Operating ACE For Downhole Blenders

HALLIBURTON ENERGY OPERATING ACE FOR
SERVICES DOWNHOLE BLENDERS
BLENDER OPERATOR DEVELOPMENT PROGRAM | HALLIBURTON ENERGY INSTITUTE

V 06/13
Notices
Confidentiality All information contained in this document is the exclusive property of

Halliburton Energy Services, Inc. (Halliburton) and contains confidential
and proprietary information, which is protected by trade secret, copyright
and other intellectual property laws and treaties. This document is intended
for use by those taking the Operating ACE for Downhole Blenders course
from Halliburton. No portion of this document may be reproduced or
duplicated, in whole or in part, without the express written consent of
Halliburton, and any review, use, distribution or disclosure of the
information contained herein by unauthorized persons is strictly prohibited.
Halliburton provides this document AS IS and makes no warranty or other
assurances as to the accuracy or completeness of the information contained
in this document and shall not be held liable for any technical, editorial, or
other errors or omissions contained therein. In no event shall Halliburton be
held liable for any special, indirect or consequential damages, whether
express, implied or statutory, or fitness for a particular purpose. This
document is not to be used in any manner or for any purpose that is
unlawful or which could cause damage, injury or impairment to Halliburton.
Document Description Date

History April 2012
First Release
March 2013
Revision Dates
June 2013
Credits Halliburton would like to thank the following for their contributions to this
manual (in alphabetical order):
Brian Dodd Robert Howard Bernardo Montell

Jerry Rendon Patrick Spaulding George Victor
Continued on next page
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Notices, Continued
Credits Halliburton would like to thank the following individuals for their input and
(continued) guidance (in alphabetical order):
John Adams Mark Adams Tokes Adoun

Billy Almon Ivan Blanco Joseph Burger
Chad Fisher Renee LeBas Mehdi Mazrooee
Jason McIntyre Max Phillippi Timothy Rains
Armando Velasquez Glenn Weightman
ACE Version This course is designed for use with ACE version 22.29 and above.
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Purpose
Course This course focuses on:

Objectives
Operating downhole blenders using ACE software
Understanding the subcomponents of the blender and their operation
Intended Better trained personnel will result in:

Results
Reduced Cost of Poor Quality (COPQ)
Increased Service Quality (SQ)
Increased understanding and application of blender concepts
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HMS References in this Document
Purpose This document adheres to and advocates the use of all HMS Process Maps,
Standards, Work Methods and other processes.
References to the HMS documents utilized in the creation are throughout

the student guide where applicable, but the following table lists the linked
documents or sites used.
Documents HMS Documents Referenced or Utilized

Description Name/Link
Process Map PM-GL-HAL-STIM-400
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Intended Users
Course This course is written for:

Audience
Current downhole blender operators
Prospective blender operators
Supervisors or any other employee needing training on blending
equipment
Course Before taking this course students should meet the following prerequisites:
Prerequisites
A minimum of 6 months of field experience
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Table of Contents
Notices.............................................................................................................................................................. i
Purpose .......................................................................................................................................................... iii
HMS References in this Document ................................................................................................................. iv
Intended Users ................................................................................................................................................ v
Table of Contents ........................................................................................................................................... vi
Course Roadmap ............................................................................................................................................. x
Unit 1: ACE and Downhole Blenders ................................................................................................................... 1-1

Unit Overview .............................................................................................................................................. 1-1
Lesson 1-1: Blender Power Pack System and Control Cabin ................................................................................. 1-3
Lesson Overview.......................................................................................................................................... 1-3
Blender Control Cabin ................................................................................................................................. 1-4
Blender Power Pack System ........................................................................................................................ 1-6
Lesson 1-2: Process Fluid Systems ......................................................................................................................... 1-9
Lesson Overview.......................................................................................................................................... 1-9
Process Fluid Systems Basics ..................................................................................................................... 1-10
Components of the Process Fluid System ................................................................................................. 1-11
Centrifugal Pumps ..................................................................................................................................... 1-12
Suction Side of the Blender ....................................................................................................................... 1-16
Blender Mixing Tub ................................................................................................................................... 1-20
Discharge Side of the Blender ................................................................................................................... 1-24
Lesson 1-3: Additive Metering Systems............................................................................................................... 1-27
Lesson Overview........................................................................................................................................ 1-27
Components of the Additive Metering System ......................................................................................... 1-28
Liquid Additive Systems............................................................................................................................. 1-29
Dry Additive Feeders ................................................................................................................................. 1-32
Proppant Delivery Systems ....................................................................................................................... 1-33
Lesson 1-4: Downhole Blenders and ACE ............................................................................................................ 1-35
Lesson Overview........................................................................................................................................ 1-35
What is ACE? ............................................................................................................................................. 1-36
Control Loops and Electronics ................................................................................................................... 1-38
Quality Assurance vs. Quality Control ....................................................................................................... 1-39
Unit 2: Equipment Rig Up and Startup ................................................................................................................ 2-1

Unit Overview .............................................................................................................................................. 2-1
Lesson 2-1: How to Select Fluid Hoses for Rig-Up ................................................................................................. 2-3
Lesson Overview.......................................................................................................................................... 2-3
Suction and Discharge Hoses ...................................................................................................................... 2-4
Hose Inspection and Use ............................................................................................................................. 2-5
Friction and Suction Hoses .......................................................................................................................... 2-7
Gel Loading and Viscosity ............................................................................................................................ 2-8
Clean Rate vs. Dirty Rate ........................................................................................................................... 2-10
How to Determine the Number of Suction Hoses ..................................................................................... 2-11
How to Determine the Number of Discharge Hoses ................................................................................. 2-13
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Lesson 2-2: Selecting Chemical Hoses and LA Pumps ......................................................................................... 2-15
Lesson Overview........................................................................................................................................ 2-15
LA Hose Information and Best Practices ................................................................................................... 2-16
How to Select the Correct LA Hose Size .................................................................................................... 2-17
Liquid Additive Pumps ............................................................................................................................... 2-18
How to Determine the Correct LA Pump to Use ....................................................................................... 2-24
Lesson 2-3: Pre-Start Inspection.......................................................................................................................... 2-25
Lesson Overview........................................................................................................................................ 2-25
Pre-Job Blender Inspection ....................................................................................................................... 2-26
Inspection Checklist ................................................................................................................................... 2-27
Lesson 2-4: How to Start Downhole Blenders ..................................................................................................... 2-29
Lesson Overview........................................................................................................................................ 2-29
The Hydraulic Start Tractor ....................................................................................................................... 2-31
How to Start Downhole Blenders .............................................................................................................. 2-32
Post-Start Inspection and Function Test ................................................................................................... 2-33
Unit 3: Calibrating Additive Delivery Systems ..................................................................................................... 3-1

Unit Overview .............................................................................................................................................. 3-1
Lesson 3-1: Bucket Testing Liquid Additive Pumps................................................................................................ 3-3
Lesson Overview.......................................................................................................................................... 3-3
How are Liquid Additives Measured?.......................................................................................................... 3-4
Importance of Bucket Testing ..................................................................................................................... 3-6
Creating an Accurate Bucket Test Bucket ................................................................................................... 3-7
The Bucket Test Manifold............................................................................................................................ 3-9
Bucket Testing Liquid Additive Pumps ...................................................................................................... 3-10
Importance of Proper Priming of the LA Pump ......................................................................................... 3-13
The Bucket Test Menu ............................................................................................................................... 3-14
Bucket Test Misconceptions ...................................................................................................................... 3-15
Bucket Test Procedure .............................................................................................................................. 3-16
Lesson 3-2: Selecting Proppants and Sand Screws .............................................................................................. 3-19
Lesson Overview........................................................................................................................................ 3-19
Confirming Sand Screws and Proppants ................................................................................................... 3-20
Lesson 3-3: Bucket Testing Dry Additive Augers ................................................................................................. 3-25
Lesson Overview........................................................................................................................................ 3-25
Dry Additive Feeders ................................................................................................................................. 3-26
Method to Bucket Testing Dry Additive Feeders ...................................................................................... 3-27
How to Bucket Test Dry Additive Feeders ................................................................................................. 3-28
Bucket Testing of Proppant Delivery Systems ........................................................................................... 3-29
Unit 4: Calibrating Process Fluids Systems .......................................................................................................... 4-1

Unit Overview .............................................................................................................................................. 4-1
Lesson 4-1: Calibrating the Densometer ............................................................................................................... 4-3
Lesson Overview.......................................................................................................................................... 4-3
Radioactive Densometers............................................................................................................................ 4-4
Blender Densometers .................................................................................................................................. 4-5
How to Calibrate the Densometer .............................................................................................................. 4-8
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Lesson 4-2: Calibrating the Blender Tub ............................................................................................................... 4-9
Lesson Overview.......................................................................................................................................... 4-9
Selecting the Correct Tub Fill Valve ........................................................................................................... 4-10
How to Calibrate the Tub Fill Valve ........................................................................................................... 4-11
The Blender Tub Level Sensor ................................................................................................................... 4-12
How to Calibrate the Tub Level Sensor ..................................................................................................... 4-13
Lesson 4-3: Calibrating the pH Probe .................................................................................................................. 4-15
Lesson Overview........................................................................................................................................ 4-15
Blender pH Probes ..................................................................................................................................... 4-16
pH Sensors and Transmitters .................................................................................................................... 4-17
Calibration of the pH Probe....................................................................................................................... 4-18
Lesson 4-4: Calibrating the Viscometer............................................................................................................... 4-19
Lesson Overview........................................................................................................................................ 4-19
What is a Viscometer? ............................................................................................................................... 4-20
FB4K Capillary Viscometer......................................................................................................................... 4-22
How to Calibrate the Viscometer .............................................................................................................. 4-24
Unit 5: Preparing for the Job ............................................................................................................................... 5-1

Unit Overview .............................................................................................................................................. 5-1
Lesson 5-1: Preparing Blending Equipment .......................................................................................................... 5-3
Lesson Overview.......................................................................................................................................... 5-3
Preparing Liquid Additives for the Treatment ............................................................................................. 5-4
Blender Upright Tanks ................................................................................................................................. 5-6
Preparing Dry Additives for the Treatment ............................................................................................... 5-10
Priming and Function Testing the Blender ................................................................................................ 5-12
Lesson 5-2: Priming Horsepower Equipment ...................................................................................................... 5-15
Lesson Overview........................................................................................................................................ 5-15
Using the Rate Tab in ACE ......................................................................................................................... 5-16
Loading the Blender Tub ........................................................................................................................... 5-17
Supplying Discharge Pressure ................................................................................................................... 5-21
Role of the Blender Operator in Prime Up ................................................................................................ 5-22
Unit 6: Performing the Job .................................................................................................................................. 6-1

Unit Overview .............................................................................................................................................. 6-1
Lesson 6-1: Monitoring Additives .......................................................................................................................... 6-3
Lesson Overview.......................................................................................................................................... 6-3
Importance of Monitoring Additive Delivery .............................................................................................. 6-4
Lesson 6-2: Performing the Treatment: Planned Events ....................................................................................... 6-5
Lesson Overview.......................................................................................................................................... 6-5
Common Planned Events ............................................................................................................................ 6-6
Lesson 6-3: Performing the Treatment: Unplanned Events .................................................................................. 6-7
Lesson Overview.......................................................................................................................................... 6-7
Being Prepared for Unplanned Events ........................................................................................................ 6-8
Examples of Unplanned Events ................................................................................................................... 6-9
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Unit 7: Post Job Activities ................................................................................................................................... 7-1
Unit Overview .............................................................................................................................................. 7-1
Lesson 7-1: Pre-Shutdown Tasks ........................................................................................................................... 7-3
Lesson Overview.......................................................................................................................................... 7-3
How to Prepare the Unit for Power-Down .................................................................................................. 7-4
Lesson 7-2: Equipment Power Down ..................................................................................................................... 7-5
Lesson Overview.......................................................................................................................................... 7-5
How to Power Down Equipment ................................................................................................................. 7-6
Course Appendix..................................................................................................................................................... I
Overview ..........................................................................................................................................................I
Performing a Gel Circulation Test (Capillary Viscometer) ...............................................................................II
Bucket Test Procedure Time Relative ......................................................................................................... IV
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Course Roadmap
ACE and Calibrating Calibrating

Equipment Rig Preparing for Performing the Post Job
Blending Liquid Additive Process Fluid
Up and Startup the Job Job Activities
Equipment Systems Systems
Blender Power
Bucket Testing Preparing
Pack System Selecting Fluid Calibrating the Monitoring Pre-Shutdown
Liquid Blending
and Control Hoses Densometer Additives Tasks
Additives Equipment
Cabin
Selecting LA Selecting Priming

Process Fluid Calibrating the Planned Equipment
Hoses and Proppants and Horsepower
Sytems Blender Tub Events Power Down
Pumps Screws Equipment
Additive Bucket Testing

Pre-Start Calibrating the Unplanned
Metering Dry Additives
Inspection pH Probe Events
Systems and Proppants
Downhole Starting
Calibrating the
Blenders and Downhole
Viscometer
ACE Blenders
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Unit 1: ACE and Downhole Blenders
Unit Overview
Introduction This unit will cover the major components and subsystems of a downhole
blender.
Course
Roadmap
Calibrating Calibrating
ACE and Equipment
Additive Process Preparing Performing Post Job
Blending Rig Up and
Delivery Fluid for the Job the Job Activities
Equipment Startup
Systems Systems
Contents This unit contains the following lessons:
Topic See Page

