conditions that often occur. Because of thisunique ability, it is possible to use a Coriolis Flow Meter on a wide variety

Theory of Operation - Magnetic Flow Meters

of chemicals without need for re-calibration or compensation to specificfluid parameters.

Several types of mass meters are available including radiation, angularmomentum, Coriolis, heat transfer, and hot-wire probes type. BJ hasstandardized 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 flowrates, which means improved product quality and reduced waste.

• Installation is simplified because there are no flow conditioning norstraight pipe run requirements.

• Low maintenance because there are no moving parts, and the systemis non-intrusive.

• Wide working range (turndown) of 10:1.• The mass meter provides an alternative to nuclear densimeters.

Mass Flow - Density DeterminationDensity is defined as mass per unit volume, or mass divided by volume. Thevolume of the fluid contained in the Flow Tubes remains constant. Then theonly way mass can change is if density changes. Because of thisrelationship, the natural frequency of the Flow Tubes indicates not only themass of the fluid contained, but also the density.The density of the process fluid can be derived from the frequency ofoscillation of the sensor. As the density increases, the natural frequency ofthe system decreases.

Micro Motion Coriolis MetersThe Coriolis meter is more expensive than conventional turbine Flow Metersor encoder systems. However, when maintenance costs are examined, theMass Flow Meter compares favorably with other methods of flowmeasurement.

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

ConclusionSome 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



Acknowledgements:

The authors would like to thank.Tomball’s Engineering Department:

References:

BJ Services Applied Fracturing-by Ken Kenner-1992

BJ Services Iron Manual

BJ Operations and MaintenanceManuals for Fracturing Equipment

BJ Services Equipment andTechnology Magazine –1994

BJ Services Power Center and BJServices Website Links.

2004 World Survey of MarineStimulation Vessels

ttc203 frac equipment manual version 1

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