Lesson 1-1: Blender Power Pack System and Control Cabin 1-3
Lesson 1-2: Process Fluid Systems 1-9
Lesson 1-3: Additive Metering Systems 1-27
Lesson 1-4: Downhole Blenders and ACE 1-35
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Lesson 1-1: Blender Power Pack System and
Control Cabin
Lesson Overview
Introduction In this lesson you will learn about the blender power pack system and the
blender control cabin.
Course
Blender Power Pack System and Control Cabin
Roadmap
Process Fluid Systems
ACE and Additive Metering Systems
Blending Downhole Blenders and ACE
Equipment
Importance Understanding components of the power pack and control cabin will help
you determine all of the inspection criteria for the equipment, and help you
understand how the blender operates.
Lesson Upon completion of this lesson, you should be able to:

Objectives
Identify the major components of the blender power pack system
Identify the major components of the blender control cabin
Contents This lesson contains the following topics:
Topic See Page

Blender Control Cabin 1-4
Blender Power Pack System 1-6
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Blender Control Cabin
Introduction In this topic you will learn about the control cabin of the blender.
Control Stands The blender you operate in the field may or may not have a control cabin,
but at minimum will typically have a control stand up on top of the blender
near the blender tub.
Control Cabin Review the following image of the control stand on the FB4K blender:
Control Cabin Review the following image of the control cabin interior of the FB4K:
Interior
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Blender Control Cabin, Continued
Control Stand Review the image of the FB4K control stand:
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Blender Power Pack System
Introduction In this topic you will learn about the power pack that provides power to the
blender.
Components of The FB4K blender is equipped with a diesel hydraulic power pack. The
the Power Pack components of the power pack are:
Diesel Engine (Prime Mover)

Hydraulic Pumps
Radiator Assembly
Hydraulic Coolers
Hydraulic Tank
Access Platforms
The deck engine provides the power source for all the systems on the
blender. Most of the hydraulic components on a blender are under
computer control.
Diesel Hydraulic Review the following image of the diesel hydraulic power pack that is
Power Pack equipped on the FB4K blender.
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Blender Power Pack System, Continued
Prime Movers A prime mover, or engine, supplies mechanical energy to drive hydraulic
pumps. The prime mover may not be the same on all benders. Late model
blenders are equipped with either Detroit or Caterpillar engines.
Hydraulic Hydraulic pumps convert mechanical energy to hydraulic energy by pushing

Pumps the hydraulic fluid through the system. Almost every component on a
blender, from control valves to the centrifugal pumps use this energy to
operate.
Hydraulic Modern blenders rely heavily on hydraulically driven components and a large
Coolers amount of heat is created. The hydraulic fluid needs to be kept below 180F
to be safe and effective. Hydraulic oil coolers work on the same basic
principle as the radiator on a car engine. Hot hydraulic fluid enters an oil
cooler heat exchanger where air or water is forced past the oil to help cool
it.
Hydraulic Tank The tank, or reservoir, is the first storehouse for the fluid until it is required
by the system. The tank provides a place for air to separate from the fluid
and permits contaminants to settle. It also helps dissipate heat that is
generated by the system.
Filters and Filters and strainers keep the hydraulic fluid clean by trapping contaminants
Strainers as fluid flows through them. Strainers are simply coarse filters.
Accumulators An accumulator stores incompressible hydraulic fluids under pressure. As the

fluid enters the accumulator chamber, it does one of three things:
compresses a spring, compresses a gas, or raises a weight. A drop in pressure
at the outlet causes the element (spring, gas, or weight) to react and force
the fluid back out. Accumulators absorb shocks or pressure surges due to the
sudden stopping or reversing of oil flow.
Valves Directional valves are used to control the direction of flow. A check valves
function is to only permit fluid flow in one direction
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Blender Power Pack System, Continued
Cylinders Cylinders are linear actuators. Linear means that the output of a cylinder is a
straight-line motion and/or force. Cylinders are used for remote operations
which require back and forth motion such as sand screw lift.
Hydraulic Motor usually refers to a rotary hydraulic actuator. Motors look very much
Motors like pumps in construction, but instead of pushing the fluid, motors are
pushed by the fluid.
This produces torque and rotating motion with drives the sand screws,
chemical additive pumps, centrifugal pumps, etc.
Hydraulics Best The main thing to understand about the hydraulic system is that the
Practices hydraulic fluid needs to be kept clean. When filling the hydraulic tank, make
sure the container you are transferring the hydraulic fluid from is clean. Also,
the hydraulic fluids temperature can and does run above 180F. The
recommended heat range is below 180F. So the fluid and thus the hoses
and connections are very hot. If the hydraulic oil temperature is above
180F, contact your local mechanic.
Note When you see a leak, DO NOT PUT YOUR HAND ON IT.
Hydraulic fluid is under pressure and can be injected
through your skin. This injection of hydraulic fluid into
your system can require the injected portion to be
removed.
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Lesson 1-2: Process Fluid Systems
Lesson Overview
Introduction In the last lesson you learned about the blender power pack system and
control cabin. In this lesson you will learn about the process fluid system.
Course
Roadmap Process Fluid Systems
Equipment

Objectives
Identify the major components of the process fluid system
Understand the function of blender manifolding and piping
Distinguish the suction and discharge sides of the downhole blender
Contents This section contains the following topics:
Topic See Page

Process Fluid Systems Basics 1-10
Components of the Process Fluid System 1-11
Centrifugal Pumps 1-12
Suction Side of the Blender 1-16
Blender Mixing Tub 1-20
Discharge Side of the Blender 1-24
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Process Fluid Systems Basics
Introduction In this topic you will learn the definition of a few components used in the
process fluid systems.
Clean Rate Clean rate, which may also be called suction rate or master rate, is defined
as the rate at which fluid is delivered to the blenders tub by the suction
pump.
Clean rate is the main variable involved in mixing chemicals and proppants in
the correct concentrations. Nearly all additives are slaved to the clean rate;
meaning additive rate follows the clean rate. In some instances we have
chemicals slaved to the sand rate, but the sand rate is still slaved to the clean
rate.
Clean rate is typically measured in barrels per minute (bpm). A blender

operator should always monitor the clean rate and insure that it is stable
and not fluctuating.
Dirty Rate Dirty rate, which may also be called slurry rate or discharge 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 also measured in bpm. During pad or before sand is
brought on the blender operator should insure the dirty rate and clean rate
are at the same value.
If the clean rate is 30 bpm then the dirty should be close to 30 bpm 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. Once we begin pumping sand or proppant the clean rate will
decrease due to the additional volume of proppant added to the tub.
The more proppant that is

delivered, the less clean
fluid will be required to
maintain the same dirty
rate.
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Components of the Process Fluid System
Introduction In the last topic you learned the definition of a few process fluid system
components. In this topic you will learn about the mechanical components
of the process fluid system.
Importance The downhole blender is responsible for mixing large quantities of fluids and
discharging those fluids under pressure to pump trucks.
Understanding the components and their function is a critical part of a

blender operators job.
Components of The following components of the fluid delivery system are present on nearly
the System every downhole blender. Refer to the equipment manual for the blender you
are operating for component specifics.
Centrifugal suction and discharge pumps

Mixing Tub
Piping System
Fluid Delivery Review the following image of the fluid delivery system of an FB4K blender.
System
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Centrifugal Pumps
Introduction In the last topic you learned about the major components of the fluid
delivery system. In this topic you will learn about the centrifugal pumps on
the blender.
Function of the Centrifugal pumps are used on blenders to draw fluids out of storage tanks
Pumps and convey sand laden fluids to high pressure pumps. Understanding
centrifugal pump operation and performance is vital if blenders are to be
operated correctly.
What is a A centrifugal pump consists essentially of one or more impellers equipped

Centrifugal with vanes. The impeller is mounted on a rotating shaft and enclosed by a
Pump? casing.
Right-Hand Centrifugal Pump
Fluid enters the pump at the center of the impeller. The fluid is then directed
radially toward the case by the vanes. As the fluid leaves the impeller, it is
collected in a volute or series of diffusing passages. This causes the fluid rate
to drop and the pressure to increase.
Usage of Centrifugal pumps are used because they are more tolerant of abrasive
Centrifugal fluids than gear or vane pumps. This tolerance causes less wear on the
Pumps pumps, therefore increasing pump life. However, they are much less tolerant
of air.
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Centrifugal Pumps, Continued
Pump Before centrifugal pump principles and operations can be fully understood,
Classification there are certain terms that must be defined. Centrifugal pumps are
classified according to:
Suction and discharge manifold diameters

Impeller diameters
Number of vanes
Direction of discharge
Other characteristics
An important distinguishing feature is whether the pump is a right-hand or

left-hand pump. To determine this, use the image on the previous page as a
reference.
As you look into the impeller from the suction side of the pump, note on
which side of the case the discharge manifold starts. In the image, the
discharge starts on the right. Therefore, it is called a right-hand pump. A left-
hand pump has the discharge starting on the left.
Head Head is generally used with centrifugal pumps rather than pressure. It refers
to the height (in feet of water) that a pump can discharge.
This is important because the more dense the fluid, the lower the head the
pump will have or the less boost pressure the pump will have. This effect will
be seen as the proppant concentration is increased.
The head or pressure developed by the centrifugal pump is entirely the

result of the fluid rate caused by the impeller rotation. This pressure is not
created by any type of positive displacement methods (plungers).
Pump Horsepower is the power required by the pump, not the hydraulic
Horsepower horsepower delivered. Unless otherwise noted on performance curves,
these values are based on a fluid with the density of water.
If the fluid being pumped has a different density than water, multiply the
horsepower by its specific gravity.
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Net Positive Net Positive Suction Head (NPSH) is divided into two categories, both
Suction Head measured in feet of liquid:
Required NPSH is the amount of pressure that must be supplied to the

suction of the pump for the pump to operate properly. It is shown on
performance curves.
Available NPSH varies with suction conditions and must be equal to or
greater than the Required NPSH.
Determining As a blender operator, you will not be expected to calculate available NPSH,
NPSH but it is important to understand this characteristic of centrifugal pumps to
avoid possible problems when laying temporary suction manifolds.
Available NPSH can be thought of as the hydrostatic pressure from the frac
tanks or other source that are feeding the suction pump. The faster fluid is
moving through the suction hoses, the more of this pressure is that is lost to
friction along the way.
The higher the flow rate, the higher the friction loss, which can result in air
or vapor separation. This is further complicated when elbows or tees are
used close to the pump or the hose length is increased beyond 20 ft.
Uneven flow patterns, vapor separation, or both, can keep the liquid from
evenly filling the impeller. This upsets the hydraulic balance and can lead to
pump cavitation, vibration and excessive shaft deflection. Shaft breakage or
premature bearing failure may result.
Reducing the Although all factors of Available NPSH can be controlled to some extent, the
Friction Loss friction loss can be altered more easily than the others. This is usually done
by varying the number and/or length of the suction lines. The maximum
volume that should be pulled through one 20 ft, 4 in. suction hose is 10 bpm.
This is only a rule of thumb, and there will be times when the volume per
hose must be lower.
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Reducing the Suction lines should be as short and as straight as possible. They also should
Friction Loss not have intermediate in-line high places to create air pockets. O-rings
(continued) should be in good condition and should be in place to prevent air intake at
the connections
Performance The centrifugal pump will adjust its rate depending on the input and output
Characteristics pressures. If an adequate head of fluid (input pressure) is available, the
pump rate will adjust to match the output pressure. If an adequate head of
fluid is not present, then vapor pockets can form in the center of the
impeller and cause pump cavitation. This can also cause serious structural
damage to the pump. Cavitation can be eliminated by down-throttling
(partially closing) a valve in the discharge line to reduce the output rate to a
point where the input head is adequate.
Faster speeds produce more pressure or head and demand more

horsepower. Slower speeds have the opposite effect.
Water Hammer Some centrifugal pump cases have been split by water hammer. Water
hammer occurs when a valve in the discharge line of the pump is closed too
quickly. This brings the fluid to a sudden stop and exerts very high pressure
throughout the system upstream from the valve. Normally, the pump case is
the weakest part of the system and is the part that fails.
A typical water hammer break is characterized by a crack running around the

centerline of the case. This may not happen the first time a water hammer
occurs, but it definitely weakens the case and increases the probability of
future failure.
A surge chamber can be installed in the discharge line to reduce the

hammer, but wont eliminate it. If possible, pump speeds should be reduced
and valves closed gradually.
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Suction Side of the Blender
Introduction The last topic discussed the process fluid system as a whole. In this topic you
will learn about the suction side of the blender.
Components of The primary components of the process fluid system on the suction side of
the Suction Side the blender are the:
Blender suction header

Suction centrifugal pump
Tub fill valves and manifolding
Blender viscometer
Blender Suction The suction header is the entry point for the clean process fluid to the
Header blender. It contains typically contains the following components depending
on the blender:
Multiple 4-inch hose connections

One 8-inch hose connection
Suction header isolation valve
Some of the valves may equipped with actuators for remote opening and
closing.
Review the following image of a suction header from the FB4K blender:
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Suction Side of the Blender, Continued
Purpose of the The suction header isolation valve can be used to limit the amount of
Isolation valve manifold that is flooded if a limited amount of hoses are needed. In that case
utilize the right side of the manifold closest to the suction centrifugal pump
for hoses and close the isolation valve.
Also, by closing the suction header isolation valve and opening the front
recirculation valves, the front half of the suction header can be connected to
the discharge manifold for pre-gelling frac tanks.
Suction The suction centrifugal pump supplies fluid to the mixing tub or directly to
Centrifugal the discharge side while the blender is operating in tub bypass. It does so by
Pump maintaining suction pressure on the suction manifold.
Review the following image of a Gorman-Rupp 12 x 12 centrifugal pump

equipped on the FB4K blender.
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Discharge of the This portion of the manifold carries clean process fluid from the suction
Suction Pump pump to the mixing tub. It contains flow meters and metering valves to
measure and control the flow rate entering the tub. Sensors also measure
the manifold pressure and fluid pH.
Tub Bypass The tub bypass valves allow clean fluid to bypass the mixing tub and
discharge pump and flow directly to the discharge manifold.
Mixing System Review the following image of the tub level valves and the mixing system of
Manifold an FB4K blender:
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Blender The FB4K trailer is equipped with a capillary viscometer. A progressive cavity
Viscometer pump supplies fluid to the viscometer.
This pump has a run-dry protection system that only allows the pump to
operate when fluid is sensed at the inlet. As part of the run-dry system, an
air vent valve is located at the pump inlet. When charge pressure from the
suction centrifugal pump forces fluid to the viscometer pump, the vent
allows air to escape from the inlet hose. The air vent automatically closes
when fluid fills the vent valve.
During normal operation, the vent valve should be open to allow venting
(turned counterclockwise as viewed from the top). The vent valve must be
closed (turned clockwise as viewed from the top) to pick up fluid in a
negative head condition, such as pumping from a bucket located on the
ground, otherwise air will enter the system through the vent and prevent the
pump from priming.
Viscometer Review the following image of the viscometer location on an FB4K blender:
Location
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Blender Mixing Tub
Introduction In the last topic you learned about the centrifugal pumps that the blender is
equipped with. In this topic you will learn about the blender mixing tub.
Function of the After being metered through the selected tub level valve, fluid enters the
Mixing Tub mixing tub. The blender mixing tub is designed to mix fluid, additives and
proppants into a dispersed mixture and feed the discharge centrifugal pump.
Components of The tub has several components, but the main components of the blender
the Mixing Tub tub are:
Mixing tub
Tub agitators
Capacity of the Different blenders have tubs with varying capacities. The FB4K blender is
Tub equipped with a tub that has a working capacity of 13.5 barrels.
While 13.5 barrels may seem to be a fair amount of fluid, assuming you had
the tub full to capacity and pumped a clean fluid at 80 bpm, you would
empty the tub in 10 seconds if you did not continue to fill it during the job.
Mixing Tub Tub level is the level of fluid that is in the blender tub. Tub level is very
Level critical to many different variables, including having enough fluid in the tub
to insure the pumps do not have air entrained.
Tub level set point is usually 70% to 75% and a reading of 105% when full to
allow the controller time to stop the tub from overflowing.
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Blender Mixing Tub, Continued
Mixing Tub Review the following image of a mixing tub from an FB4K blender:
Tub Agitators The tub is equipped with an agitator that disperses the proppant into the
process fluid. The tub agitator consists of two sets of blades on a shaft. The
bottom blades are set just off bottom of the mixing tub.
The agitator is hydraulically driven and has a variable speed control. The
agitator can be run manually from the control stand but is normally run
automatically by the ACE controller.
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Tub Agitators
(continued)
Agitation: The
stirring of the fluids
in the blender tub
with the agitator or
paddles mounted in
the tub.
The purpose of the agitator is to help keep the proppant suspended in the
fluid without entraining air. If the agitator speed is too low, the proppant can
build up on the bottom of the tub and suddenly get picked up as a slug and
sent to the pumps. The agitator must be turned fast enough to mix proppant
without entraining unnecessary amounts of air into the process fluid.
The ACE system computer adjusts the agitator speed based on proppant
concentration. In the computer, the agitator is given a set speed without
proppant. When proppant is added to the fluid in the tub, computer will
increase the agitators rpm as the proppant concentration is increased. The
default setting is 40 rpm without proppant and adding 4 rpm per pound of
proppant added, as determined by sand screw rpms.
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Tub Level The tub level control system is an electro-hydraulic system designed to hold
Control System a near-constant fluid level in the tub by controlling the flow of clean fluid
into the mixing tub.
The FB4K blender is equipped with two tub level valves for different rate
applications.
How the System Review the following process of the tub level system:
Works
Stage Description
1 The tub level sensor measures the fluid level in the tub and
converts the level to an electrical signal. The fluid level is
displayed in the control stand as 0 to 100% tub level.
2 A set point of 0 to 100% tub level is entered at the computer. The
computer compares this set point to the tub level from the
sensor and adjusts the tub fill valve to provide the correct flow
into the mixing tub.
3 Two gauges on the computer are visible to the operator:
%FLUID LEVEL gaugeindicates the desired (set) position
of the tub level
FILL VALVE %OPEN gaugeindicates the open position of
the tub fill valve
4 The tub level valves operate best in the 30 to 70% open position.
If a valve is operating above 70%, increase the suction pump
pressure.
Tub Level Many times blender operators are concerned during a function test of the
Operation tub level valve that beyond being open 70%, the opening of the valve takes
some time.
This should be of no concern, as there is essentially no increase in the flow

through the valve beyond 70%.
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Discharge Side of the Blender
Introduction In the last topic you learned about the blender mixing tub. In this topic you
will learn about the discharge side of the blender.
Components of The primary components of the process fluid system on the discharge side of
the Discharge the blender are the:
Side
Discharge centrifugal pump
Discharge manifold
Prime up line
Discharge Side The discharge centrifugal pump supplies the high-pressure pumping units
Centrifugal with fracturing slurry at a boosted pressure of approximately 55 psi.
Pump
Discharge pressure, also called Boost, is defined as the psi that is
maintained on the discharge manifold. Discharge pressure is needed to insure
proper high pressure pump operation and accurate densometer operation.
Review the following image of a Flowserve 10 x 12 centrifugal pump

equipped on the FB4K blender.
The only time during the job that the discharge pump will not be necessary is
when utilizing tub bypass mode on the blender.
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Discharge Side of the Blender, Continued
Discharge The discharge manifold conveys the slurry from the discharge pump to the
Manifold discharge header where the sand-laden fluid exits the blender. It contains an
8-inch magnetic flow meter and densometer to monitor the rate and sand
concentration of the slurry. Sensors also measure manifold pressure and
fluid pH.
The discharge header typically contains:
Multiple 4-inch hose connections

One 8-inch hose connection
Other Manifold The discharge header isolation valve enables closing off the forward half of
Components the header.
Slurry leaving the discharge pump may be returned to the mixing tub
through the 2-inch tub recirculation line. This line is useful for purging air
during pump prime-up and for circulating the mixing tub and discharge
pump when using the tub bypass function if needed.
Discharge Side Review the following image of the discharge side of an FB4K blender:
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Discharge Side of the Blender, Continued
Prime Up Line To aid in priming the high-pressure pumping units, the discharged fluid from
the pumps can be routed back to the mixing tub via the prime-up line.
Review the following image of a prime up line as equipped on the FB4K

blender:
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Lesson 1-3: Additive Metering Systems
Lesson Overview
Introduction In the last lesson you learned about the process fluid systems on the
blender. In this lesson you will learn about the additive metering systems.
Course
Equipment

Objectives
Identify the major components of the liquid additive systems
Identify the major components of the dry additive feeders
Identify the major components of the proppant delivery systems
Topic See Page

Components of the Additive Metering System 1-28
Liquid Additive Systems 1-29
Dry Additive Feeders 1-32
Proppant Delivery Systems 1-33
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Components of the Additive Metering System
Introduction In the last topic you learned about the blender tub. In this topic you will
learn about the additive metering system on the blender.
Importance Every fracturing treatment is controlled by mixing the proper concentration

of additives to the fluid. These additive systems include:
Liquid Additive Pumps

Dry Additive Feeders
Sand Screws
Due to the nature of stimulation fluids, some additives can only be added
on-the-fly (while pumping). These additives are in liquid or solid form.
Various pumps and hoppers mounted on the blender allow accurate
measuring and addition of these additives.
System Review the following diagram of the additive metering systems equipped on
Overview the FB4K blender:
Importance of In order to mix additives at the correct concentration, these additive

Calibration metering systems must be properly calibrated before the treatment.
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Liquid Additive Systems
Introduction In the last topic you learned about the additive metering system as a whole.
This topic will discuss liquid additive pumps.
Importance Halliburton has many fracturing fluids that require a large number of
chemical additives for proper performance. Many of these additives are
liquid.
Liquid additive pumps are used on the jobsite to mix the correct amount of
additive into the fluid. Some of the additives mixed include:
Crosslinkers
Friction Reducers
Conductivity Enhancers
Clay Control Agents
These and other additives are critical to not only the successful outcome of
the fracturing treatment, but to the performance of the well for the
customer. The liquid additive systems on blenders are designed to blend the
liquid chemicals into the fracturing fluids.
Purpose of Most blenders are equipped with chemical transfer pumps and liquid
Additive Pumps additive pumps. Review the following table that describes the purpose of the
pump types:
Pump Type Purpose

Chemical Transfer Used to load Hal-Tanks on the blender; delivery
Pump rate cannot be changed
Used to inject additives into the fracturing fluid
Liquid Additive Pump
stream; can be metered into fluid as needed
The FB4K blender is typically equipped with 7 liquid additive pumps and 6
chemical transfer pumps.
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Liquid Additive Systems, Continued
Micro Motion The Micro Motion T-Series meters are straight-tube flow meters. The
Flow Meters straight-tube design is self-draining, compact, and reduces plugging. The
wetted parts of the mass flow meters are constructed from titanium for
excellent corrosion resistance. The flow meters are sized to match the flow
rates of the supplied LA pumps.
Bucket Test The FB4K blender is equipped with a bucket test manifold.
Manifold
Mounted above each Micro Motion flow meter is a pair of three-way ball
valves that allow the chemical to be routed to the following locations:
Bucket test hose

40-gallon holding tank
LA bulkhead panel
LA Bulkhead On the FB4K blender, the LA bulkhead panel is located just forward of the
Panel suction centrifugal pump and allows routing of the LAs to the following
injection locations on the blender:
Discharge pump inlet

Discharge pump outlet
Mixing tub.
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Liquid Additive Systems, Continued
LA Bulkhead In addition to the LA bulkhead panel, LA injection ports are located on the
Panel suction header.
(continued)
Blender Upright Stainless steel liquid additive tanks are mounted on the blender. All of the
Tanks stainless steel tanks have a bottom suction connection. They also have sight
tubes for visually checking levels along with electronic fluid level sensors.
The LA totes on the blender are designed to be filled by transfer pumps

before the job or on-the-fly if needed. You may also use the LA totes to
dilute or cut an additive.
Note Care must be taken to only put chemicals inside that

are compatible with stainless steel. Vicon HT breaker is
one chemical that is not compatible with stainless steel.
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Introduction In the last topic you learned about the liquid additive systems on the
blender. In this topic you will learn about the dry additive (DA) feeders
equipped on the blender.
Dry Additive Dry additive feeders meter dry chemicals into the blender tub. Nearly every
Feeder Function blender in the field has two Acrison dry additive assemblies on the blender
deck.
The FB4K trailer is equipped with an additional an auger that can meter and
convey large volumes of chemical from the ground level, eliminating the
need to transport bags to the top of the blender as would be required if an
Acrison feeder was used.
The auger and discharge tube on the Acrison feeders can be replaced with
different sizes to adjust the output.
DA Systems Review the following image of the dry additive assemblies equipped on the
FB4K blender:
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Proppant Delivery Systems
Introduction In the last topic you learned about the dry additive feeders. In this topic you
will learn about the proppant delivery system equipped on the downhole
blender.
Importance Fracturing jobs normally require the addition of propping agents into the
fluid. Sand screws convey those propping agents from bulk equipment to the
blender tub. The propping agent may be sand, lightweight ceramics,
intermediate or high strength bauxite, or a resin coated version of any one of
these types.
Sand Screw Each sand screw on the blender is operated independently through
Control computer controlled hydraulic throttling.
Review the following image of the proppant delivery system equipped on

the FB4K blender:
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Proppant Delivery Systems, Continued
Sand Screws The proppant delivery system on downhole blenders usually consist of 2 or 3
hydraulically-driven sand screws, or augers, located at the rear of the
blender.
These augers are used for metering and conveying proppant to the
blender/mixing tub. The augers are cut down for use with conductivity
enhancement systems such as SandWedge and Expedite.
Screw Inlets The sand screw inlets located in the hopper should always be covered with
an adequate amount of proppant to ensure proper metering.
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Lesson 1-4: Downhole Blenders and ACE
Lesson Overview
Introduction In the last lessons you have learned about the various subsystems equipped
on the downhole blender. In this lesson you will learn how these subsystems
relate to ACE.
Course
Equipment

Objectives
Identify the major components of ACE
Understand electronic and feedback loops on the blender
Contents This chapter contains the following topics:
Topic See Page

What is ACE? 1-36
Control Loops and Electronics 1-38
Quality Assurance vs. Quality Control 1-39
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What is ACE?
Introduction In this topic you will learn about ACE and its components.
What Does ACE ACE stand for Automatic Controlled Equipment. Nearly all fracturing
Stand For? equipment is currently outfitted with ACE for enhanced job control,
including:
Horsepower Pumps
Blenders
Technical Command Centers
Mountain Movers
Major Hardware The major components of the ACE system include:

Components of
ACE Laptop or industrial computer with the ACE software installed
Networking components of the Data Acquisition System (DAS)
What is DAS? DAS stands for Data Acquisition Systems. It is a major component of the ACE
system and includes:
Control Area Network (CAN) input/output modules

Smart Distribution System (SDS) serial control network
JLAN interface box
LAN cables or wireless connection
Pumping unit uplink
Equipment transducers and sensors
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What is ACE?, Continued
What Does DAS The Data Acquisition System collects data from the sensors on the
Do? equipment and relays the data to ACE.
DAS also allows ACE to send commands to the blender using JLAN as an
interface for equipment to communicate through.
How is DAS Downhole blenders connect to DAS via the Ethernet cable or wireless
Connected? network.
The E-tech may typically connect the blender to DAS, but the operator is
required to verify that the blender connected to DAS before the job begins.
Note Wireless communication is not currently in common

use. It is to be implemented sometime in the future.
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Control Loops and Electronics
Introduction In the last topic you learned about the basics of ACE control on the jobsite. In
this topic you will learn how ACE is connected to the blending equipment.
SDS Control Control of the delivery devices on the blender is accomplished by electrical
Modules signals from the ACE controller sent to the control valves by 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.
Hydraulic Valves The 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. Electrical signals from the sensors (i.e. pressure or pH) referred to as
feedback monitor the speed or valve position.
What is Feedback is nothing more than a term for the signal being returned to the
Feedback? 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.
Closed Loop This type of control system is defined as a closed loop control. At application
Control 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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Quality Assurance vs. Quality Control
Introduction In the last topic you learned about the electronics and control loop on the
blender. In this topic you will learn how the blender operates as a quality
assurance device.
QA/QC Quality Assurance and Quality Control are two terms that are often
incorrectly summed up as one concept, or incorrectly interchanged for one
and other. In reality the two are entirely different concepts.
Quality Quality Assurance (QA) refers to the planned and systematic activities
Assurance implemented in a quality system so that quality requirements for a product
or service will be fulfilled. It is the systematic measurement, comparison
with a standard, monitoring of processes and an associated feedback loop
that confers error prevention. (Wikipedia.com)
In other words when operating the downhole blender Quality Assurance can
be summed up as:
Properly calibrating blender components for delivering needed

proppant and additives
Mixing additives at the concentration in the fluid schedule
Monitoring inventories to validate the correct concentrations are
being mixed
Quality Control Quality Control (QC) is a process by which entities review the quality of all
factors involved in production. This approach places an emphasis on three
aspects:
1. Elements such as controls, job management, defined and well

managed processes, performance and integrity criteria, and
identification of records
2. Competence, such as knowledge, skills, experience, and qualifications
3. Soft elements, such as personnel integrity, confidence, organizational
culture, motivation, team spirit, and quality relationships.
(Wikipedia.com)
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Quality Assurance vs. Quality Control, Continued
Quality Control When performing fracturing treatments, Quality Control can be summed up
(continued) as:
Ensuring the fluid or fluid system is performing as necessary

Validating the concentrations of additives being mixed on the blender
Role of the The role of the blender operator simply put falls entirely into the Quality
Blender Assurance category. The job of the blender operator is to supply hydraulic
Operator horsepower pumps a correctly blended mixture of the following
components:
Water or base fluid

Liquid additives
Dry additives
Proppant
Proper calibration, understanding of the subsystems that deliver these

different components and monitoring of the inventory delivered are 3 major
functions a blender operator must perform on the jobsite.
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Unit 2: Equipment Rig Up and Startup
Unit Overview
Introduction In the last unit you learned about the major components of a downhole
blender. In this unit you will determine what hoses to rig up and about
equipment inspection.
Course
Roadmap
ACE and Equipment
Blending Rig Up and
Equipment Startup
Systems Systems
Topic See Page

Lesson 2-1: How to Select Fluid Hoses for Rig-Up 2-3
Lesson 2-2: Selecting Chemical Hoses and LA Pumps 2-15
Lesson 2-3: Pre-Start Inspection 2-25
Lesson 2-4: How to Start Downhole Blenders 2-29
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Lesson 2-1: How to Select Fluid Hoses for Rig-Up
Lesson Overview
Introduction In this lesson you will learn how to select fluid hoses for rigging up the
downhole blender.
Importance HMS Process Map PM-GL-HAL-STIM-400 activity step 5.0 states that we must
perform all job calculations necessary to complete the job. Determining the
number of hoses required for the job is a critical job task.
Course
How to Select Fluid Hoses for Rig-Up
Roadmap
Selecting Chemical Hoses and LA Pumps
Equipment Rig Up
Pre-Start Inspection
and Startup How to Start Downhole Blenders

Objectives
Understand the effect of friction on hose selection
Select the correct number of suction hoses for blender rig up
Select the correct number of discharge hoses for blender rig up
Topic See Page

Suction and Discharge Hoses 2-4
Hose Inspection and Use 2-5
Friction and Suction Hoses 2-7
Gel Loading and Viscosity 2-8
Clean Rate vs. Dirty Rate 2-10
How to Determine the Number of Suction Hoses 2-11
How to Determine the Number of Discharge Hoses 2-12
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Suction and Discharge Hoses
Introduction In this topic you will learn about suction and discharge hoses.
Spiral Reinforcement will prevent the hose from collapsing under suction. What
Reinforced may not be so easily recognized is that the wire also serves as a conductor
Hoses that grounds the equipment.
Discharge Hose Discharge hoses are used to transfer combined liquids and additives from
Description the blender to the high-pressure pumps.
Since these hoses are usually supercharged when transferring the treating
fluid from the blender, they will have a higher pressure rating than the
suction hoses. Discharge hoses are normally about 10 feet long.
Like suction hoses, discharge hoses are also spiral reinforced with wire.
Hose Covers Since the discharge hoses are under pressure when transferring liquids and
additives, they should be covered with hose covers to deflect fluid in case of
leaks.
This is especially true when pumping flammable fluids. Failure to cover the
hose may cause a flammable liquid to be sprayed into the intake manifold on
an engine and cause an equipment fire.
Discharge Hose If using three inch discharge hoses, remember that a 4 inch hose has 12.6 in2
Selection of area to flow through, while a 3 inch hose has only 7.07 in2 of area.
Therefore it will take two, 3 inch discharge hoses to equal the flow capacity
of one 4 inch hose.
Discharge Hose
Safety Note Do not stand on or straddle any line or hose under
pressure.
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Hose Inspection and Use
Introduction In the last topic you learned the difference between suction and discharge
hoses. In this topic you will learn about correctly caring for the hoses.
Hose Inspection The key to efficient maintenance is constant awareness of the hose
condition. Frac crew members should inspect a hose for the following signs
of wear and tear each time the hose is loaded or unloaded:
Inspection Criteria Description

Couplings Check for cracks, signs of slippage, kinks, and hose
condition at the coupling. The abrasive action of
sand laden fluids will wear the hose faster if it is
kinked.
Hose Covers Be on the lookout for cuts, exposure of the
reinforcement, a kink (flat spot) or blister.
Hose Tube Shine a flashlight into one end of the frac hose and
look into the other end for obstructions, cracks,
tube pulling away and blisters.
Best Practices To increase hose life, follow these common-sense guidelines while using and
storing hoses:
Guidelines
Never drag the hose or pull it by the coupling when moving a hose.
Do not drive vehicles over hoses or use hoses for wheel chocks.
Do not drop hoses so the couplings receive undue shock.
Pay particular attention to any sharp edge that might cut the hose, such as
a well-beaten hammer union lug.
Be sure to allow enough free length in the hose to avoid a problem. Hoses
could contract up two to three percent in length when pressurized during
frac jobs.
A hose that is too short for the application will be damaged at the coupling
and can lead to early hose failure.
When the job is completed, flush and drain the frac hoses prior to placing
them back on the blender.
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Hose Inspection and Use, Continued
Dos and Donts Following are some helpful tips developed over the years that can help
increase hose life:
DOs DONTs
Use the proper hose for each Stretch a hose to reach a
application i.e., suction hose for connection. The stress added to the
suction application and the proper internal pressure could lead to
hose for the materials being shortened hose life.
pumped.
Inspect hose as often as practical. Drag the hose over especially
Look for signs of leakage, blistering abrasive or sharp surfaces. Never
or loose covers. Cuts, gouges and pull it by the coupling assembly.
abrasions can lead to weakened
hose reinforcement.
Match hose pressure ratings with Re-couple a failed hose
job specifications.
Reasons to The last thing needed at a frac job is a premature failure because the wrong
Inspect and hose was used on the job or the hose was not properly maintained.
Maintain
It is good business to follow a few simple common-sense practices in the
selection, care and maintenance of a frac hose to help perform a safe,
efficient and profitable operation.
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Friction and Suction Hoses
Introduction In the last topic you learned some best practices for using suction and
discharge hoses. In this topic you will learn about how friction affects hose
selection.
Friction Friction is a force that resists motion. We commonly view friction as an

Definition increase in pressure; such as an increase in treating pressure on the
horsepower pumps due to friction in tubing.
In actuality, friction is measured as a pressure drop across a given distance. A

downhole gauge could measure the pressure value at the end of the tubing
in the above scenario in order to measure the pressure drop or loss.
Net Positive This is a term that defines the amount of pressure that must be supplied to the
Suction Head suction of the pump for the pump to operate properly.
(NPSH)
The height of the fluid in a frac or hydration tank will help supply this NPSH,
but if you have too few hoses on the suction side of the blender the fluid will
move at a higher velocity through the hoses.
The faster the velocity through the suction hoses, the more pressure loss
that you will encounter at the suction pump inlet, thereby reducing the
available NPSH.
Effect on Hose There is a limit to the amount of fluid that can be effectively transferred
Requirements through one hose. Therefore, more hoses are required when the flow rate
increases.
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Gel Loading and Viscosity
Introduction In the last topic you learned how friction can affect suction hoses. In this
topic you will learn about gel or polymer loading.
What is Gel Gel or polymer loading is the concentration of guar or other polymer that is
Loading? added to the tank water for the treatment to create viscosity.
Gel loading is generally spoken of in lbs. of polymer per 1,000 gallons of

clean fluid, or:
It is commonly written as lb/Mgal, with M being the Roman numeral for

1,000.
Reasons for Gel loading is dependent upon several factors on the jobsite, but the main
Different Gel considerations are:
Loadings
The gel will need to create enough viscosity to transport proppant
The gel will need to be able to be broken and cleaned up out of the
well following the treatment with minimal residue desired
Why Does Gel Higher gel loading will increase the viscosity of the fluid. This will result in
Loading Matter the blender suction pump having to work harder to move the more viscous
for Hoses? fluid, thereby increasing the number of required hoses.
Definition of Viscosity is a measure of a fluid's resistance to the deformation rate. Said

Viscosity another way, viscosity is the measure of a fluid's resistance to flow. Viscosity
is generally written with the Greek symbol mu () and reported in units of
centipoise (cP).
Fresh water has a viscosity of 1.0020 cP at standard temperature and

pressure.
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Gel Loading and Viscosity, Continued
Viscosity and Use the following table to identify the common range for gel loading versus
Gel Loading viscosity to help with hose selection:
Viscosity Classification Gel Loading

Low Viscosity Equal to or less than 30 lbs/Mgal
Moderate Viscosity From 30 lb/Mgal to 70 lbs/Mgal
High Viscosity 70 lbs/Mgal or above
Effect on Hose Viscosity will have an effect on the number of suction hoses needed to
Selection perform the job.
If using a hydrocarbon based fluid system, it is recommended to classify the

fluid as high viscosity for hose selection.
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Clean Rate vs. Dirty Rate
Introduction In the last topic you learned how to determine gel loading from a gel
concentrate. In this topic you will learn about the difference between clean
rate and dirty rate.
Definition of Clean rate or volume is the fluid that enters the suction side of the blender.
Clean Rate The term clean does not refer to fluid quality, but that it does not contain
many proppants or additives that will be added at the blender.
There may be additives that are in the clean fluid, such as a gelling agent or a
biocide before the fluid reaches the blender. Another way to define clean
rate is as suction rate.
Definition of Dirty rate or volume is the fluid as it leaves the discharge side of the blender.
Dirty Rate Additives such as crosslinkers, friction reducers and breakers may be added
along with a proppant before boosting the fluid to the horsepower pumps.
Dirty rate is the combined fluid, proppant and additive rate entering the
wellbore. Dirty rate is often also called discharge rate or slurry rate.
Differences in After horsepower pumps reach the desired pumping rate during a
Rates treatment, the dirty rate may not change on the flow meter, but changes in
proppant concentration will cause a variation in the clean rate.
The more proppant that is added to the fracturing fluid, the less clean fluid is
needed to total the dirty rate.
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How to Determine the Number of Suction Hoses
Introduction In the last topic you learned about different rates on the blender. Now you
can apply the procedure to determine the number of suction hoses.
HMS Reference PM-GL-HAL-STIM-400:
Step 5.0: Perform Job Calculations

o Step 5.1: Perform Necessary Calculations
This Process Map is included in the Perform

Services Mainstay of the HMS process.
Selection Suction hose selection involves answering the following items:

Criteria
What is the flow rate?
What type of treating fluid is being used?
Procedure Use the following procedure to determine the proper amount of suction
hoses to rig up for the job.
Step Action
1 Determine maximum job clean rate
2 Determine viscosity classification and utilize the following:
Viscosity Then
Low Viscosity Allow 10 bpm for every 20 section of hose
Moderate Allow 8 bpm for every 20 section of hose
Viscosity
High Viscosity Allow 6.67 bpm for every 20 section of
hose
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How to Determine the Number of Suction Hoses,
Continued
Procedure Step Action

(continued) 3 Divide the maximum clean rate by the corresponding value in
the table.
Note Always round up on suction hoses.
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How to Determine the Number of Discharge Hoses
Introduction In the previous topic you learned the definition and use of discharge hoses.
Now you can apply the procedure for determining the number of discharge
hoses to use.
HMS Reference This calculation is also referenced in Process Map PM-GL-HAL-STIM-400,

step 5.1.
Procedure Use the following procedure to determine the proper amount of discharge
hoses to rig up for the job.
Step Action
1 Determine maximum job dirty rate
2 Divide maximum dirty rate by 10 to determine the number of
discharge hoses required.
Note Always round up on discharge hoses.
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Lesson 2-2: Selecting Chemical Hoses and LA Pumps
Lesson Overview
Introduction In the last lesson you learned how to select the correct number of suction
and discharge hoses for the job. In this lesson you will learn how to select
the correct hoses and pumps to use.
Importance Selecting the correct sized hose and the correct pump for the additive is a
critical task in mixing chemicals in the correct concentrations.
HMS Process Map PM-GL-HAL-STIM-400 activity step 5.0 states that we must
perform all job calculations necessary to complete the job. We need to
properly determine the correct hoses to use for the job.
Course
Roadmap
Equipment Rig Up
and Startup How to Start Downhole Blenders

Objectives
Select the correct size of hose for the additive being pumped
Select the correct LA pump for the additive being pumped
Topic See Page

How to Select the Correct LA Hose Size 2-17
Liquid Additive Pumps 2-18
How to Determine the Correct LA Pump to Use 2-24
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LA Hose Information and Best Practices
Introduction In this topic you will learn about some of the types and sizes of hoses used
for delivering chemicals to the LA pumps.
Sizes of Hoses There is a wide variety of hose sizes available for use with liquid additives.
The most common hose sizes are 1, 1.5 and 2. Different applications may
call for hoses outside of the common hose sizes.
Hose Hoses must be compatible with the substances that are to be drawn or
Compatibility pumped through them. Acid and chemical resistant hoses used for every
additive is recommended so that you dont use the wrong type of hose by
mistake.
Care and Much like the suction and discharge hoses, proper care and inspection of LA
Inspection of LA hoses will extend the life of the hose as well as create a safe working
Hoses environment. Here are some best practices relative to LA hoses:
Do not kink or step on LA hoses

Ensure gaskets are inspected and replaced for a proper seal if
necessary
Ensure hose connections are tight. A loose connection may mean
mismatched components and a leak is inevitable.
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How to Select the Correct LA Hose Size
Introduction In the last topic you learned about liquid additive hose best practices. Now
you can apply the following procedure to select the correct additive hoses.
HMS Reference
PM-GL-HAL-STIM-400:
Step 5.0: Perform Job Calculations

o Step 5.1: Perform Necessary Calculations
Guidelines Use the following guidelines to select the correct sized liquid additive hose:
Guidelines of the Task

Determine gallon per minute rate for additive
The following table is relative to fluids up to a viscosity of 10 cP.

If ... Then ...
Less than 7 gpm Use a 1 hose
From 7-15 gpm Use a 1.5 hose
Above 15 gpm Use a 2 hose
If 1.5 hoses are not used in your district, rates above 7 gpm will need a 2
hose at minimum.
Selection of a larger sized hose may be necessary when:

Fluids exceed a viscosity of 10 cP
Pumping conductivity enhancers
Cold weather operations
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Liquid Additive Pumps
Introduction In the last topic you learned about the guidelines to use when selecting
liquid additive hoses. In this topic you will learn about the different types of
LA pumps.
Types of Most blenders are composed of a combination of a few different types of

Additive Pumps liquid additive pumps. The style of pumps may include:
Gear
Lobe
Progressive Cavity Pumps
Diaphragm Pumps
Gear Pumps This type of pump uses gears to relay the additive through the system. There
are two main variations; external gear pumps which use two external spur
gears, and internal gear pumps which use an external and an internal spur
gear:
Review the following image of external gear pump operation:
External Gear Pump
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Liquid Additive Pumps, Continued
Gear Pumps Review the following image of an internal gear pump:

(continued)
Internal Gear Pump
Lobe Pumps Lobe pumps operate similar to gear pumps, but the lobes do not make
contact as the spur gears make contact in a gear pump. This allows a
substance with more particulates to be pumped through a lobe pump
Waukesha Universal Lobe Pump
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Lobe Pumps The FB4K blender is typically equipped with several Waukesha lobe pumps
(continued) which may include:
Model 6-UL
Model 18-UL
Model 30-UL
Model 60-UL
Progressive Progressive cavity pumps are typically comprised of two major components:
Cavity Pumps the stator and the rotor. The advantages of using the progressive cavity
pump include:
Ability to pump highly viscous fluids

Limited shearing effect on additives
Progressive Cavity Pump
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Reasons to Use Progressive pumps are used mainly because they are more tolerant of trash
Progressive and the most accurately controlled. These pumps have to be sized for the
Cavity Pumps amount of fluid you wish to pump. The minimum rate they will pump is
typically one tenth of the maximum volume they will pump.
Progressive cavity pumps are also commonly used because of the ability to
pump against pressure compared to other pump types. Some progressive
cavity pumps on the blenders can pump against as much as 150-300 psi.
Common Issues The most common problem with these pumps is that when they are run dry,
with it destroys the stator (pump liner). The pumps can be purchased with
Progressive different stators depending on the chemical to be pumped.
Cavity Pumps
The accuracy and the life of this pump are dependent on the operator using
the appropriate stator material and taking care not to run the pump dry. The
Roper pump has a very poor suction capability. A few guidelines when using
progressive cavity pumps are as follows:
The chemical tanks should always be above the suction of the pump
Pump suction hoses should be large enough to free flow the amount of
chemicals you intend to pump
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Diaphragm Diaphragm pumps are utilized at times when dealing with shear sensitive or
Pumps highly corrosive materials that would greatly reduce the life of a gear, vane
or progressive cavity pump.
Diaphragm pumps are often referred to as membrane pumps.
Peristaltic A peristaltic or a roller or hose pump works by drawing fluid in through a

Pumps hose or tube. The pump is equipped with a rotor or roller that pinches the
hose and causes the fluid being pumped much like we get toothpaste out of
a tube.
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Why Use a Hose The hose pump is typically used with aggressive chemicals that would
Pump? otherwise corrode or damage lobe, progressive cavity or gear pumps.
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How to Determine the Correct LA Pump to Use
Introduction In the last topic you learned about different types of liquid additive pumps
and their various purposes. Now you can apply the guidelines for selecting
the correct pump for the chemical.
Clean Rates When selecting the correct hose size you only need to determine the
maximum clean rate for the job because of friction loss.
When determining which pump to use you need to determine gallons per
minute for the additive at both maximum and minimum clean rates. This will
ensure that the pump has a range capable of delivering the additive
throughout the treatment.
Guidelines Use the following guidelines to help determine the correct pump for the
additive to be pumped:
Guidelines of the Task

Determine gallon per minute rate for additive for minimum and maximum
clean rates
Reference pump capabilities
Ensure pump is capable of handling both the low and high end of the gpm
rates
Ensure pump is compatible with additive based upon:
Chemical type
Viscosity
Amount of solids in the additive
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Lesson 2-3: Pre-Start Inspection
Lesson Overview
Introduction In the last lesson you learned how to select the correct liquid additive pumps
and hoses for the job. In this lesson you will learn about the importance of
equipment inspection.
Course
Roadmap
Equipment Rig
Up and Startup How to Start Downhole Blenders

Objectives
Perform a pre-job blender inspection
Topic See Page

Pre-Job Blender Inspection 2-26
Inspection Checklist 2-27
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Pre-Job Blender Inspection
Introduction In this topic you will learn about the importance of pre-job equipment
inspection.
Importance of Pre-job inspections are a critical aspect of your job role. In order to address
Inspection any issues before the treatment, you must take the time to identify them.
Here are some reasons a pre-start up inspection is necessary:
You may not have been the person to inspect the equipment when it
was driven to location
Dirt roads have the tendency to rattle things loose and throw rocks
that can cause pinholes in fluid reservoirs
You are uncertain if an inspection has been performed
Crew or shift change
There are multiple other reasons that you can identify, but inspecting the
tools you will use for the job is very important.
Inspection Different types of equipment have different inspection criteria. Review the
Criteria manual for the equipment you are running for the day before performing
inspections to ensure not to miss any critical items.
Connection to The frac van will want to monitor and record all bucket testing and
ACE calibration, so ensuring that the blender is connected to ACE by JLAN is
important.
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Inspection Checklist
Introduction In the last topic you learned about the importance of a pre-job inspection.
Now you can apply the checklist to perform a blender inspection.
Checklist Use the following checklist to perform a pre-job inspection of a downhole

blender:
Step Action X
1 Engine oil level
2 Engine coolant level
3 Hydraulic fluid level
4 Pump drive gearbox lube
5 Belts and hoses for wear or damage
6 Air filter indicator for filter condition
7 Verify fire extinguishers are properly charged
8 Inspect emergency engine air shutdown flapper valve and
linkage
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Lesson 2-4: How to Start Downhole Blenders
Lesson Overview
Introduction In the last lesson you learned how to perform a pre-job inspection of the
blender. In this lesson you will learn the correct sequence to start the
downhole blender.
Course
Roadmap
Equipment Rig
Up and Startup How to Start Downhole Blenders
Importance Understanding how to correctly start blending equipment will ensure that
the equipment and electronic components are protected.
Once the blender is correctly started, we need to perform a function test of

blender components per HMS Process Map PM-GL-HAL-STIM-401 activity
step 5.0.
Lesson Upon completion of this lesson you should be able to:

Objectives
Start downhole blenders in the correct sequence
Understand the components that are responsible for starting the
blender
Understand the importance of function testing blending equipment
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Lesson Overview, Continued
Topic See Page

The Hydraulic Start Tractor 2-31
How to Start Downhole Blenders 2-32
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The Hydraulic Start Tractor
Introduction In this topic you will learn about the hydraulic start tractor used to start the
downhole blender.
Starting a Most blending equipment currently uses a hydraulic system to start.

Blender
Fluid is much more efficient than air, and can generate the required head to
start the blender engine without requiring the system to recharge, unlike air
with a pneumatic start system.
What is a PTO? Hydraulic start tractors at Halliburton are equipped with a PTO, or a power
take-off device.
The PTO has a driveshaft which draws power from the tractor engine when
engaged. This driveshaft then powers a hydraulic pump which circulates the
hydraulic fluid in the tractors reservoir through the hydraulic hoses that are
connected in between the tractor and trailer.
How does it While circulating the fluid through the hoses, the hydraulic motor converts
Start the the hydraulic force into the mechanical force required to start the blender.
Blender?
PTO Best There are a few cautions when using a PTO:

Practices
Always engage the PTO at tractor low idle
Never exceed the recommended tractor RPM when using the PTO
(Typically 1800-2000 RPM)
There are many couplings and joints from the tractor engine to the hydraulic
pump that can be damaged by shocking the system when operating if best
practices are not followed.
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How to Start Downhole Blenders
Introduction In the last topic you learned how to perform a post-start inspection. Now
you can apply the procedure to start the downhole blender.
Procedure Use the following procedure to start the downhole blender:
Step Action
1 Turn on CANs
2 Turn on main power
3 Start tractor
4 Engage PTO
5 Idle PTO to recommended setting
6 Turn on ECM and SW.ECM
7 Start blender
8 Turn on computer and log in if necessary
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Post-Start Inspection and Function Test
Introduction In the last topic you learned about the electronic components critical to
blender start-up. In this topic you will learn the criteria for the post-start
inspection.
Importance Once the downhole blender is started you must ensure to inspect the
equipment and confirm that the gauges are operating normally.
Inspection After starting the blender, ensure to inspect:

Criteria
Engine oil pressure
Hydraulic pressure gauges
Inspect air, fuel, coolant, and hydraulic systems for leaks
Hydraulic filter indicators
Function Testing Once the blender is started and the post-start inspection has been
the Blender performed, it is important to function test the blender.
PM-GL-HAL-STIM-401: activity step 5.1 states:
Function test equipment (e.g. blender sand screws, conveyor belts, ball
injectors, etc.)
We need to be certain the blender will function as designed for the job, so
ensure to perform a function test.
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Unit 3: Calibrating Additive Delivery Systems
Unit Overview
Introduction In the last unit you learned how to select the correct hoses for rig up and
about pre-start inspection criteria. In this unit you will learn how to calibrate
blender subsystems.
Importance HMS Process Map PM-GL-HAL-STIM-401 activity step 4.2 highlights the
importance of calibrating all sensors and equipment.
Course
Roadmap
ACE and Equipment
Blending Rig Up and
Equipment Startup
Systems Systems
Topic See Page

Lesson 3-1: Bucket Testing Liquid Additive Pumps 3-3
Lesson 3-2: Selecting Proppants and Sand Screws 3-19
Lesson 3-3: Bucket Testing Dry Additives and Proppants 3-25
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Lesson 3-1: Bucket Testing Liquid Additive Pumps
Lesson Overview
Introduction In this lesson you will learn how to properly bucket test and calibrate LA
pumps.
Course
Roadmap Bucket Testing Liquid Additive Pumps
Selecting Proppants and Sand Screws
Calibrating
Additive Delivery
Bucket Testing Dry Additives and Proppants
Systems

Objectives
Perform a bucket test on liquid additive pumps
Correctly calibrate liquid additive pumps
Topic See Page

How are Liquid Additives Measured? 3-4
Importance of Bucket Testing 3-6
Creating an Accurate Bucket Test Bucket 3-7
The Bucket Test Manifold 3-9
Bucket Testing Liquid Additive Pumps 3-10
Importance of Proper Priming of the LA Pump 3-13
The Bucket Test Menu 3-14
Bucket Test Misconceptions 3-15
Bucket Test Procedure 3-16
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How are Liquid Additives Measured?
Introduction In this topic you will learn about how the delivery rate of liquid additives is
measured.
How Are The delivery of liquid additive chemical is accomplished by using liquid
Additives pumps driven by hydraulic pumps. The liquid pumps are connected to
Delivered? chemical tanks either on board or on transports depending on chemical
valve positions and plumbing. How much chemical is delivered depends on
the liquid pump size and pump speed.
Liquid Additive The liquid additive control loop uses the two following feedback signals for
Control Loop the rate of a liquid additive pump:
Tachometer
Micro Motion
Micro Motions and tachometer sensors work very differently.
Tachometer The speed of a liquid pump is measured by a device called a tachometer

Measurement pickup. As the pump turns, the tachometer will output pulses which are by
process sent to the ACE controller every time a tooth on the sprocket passes
by the magnetic pickup.
The sprockets are mounted to the pump's shaft. So the controller is not
aware of the chemical rate flowing through the pump or if chemical is even
going through the pump. All the controller knows is how fast the pump is
turning. The controller then calculates the rate based on the speed of the
additive pump. Tachometer sensors are our backups to the Micro motions.
Micro Motion Micro Motions are known to be more accurate than Tachometers. The Micro
Measurement Motion meter measures measure mass flow and sends out pulses which are
by process sent to the ACE controller.
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How are Liquid Additives Measured?, Continued
Micro Motion Micro Motion is the standard for liquid additive feedback. The downside to
Measurement the Micro motion is that they are not tolerant to air infiltration. The liquid
(continued) additives must be kept primed while running Micro Motions to insure you do
not allow air entrainment.
Air entrainment will cause Micro Motions to give very erratic feedback to the
controller causing erratic drive to the. Micro Motions also require good
cleaning after the job to insure they are not clogged with chemicals.
Drive Signal The ACE controller is sending a drive signal out to the pump based on the
feedback. A very common and disastrous problem can occur when the
magnetic pickup or Micro Motion fails.
If the device is in AUTO with a set point and clean rate, the controller will
drive the pump until it sees adequate feedback. If it sees zero for feedback
because of a bad sensor it will drive the pump wide open.
It is always good practice to get a visual on the pump if the feedback fails.
Tachometers are installed as a backup to be used if the Micro Motion fails or
is inaccurate. Always switch to tachometer measurement on the job; never
adjust Micro Motion calibration during the job.
Proper Micro Bucket testing before the job and strapping during the job will eliminate
Motion many problems.
Calibration
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Importance of Bucket Testing
Introduction In this topic you will learn the definition of and importance of bucket testing
liquid additive pumps.
What is a A bucket test is a performance test of the equipment. The job calls for mixing
Bucket Test? additives at the required concentrations, and the test will verify the
equipment will perform as desired during the job.
Typically a 1- or 5-gallon bucket is used to perform the test, which is where

the term bucket test comes from.
Bucket Test There are a few different methods to performing a bucket test with ACE
Method software. The preferable method is to use the bucket test function in the
software to perform an accurate bucket test.
Micro Motion Micro Motion flow meters are installed on the liquid additive pumps because
Flow Meters of their accuracy. Micro Motions provide feedback to the computer on the
blender that allows it to accurately control the addition of chemicals to the
treatment slurry.
Typically, they are accurate to within 0.25-1% of the volume actually

pumped. A problem that may be encountered with the Micro Motion meter
is that air in the fluid causes an erroneous flow rate. Thick or viscous fluid is
not recommended. The Micro Motion flow meters must also be sized for the
rate of the fluid that is to be pumped through them.
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Creating an Accurate Bucket Test Bucket
Introduction In the last topic you learned about what bucket testing is. In this topic you
will learn some tips on how to create a precision bucket test.
Tip #1 Do not ever trust the marks on a bucket purchased for bucket testing,
whether it was purchased at the local hardware store or received from the
warehouse at the field camp.
Always validate the readings that are on the bucket by physically measuring
fluids in the bucket.
Tip #2 Do not use mass by way of measuring the weight of the fluid on a scale. The
density of water is relative. This means that it weighs 8.33696 lbs/gal at STP.
STP is an acronym for standard temperature and pressure. With the density
of water, standard temperature is equal to the ambient pressure at sea level,
or 14.7 psi. Standard temperature is 60 degrees Fahrenheit.
Unless you are at STP you cannot use mass as an accurate measurement.
Volume We are measuring volume on the Micro Motion

flow meter. We can also create a precise bucket
test bucket based upon the same unit type of
volume.
Graduated cylinders are effective and more

accurate the narrower they are. It is
recommended to use this lab ware to make
and 1 gallon marks up to 4 gallons. Many plastic
types of graduated cylinders are just as accurate
as glass and breaking is not an issue.
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Creating an Accurate Bucket Test Bucket, Continued
Measuring the One gallon is equal to approximately 3785.4 ml, which is what most
Bucket graduated cylinders measure. To make the bucket:
Step Action
1 Place empty bucket on a level surface
2 Add 1893 ml into the bucket
3 Make 3 4 markings of gallon evenly spaced around bucket
4 Repeat steps 2 and 3 seven more times to create an accurate
bucket to 4 gallons
Dont Use the The temptation may be there to reuse the same bucket to create another
Bucket as a bucket test bucket. Dont do so, as some of the more accurate graduated
Template cylinders will be within 2-6 ml every thousand ml or worse.
The bucket made from these graduated cylinders will be accurate, but using
the bucket test bucket as a volume template is not recommended.
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The Bucket Test Manifold
Introduction In the last topic you learned about the importance of bucket testing. This
topic will describe using the bucket test manifold on the blender.
Manifold The FB4K blender is equipped with a bucket test manifold.
Mounted above each Micro Motion flow meter is a pair of three-way ball
valves that allow the chemical to be routed to the following locations:
Bucket test hose

40-gallon holding tank
LA bulkhead panel
Micro Motion
flow meter
with bucket
test
manifold
valves
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Bucket Testing Liquid Additive Pumps
Introduction In the last topic you learned of the importance of bucket testing. In this topic
you will learn how to bucket test liquid additive pumps.
Bucket Test When performing a bucket test it is critical to identify 2 different data points
Method to test to. Just testing the pump at one rate will not validate that the pump
can perform as needed on the job.
It is recommended that each liquid additive pump to be used on the job is

tested at 2 values.
1. A value lower than the least expected gpm delivery rate for the job
2. A value higher than the highest expected gpm delivery rate for the
job
Example: The additive you are scheduled to pump is going to be in the range
of 2-3 gpm during the job. Perform a bucket test at 1 gpm and at 4 gpm to
ensure that the pump operates as desired.
Clean Rate for During the job, liquid additive pumps will be slaved to the selected suction
Bucket Test rate. However, during the bucket test it is uncommon for any fluid to be
passing through the suction flow meter.
This requires that we select a different rate for bucket tests. Use the
following steps to place the LA pump in bucket test mode:
Select the
desired pump
in the
Additive
Summary
Area
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Bucket Testing Liquid Additive Pumps, Continued
Clean Rate for

Bucket Test
(continued)
Click the Select Master Rate button
Click:
Conc = RateSetpoint-Bucket test,
Then:
Use the Highlighted Rate button
Note Ensure when you are done bucket testing to go back in

and reselect the selected suction rate.
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Bucket Testing Liquid Additive Pumps, Continued
Why 23.81? ACE uses the value of 23.81 bpm for the clean rate for bucket test mode.
This will make your desired gpm rate equal the set point on the pump via the
following formula:
1 23.8 42 1
=
1
How Long The optimal test time for each value on each pump is 120 seconds or longer
Should the Test if needed, but ensure to test a minimum of 60 seconds each time for proper
Be? calibration.
Bucket Test While a 1-gallon bucket can be used to perform a bucket test, a properly
Bucket labeled 5-gallon bucket test bucket is recommended to accommodate the
volume that is needed for an accurate test.
Bucket Testing All ACE blenders with updated software should perform a bucket test using
in ACE the Delay7 Auto function in ACE. That method will be taught in this manual,
but refer to the appendix on the method to perform a time-relative bucket
test if necessary.
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Importance of Proper Priming of the LA Pump
Introduction In the last topic you learned about the basics of bucket testing liquid additive
pumps. In this topic you will learn how to ensure there is no air in the system
before the test.
Importance As stated in a previous topic, Micro Motion flow meters are not tolerant of
air passing through them. Most issues attributed to a pump not bucket
testing related directly to not getting the air out of the system.
You Need to See There is no time or volume relative way to get the air out of the system. For
It example, rolling the LA pump over for 1 minute or for 5 gallons does not
guarantee the absence of air in the flow loop.
In order to see or monitor the evacuation of the air in the system you need
to have the flow loop end under fluid level so you can see when the air stops
bubbling.
Utilizing the In order to best see when the pump is primed, use the upright blender tanks
Uprights to validate this. You can either load enough volume (32-35 gallons) to get
above the filling point, or run a hose down into a lesser volume.
Either method works, but you must end the flow loop under the level of fluid
to be able to see the air bubbles.
If it Continues If the air continuously is bubbling into the tank, you are introducing air into
to Bubble the system somewhere. The following items will allow air into the system:
Loose hose and tank fittings

Faulty hose gaskets
Loose LA pump packing
Ungreased LA pumps
A soapy water solution applies to fittings and connection point can help
identify where an air leak in the system may be.
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The Bucket Test Menu
Introduction In the last topic you learned about the bucket test method used in ACE. This
topic will describe the components of the bucket test menu.
How to Open There are a few different ways to open the bucket test menu. One method is
to select the liquid additive you are going to test and press the F4 button.
Image of the Review the following image of the buck test menu:
Menu
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Bucket Test Misconceptions
Introduction The last topic discussed the bucket test menu. In this topic you will learn
about some common misconceptions regarding bucket testing.
Misconception I need to bucket test the pump in Micro Motion, then bucket test in
#1 tach.
In order to dispel this misconception we need to look at the difference

between Micro Motion measurement and tachometer measurement.
Measurement Type Description

Micro Motion Micro Motion flow meters are not relative to the
pump itself. It measures flow rate regardless of
pump performance or pump RPMs
Tachometer The tachometer is similar to a driveline counter as
equipped on many horsepower units. It is a
displacement calculation: the pump turns this many
times and therefore delivers this many gallons of
fluid.
Based upon the above definitions of the measuring devices it can be seen
that one (Micro Motion) is an actual measurement of flow rate. The other
(Tachometer) is a calculated value based upon the pump turning.
Bucket testing in tach is fruitless, but calibrating tach based off of accurate
Micro Motion data is critical to ensure you have a backup of the
measurement if the Micro Motion fails during the job.
Misconception My pump wont bucket test correctly in Micro Motion. The pump must
#2 need repaired or replaced.
While there is a potential of a pump having issues delivering a stable flow

rate due to wear and tear, the Micro Motion flow meter is a measurement
device of flow rate. The issue more likely than not lies in air in system or the
Micro Motion needing zeroed to clean up the feedback loop.
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Bucket Test Procedure
Introduction In the last topic you learned about the bucket test menu. In this lesson you
will learn how to perform the bucket test procedure.
Pre-Test To be properly prepared to perform the bucket test on the LA pump,

Procedure perform the following pre-test steps:
Step Action
1 Select the pump to bucket test
2 Confirm the Selected Master Rate is set to bucket test mode
3 Determine gallons per minute rate for the LA pump at the low
and high end of job clean rates
4 Determine the 2 points for the test:
# Description
1 Below the minimum needed gpm delivery rate
2 Above the maximum needed gpm delivery rate
5 Circulate fluid through the LA pump until all air is purged from
the system
6 Turn pump off
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Bucket Test Procedure, Continued
Bucket Test Use the following procedure to bucket test the LA pump using ACE.
Procedure
Step Action
1 Enter first set point for LA pump from Step 4 from the
preparation procedure
2 Open bucket test menu
3 Select volume from the Shut off @ vol drop down to fill the
bucket test bucket.
The combination of volume and the set point must be a minimum

of a 1 minute bucket test.
4 Click the Delay7 Auto button
After the pump shuts off; compare the volume in the bucket to
the volume listed under the Micro Motion on the bucket test
screen:
If ... Then ...

The volume is correct Go to Step 6
The volume is not correct Review troubleshooting
guidelines
6 Repeat Steps 1-5 for the second set point value
Repeat Pre-Test Procedure and Bucket Test Procedure for
7
remaining LA pumps
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Bucket Test Procedure, Continued
Steps to Take if If the pump is not bucket testing accurately use the following guidelines and
Not Bucket suggestions to fix the problem:
Testing
Step Action
1 If the Micro Motion test does not time correctly the first time:
Sub-Step Action
1.1 Double check all user-entered data
1.2 Perform bucket test again
2 Take the time needed to ensure ALL air has been purged from
system. Check fittings, tighten packing, grease packing etc.
3 Zero Micro Motion with E-tech assistance:
Sub-Step Action
2.1 Ensure the Micro Motion is completely flooded
with fluid
2.2 Close all valves to isolate any motion through the
Micro Motion
2.3 Locate the Micro Motion CAN module and press
the Zero button until the light starts to flash, then
release the button
2.4 Reconfigure valves to bucket test
2.5 Perform bucket test again
4 If it still continues to fail the bucket test consult the E-tech for
repairs to the Micro Motion flow meter
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Lesson 3-2: Selecting Proppants and Sand Screws
Lesson Overview
Introduction In the last lesson you learned how to bucket test liquid additives. In this
lesson you will learn how to select the correct proppants and sand screws for
the job in ACE.
Course
Calibrating
Bucket Testing Dry Additives and Proppants
Additive Delivery
Systems

Objectives
Select the correct proppants and sand screws for the job
Understand the impact of bulk density on sand delivery
Properly select when you need bulk density, and when you need the
absolute volume factor for calculations
Topic See Page

Confirming Sand Screws and Proppants 3-20
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Confirming Sand Screws and Proppants
Introduction In the last topic you learned when to use either bulk density or absolute
volume factors. In this topic you will learn how to confirm sand screws and
proppants in ACE.
Importance Sand screws are capable of delivering a set volume of proppant, typically
expressed in the measurement of ft3.
Based upon the ft3 delivery per sand screw revolution and the bulk density of
the proppant, ACE will determine how many pounds per revolution that the
screw can deliver. Ensuring correct components and proppant settings is
critical for delivering the proppant to the blender tub in the correct
concentration.
Opening the Click on the heading that defines the sand screw you want to confirm or
Sand Screw modify settings for:
Menu
Opening the Click the rate/calibration button to open the menu:

Calibration
Menu
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Confirming Sand Screws and Proppants, Continued
Sand Screw Review the following image of the sand screw calibration menu. The various
Calibration parts will be described next.
Menu
Proppant Review the following image of the proppant selection menu:

Selection Menu
Select the proppant to

be used for the job.
This will ensure the
correct information
carries over so that
the screws will deliver
proppant in the
correct concentration.
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Current Review the following image of the currently selected proppant:

Proppant
Selection
Proppant Absolute
Bulk Density Specific
Description and Volume
(lbs/ft3) Gravity
Mesh Size Factor
(gal/lb)
Changing the current proppant selection will adjust the bulk density,
absolute volume factor and specific gravity for the given proppant as
needed.
If the exact proppant type is not available for selection, choose a proppant
with similar properties and manually adjust the bulk density or absolute
volume factor as needed.
Sand Screw Review the following image of the sand screw selection menu:
Selection
Screw
Selection
Drop-Down
Calculated
Screw Pounds per
Volumetric screw
Output and revolution
pulses per
pound
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Accepting You must ensure to accept any changes before leaving the menu. The
Changes calculated pounds per revolution information will highlight in yellow to help
you remember to do so.
Ensure to click the Accept Sand Change Type button before leaving the
menu.
Current You can adjust the current lbs/rev setting for the sand screw, but given the
Calibration correct screw and proppant bulk density, adjusting this setting is typically
Information unnecessary.
Adjusting this setting

when not needed may
cause drastic changes
in screw delivery.
Ensure that the
proppant and screw
information is correct
before modifying
setting.
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Percent There are times you may need to apply a percent of correction due to
Correction proppant delivery issues, but more often than not delivery problems are due
to incorrect proppant information in ACE.
Proppant Percent
Correction Button
If you do have to use this function on the job, recognize that after adjusting
the setting the proppant has to be transferred up the screw, into the blender
tub and discharged through the blender densometer before the change in
proppant concentration will be seen.
When changing
correction percent,
make small changes
and wait for the
response before
continuing to adjust
to avoid
concentration
problems.
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Lesson 3-3: Bucket Testing Dry Additives and
Proppants
Lesson Overview
Introduction In the last lesson you learned how to select the correct proppant and screw
information in ACE. In this lesson you will learn how to bucket test the dry
additive feeders.
Course
Calibrating Bucket Testing Dry Additives and Proppants
Additive Delivery
Systems

Objectives
Bucket test dry additives
Topic See Page

Dry Additive Feeders 3-26
Method to Bucket Testing Dry Additive Feeders 3-27
How to Bucket Test Dry Additive Feeders 3-28
Bucket Testing of Proppant Delivery Systems 3-29
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Introduction In the last topic you learned about different types of liquid additive pumps.
In this topic you will learn about dry additive feeders.
Importance In addition to the liquid additives required to make up the different

fracturing fluids, there are also many dry additives that must be used. A dry
additive system improves the blending of dry additives into a fracturing fluid.
The mechanical equipment on the dry additive system usually includes two
Acrison-Feeders. Tube diameter size depends on the area that the blender is
used in. The sizes can run from 1-3/8 inches to 4-1/2 inches. Blenders
typically come equipped with two Acrisons, a 4 inch and a 1 3/8 inch.
Dry Additive Dry additives are sack-fed into the hopper and dispensed by a screw feeder
Delivery through eductors or by gravity into the blender mixing tub. The eductor
should be used with caution on high pump rate jobs as air entrainment into
the slurry can cause the boost pressure to decrease. Proper calibration of
the dry additive screws is imperative for correct additive dispersal. This
requires the operator to have a set point value for the amount of pounds of
dry additive that will be dispersed for each revolution of the Acrison Screw
for each dry additive to be used.
Post-Job Clean At the end of the job, the hopper and screw should be cleaned of material.
Up Material left inside can harden and prevent them from turning.
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Method to Bucket Testing Dry Additive Feeders
Introduction In the last topic you learned how to and practiced determining mass. Now
you can apply the procedure to bucket test dry additive feeders.
Method to While similar to the liquid additive bucket test in performing both a high-end
Bucket Test and low-end test, bucket testing the dry additive feeder will measure the
mass delivered in 1 minute for each end of the range.
This is due to the fact that while measuring a liquid volume you can easily
measure 1 gallon of fluid using your eyes and a bucket. This is not so simple
when trying to determine when one pound of mass has entered the bucket.
Determining After completing both the high-end and low-end bucket test you need to
Auger Accuracy determine the accuracy of both tests. The accuracy is determined by
applying the following formula:
This formula will result in a percent of accuracy in decimal format (1.0 =

100%, 0.92 = 92%)
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How to Bucket Test Dry Additive Feeders
Introduction In the last topic you learned the method for bucket testing dry additive
feeders. Now you can apply the procedure to perform the test.
Procedure Use the following procedure to bucket test dry additive feeders:
Step Action
1 Load dry additive hopper with material
Ensure correct settings in ACE
2 Auger pounds per revolution
Bulk density of material
3 Determine minimum and maximum clean rates for treatment
4 Determine mass of empty bucket
Determine lbs per minute value for the material for both clean
5
rate values.
Perform low-end bucket test:
Sub-Step Action
6 1 Override clean rate to lower value from Step 1
2 Enter job set point
3 Run auger for 1 minute
4 Determine mass of material in bucket
Perform high-end bucket test:
Sub-Step Action
7 1 Override clean rate to higher value from Step 1
2 Enter job set point
3 Run auger for 1 minute
4 Determine mass of material in bucket
8 Determine auger accuracy for both high and low values:
Is the accuracy within 5% of the desired value?

9 If ... Then ...
Yes Bucket test is complete
No Verify ACE settings and run tests again
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Bucket Testing of Proppant Delivery Systems
Introduction In the last topic you applied the procedure to bucket test dry additive
feeders. In this topic you will learn how to bucket test proppant delivery
systems.
Importance While bucket testing of the sand screws is not a common occurrence, the
need may arise given some of Halliburtons recent advances in technology
for accurate distribution of particular additives or proppants.
How to Bucket By applying all of the principals involved and following the procedure for
Test bucket testing of dry additive feeders to perform a sand screw bucket test.
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Unit 4: Calibrating Process Fluids Systems
Unit Overview
Introduction In the last unit you learned how to calibrate the additive delivery systems. In
this unit you will learn about how to calibrate components of the process
fluid system.
Importance Calibration of blender components is critical and is highlighted by activity

step 4.2 of HMS Process Map PM-GL-HAL-STIM-401.
Course
Roadmap
ACE and Equipment
Blending Rig Up and
Equipment Startup
Systems Systems
Topic See Page

Lesson 4-1: Calibrating the Densometer 4-3
Lesson 4-2: Calibrating the Blender Tub 4-9
Lesson 4-3: Calibrating the pH Probe 4-15
Lesson 4-4: Calibrating the Viscometer 4-19
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Lesson 4-1: Calibrating the Densometer
Lesson Overview
Introduction In the last lesson you learned how to bucket test dry additive feeders. In this
lesson you will learn how to calibrate the blender densometer.
Course
Calibrating the Densometer
Roadmap
Calibrating the Blender Tub
Calibrating Calibrating the pH Probe
Process Fluid Calibrating the Viscometer
Systems

Objectives
Understand the density relative to the radioactive densometer
Handle the densometer safely and correctly
Calibrate the radioactive densometer
Topic See Page

Radioactive Densometers 4-4
Blender Densometers 4-5
How to Calibrate the Densometer 4-8
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Radioactive Densometers
Introduction In the last topic you learned about density. In this topic you will learn about
the radioactive densometer that is equipped on the downhole blender.
Densometer Radioactive densometers are used for measuring stimulation fluid density.
Function From this density, the computer calculates the proppant concentrations.
Densometers consist of:
A lead shielded source material (Cesium-137)

A flow chamber
A photomultiplier tube (PM tube)
These densometers work on the principle of absorption of radioactive

particles. The source and PM tube are on opposite sides of the flow
chamber. Radioactive emissions are directed across the flow channel and are
detected and amplified by the PM tube.
As fluid passes in front of the source, it absorbs some of the radiation. The
denser the fluid, the less radiation is picked up by the PM tube. This can then
be converted into a fluid density or sand concentration.
Densometer Densometers range in size from 2 inches up to 8 inches. Typically, 6 inch and
Types 8 inch densometers are used on the blender.
A densometer can be calibrated no matter what fluid is in the flow chamber,

but is more accurate when calibrated using the Low Cal value with the flow
chamber empty of fluid.
Note The PM Tube should always be removed prior to

hammering up or loosening the connections.
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Blender Densometers
Introduction In the last topic you learned how to calculate slurry density. In this topic you
will learn a few critical things when it comes to ACE inputs for the blender
densometer.
Importance The densometer does not measure sand concentration. It measures slurry
density, and given the correct inputs will correctly calculate sand
concentration. The problem is that we often give the blender incorrect
inputs, and then wonder why we are not pumping the correct amount of
sand as the long job progresses.
Densometer The densometer measures the density, and then applies the following
Calculation formula:

=
1 ( )
Being that slurry density is measured, if we calibrated the densometer

before the job then that leaves either an incorrect AVF or an incorrect base
fluid density as the culprit.
Base Fluid Review the following table demonstrating the margin of error with an
Example incorrect fluid density. The correct base fluid for the job was 8.28 lbs/gal, but
the blender operator entered 8.34 lbs/gal.
Sand Conc. Scheduled Prop Actual Prop

Clean Vol (Gal)
(lb/gal) Mass (lbs) Mass (lbs)
1.00 ppg 20000 gal 20,000 lbs 21,797 lbs
2.00 ppg 20000 gal 40,000 lbs 41,861 lbs
3.00 ppg 20000 gal 60,000 lbs 61,925 lbs
4.00 ppg 20000 gal 80,000 lbs 81,989 lbs
5.00 ppg 20000 gal 100,000 lbs 102,053 lbs
Totals 100000 gal 300,000 lbs 309,625 lbs
So even with a relatively small job, minor errors in base fluid density can
have a huge impact, and in this case the error means we ran 9,625 more
pounds of proppant than was intended.
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Blender Densometers, Continued
Base Fluid in The density of fluids change based on temperature and pressure. It changes
Actuality as the fluids expand or contract to occupy more or less space, therefore
increasing or decreasing density.
Fresh water has a density of approximately 8.34 lbs/gal at standard

temperature and pressure (STP) which is 60F, and 1 ATM.
1 ATM is equal to the pressure seen at sea level ~14.7 psi.
Pressure Effects The atmospheric pressure effects on the density of the fluid are not large,
but high pressures will obviously compress the fluid and increase the
density. This is why it is common to see a higher density on the inline
transducer.
Temperature Temperature however plays a bigger role on the base fluid density for the
Effects blender. Review the image below.
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Blender Densometers, Continued
Summary Ensuring the correct base fluid density value is in the densometer is
paramount to running the correct amount of proppant. Using 8.33 or 8.34
every day for a base fluid density for fresh water is not a good idea.
Properly use hydrometers on base fluids and correctly apply the correction
charts.
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How to Calibrate the Densometer
Introduction In the last topic you learned about the radioactive densometer. Now you can
apply the procedure to calibrate the densometer.
Procedure Use the following procedure to calibrate the blender densometer:
Step Action
Ensure that the densometer is empty and dry, and that the Hi
1
Cal/Lo Cal knob is in the operate (OPR) position.
Verify in ACE that the density is 0.00 pounds per gallon. (Air
2 calibration)
Allowable tolerance is 0.00, 0.75 lb/gal.
Turn the knob on the densometer to the LOW position.
3 Auto-calibrate according to the instruction manual for the
particular electronic readout equipment involved.
Turn the knob on the densometer to the HI position. Verify that
the density corresponds to that recorded for Hi Cal in the
4 documentation package included with the densometer DOT
shipping papers.
Allowable tolerance is Hi Cal density 0.15 lb/gal.
5 Return the knob on the densometer to the OPR position.
Were air and HI calibration tolerances met?
If ... Then ...
Yes Densometer is calibrated
6
No The densometer should be marked Out of
Calibration and returned to the shop for calibration,
and a different densometer should be used
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Lesson 4-2: Calibrating the Blender Tub
Lesson Overview
Introduction In the last lesson you learned how to calibrate the blender densometer. In
this lesson you will learn how to calibrate the blender tub.
Course
Roadmap Calibrating the Densometer
Systems

Objectives
Calibrate the tub fill valve
Calibrate the tub level sensor
Select the correct tub fill valve for the job
Topic See Page

Selecting the Correct Tub Fill Valve 4-10
How to Calibrate the Tub Fill Valve 4-11
The Blender Tub Level Sensor 4-12
How to Calibrate the Tub Level Sensor 4-13
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Selecting the Correct Tub Fill Valve
Introduction In this topic you will learn how to select the correct tub fill valve for the job.
Description The tub fill valve accurately meters fluid supplied by the suction centrifugal
pump into the blender mixing tub.
The blender may be equipped with a 4 inch and an 8 inch tub fill valve.
Which Valve to The blender is equipped with both a 4 inch and an 8 inch tub level valve. Use
Use? the following guidelines to select the correct valve for the treatment:
If ... Then ...

Flow is less than 15 bpm Use the 4 inch valve
Flow is equal to or more than 15 bpm Use the 8 inch valve
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How to Calibrate the Tub Fill Valve
Introduction In the last topic you learned how to select the correct tub fill valve for the
job. Now you can apply the procedure to calibrate the tub fill valve.
Procedure Use the following procedure to calibrate the tub fill valve:
Step Action
Isolate the blender; make sure all incoming and outgoing fluid
1
sources are closed
2 Ensure both suction and discharge pumps are turned off
3 Select the correct tub fill valve to calibrate (8 in or 4 in)
Use the manual up and down arrows to fully open and fully
4 close the valve and visually inspect that this is happening before
calibrating
5 Manually Close Tub Fill Valve:
6 Press the Adjust Offset and enter in a value of 0.
7 Manually open the tub fill valve fully
8 Press the Adjust High button and enter 100
9 Verify slope of 6.25
10 Repeat steps 1-9 for second tub fill valve if necessary
Note While you may only use one valve or the other for the
job, calibration of both valves is recommended in case
you need to use both during the job.
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The Blender Tub Level Sensor
Introduction In the last topic you applied the procedure and calibrated the tub fill valve. In
this topic you will learn about the tub level sensor.
Importance A properly calibrated tub level sensor will ensure that the automated
functions in ACE are performed correctly. Incorrect calibration can result in
either emptying or overflowing the tub during the job.
Types of
The blender may be equipped with a manual tub level float or a K-tec tub
Sensors
level sensor. Review the following descriptions of the function of each type
of sensor:
Sensor Type Description

Manual tub A stainless steel ball, that will float on the top of the fluid
level float surface
K-tec tub level A transmitter that sends a signal to sense the current tub
sensor level
Notes on the While the manual tub level float may seem to be the simpler option, it does
Manual Float have some potential problems:
If pumping abrasive chemicals through the blender tub, the stainless

steel ball might suffer from erosion not allowing it to properly sense
the tub level
Conductivity enhancers such as SandWedge may cause the stainless
steel ball to stick to the side of the tub rendering it useless in
measuring tub level.
Notes on the K- The K-tec tub level sensor must be preprogrammed with the tub height and
tec Sensor shape for correct volume and tub level percent calculations.
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How to Calibrate the Tub Level Sensor
Introduction In the last topic you learned about the different types of tub level sensors.
Now you can apply the procedure and calibrate the sensor.
Procedure Use the following procedure to calibrate the tub level sensor:
Step Action
1 Ensure the tub is as empty as possible
2 Adjust Offset and enter in a value of 0.
If the blender is
Then ...
equipped with a...
K-Tec tub level Completely fill the tub
sensor
Manual tub float Sub-
Action
3 sensor Step
Remove the Victaulic clamp
3.1 and seal around the shaft of
the tub level probe
Pull the float all the way to
3.2
the top of the shaft
Press the Adjust High button and enter in the maximum tub level
4
value of 110.
5 Verify slope value is 6.25
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Lesson 4-3: Calibrating the pH Probe
Lesson Overview
Introduction In the last lesson you learned how to calibrate the blender tub. In this lesson
you will learn how to calibrate the pH probe on the blender.
Course
Calibrating the Densometer
Roadmap
Systems

Objectives
Validate the calibration of the blender pH probe is correct
Understand the importance of a functional pH probe
Topic See Page

Blender pH Probes 4-16
pH Sensors and Transmitters 4-17
Calibration of the pH Probe 4-18
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Blender pH Probes
Introduction In this topic you will learn about the pH probes equipped on the downhole
blender.
Importance Many job types are pH sensitive. Proper calibration of the pH probe on the
blender will help identify a problem potentially before a job issue happens.
Definition of pH pH stands for potential of hydrogen.
pH is a measure of the presence of hydrogen (H+) ions in liquid. It varies from

0 (acidic) to 14 (basic) with 7 being neutral.
pH Probes A pH probe is an instrument that will accurately measure the pH of the fluid
if properly calibrated.
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pH Sensors and Transmitters
Introduction In the last topic you learned about pH and pH probes. In this topic you will
learn about the pH probe as equipped on the FB4K blender.
Probe Mounting The pH probe mounting system but not the sensor itself is supplied with the
System blender when the unit is shipped from the Duncan Manufacturing Center.
Probe Storage It is important to keep the pH sensor wetted during storage. The FB4K
blender is equipped with a pocket that will keep the sensor wetted during
transport.
When working or transporting equipment in freezing conditions, it is

recommended to remove the probe from the mount and place in the pH
storage assembly, and placed somewhere where it will not freeze. The pH
storage assembly is used to protect the sensor cable end from damage.
Other Probes Certain probe types, such as some Endress-Hausser pH meters do not
contain fluid that can freeze and cause damage to the probe. They do not
need wetted during storage either.
They do require a little extra time to rehydrate prior to use on the job.
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Calibration of the pH Probe
Introduction In the last topic you learned about the pH sensors and transmitters equipped
on the blender. In this topic you will learn about pH probe calibration.
Importance A pH probe that is properly calibrated and recalibrated as needed by an E-

tech is a tool that can help identify a problem before it happens with a fluid
system.
Guidelines You are not responsible for pH sensor calibration, but as a blender operator
there are some things you can do to ensure proper readings. Use the
following guidelines when working with the pH probe:
Guidelines
Ensure the correct slope in ACE (0.875 psi/mA with the FB4K)
Verify readings in ACE with what the QA/QC is recording for the fluid
If the sensor has not been calibrated in the last 6 months, recommend
recalibration
Do not transport or leave the probe on the blender if working in cold-
weather environments, disconnect and store in approved container and
fluid during transit
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Lesson 4-4: Calibrating the Viscometer
Lesson Overview
Introduction In the last lesson you learned how to calibrate the pH probe on the blender.
In this lesson you will learn how to calibrate the blender viscometer.
Course
Roadmap Calibrating the Densometer
Systems

Objectives
Understand the style and function of viscometer equipped on the FB4K
blender
Calibrate the blender viscometer
Topic See Page

What is a Viscometer? 4-20
FB4K Capillary Viscometer 4-22
How to Calibrate the Viscometer 4-24
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What is a Viscometer?
Introduction In this topic you will learn about viscometers.
Definition A viscometer is an instrument used to measure the viscosity of a fluid.
Importance Viscosity during a fracturing treatment is what helps carry proppant to

formation. The ability to monitor viscosity on-the-fly will help ensure the
fluid is being pumped as designed.
Fann 35 There are many varieties of viscometers available for use. A commonly used
viscometer in field laboratories for QA/QC functions is a Fann 35.
Fann 35
viscometers
are defined as
Couette or
concentric
cylinder
viscometers.
A concentric cylinder viscometer works by measuring the viscous drag or

resistance applied to the bob of the viscometer.
FB4K The viscometer equipped on the FB4K blender is not a concentric cylinder
Viscometer viscometer like the Fann 35. It is a capillary viscometer.
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What is a Viscometer?, Continued
Capillary Action A capillary is a very small space that a substance can be potentially drawn
through without any applied forces.
Capillary action, or capillarity, is this phenomenon at work, even opposing

gravity at times. It is a function of:
Surface tension of the fluid

Fluid cohesion (tendency of molecules to want to stay together)
Adhesive properties (tendency to want to stick to the capillary)
Example of Review the following image of capillary action at work:

Capillary Action
The image
compares the
capillary action of
water (H2O) to that
of Mercury (Hg) in a
capillary (such as a
small tube of glass).
Note that with the
water, the smaller
the capillary, the
more the capillary
action.
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FB4K Capillary Viscometer
Introduction In the last topic you learned about viscometers and capillary action. In this
topic you will learn about the viscometer equipped on the FB4K blender.
How the The capillary viscometer system enables real time viscosity measurement of
Capillary fracturing fluids on ACE blenders.
Viscometer
Works The capillary viscometer pumps the fluid through a flow loop at a set flow
rate (0.277 gallons per minute). Pressure is measured at the beginning and
at the end of the flow loop, and from this change in pressure the viscosity of
the fluid can be determined.
The control of the flow rate is performed by a stand-alone motor controller.
Valve Positions Prior to operation, check the position of all viscometer system valves.
During operation the valves should be opened to allow flow from the tank
outlet back to the tank return. The air vent valve should typically be open.
All drain valves and air purge valves should be closed.
Power Switch The capillary viscometer system has a power switch that energizes the DC
motor controller and sensors on the skid. In addition, two loop-powered
transducers, the delta pressure transducer and the temperature transducer,
become energized when the ACE CAN modules are energized.
Run Dry The viscosity system has a switch installed at the suction of the progressive
Protection cavity pump to prevent the pump from spinning if no fluid is present.
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FB4K Capillary Viscometer, Continued
Priming the Normally, gravity or boost will drive fluid into the suction manifold and air
Pump will exit via an air vent allowing the pump to run normally.
If the pump must be spun up to prime the system, hold the main viscometer
power switch to the prime position for 5 to 10 seconds to allow the control
system to pull fluid in. Make sure that all valves are open before attempting
to prime the system.
The progressive cavity pump stator can be burned up by running dry for too
long, so use the prime switch sparingly.
Maintenance Generally, it is permissible to leave gel or non-acidic/non-caustic fluids in the

and Protection system after a job is completed. However the viscometer should be drained
if freezing weather is expected or if there are any concerns about fluid
incompatibility.
Running the viscometer system through the flush stage is recommended to

minimize depositing gel inside the tubing.
System Draining To drain or purge the system, open the system drain valve, close the return
valve, connect the air supply at the quick disconnect at system purge valve
and slowly open the system purge valve. Any fluid in the viscometer piping
between the return valve and the pump skid should be discharged out the
system purge outlet. Afterward close the system purge and system drain
valves and disconnect the air supply.
While draining the suction and discharge manifolds of the blender, open the
pump suction supply valves at each header and the air purge valve to empty
the liquid additive pump supply lines. Afterwards open the pump drain valve
to drain any remaining fluid from the suction side of the pump. If air is used
to purge the suction side of the pump, do not exceed 180 psi or the
mechanical seal may be damaged.
The capillary viscometer system volume is approximately 0.14 gallons.
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How to Calibrate the Viscometer
Introduction In the last topic you learned about the type of viscometer equipped on the
FB4K blender. In this topic you will learn how to calibrate the viscometer.
Opening the To properly calibrate the blender viscometer you must open the viscosity
Viscosity Menu calibration dialog box from the main blender screen.
Zero Procedure Before performing a fluid circulation test you must perform the zero
procedure for the viscometer.
Follow the steps below to complete the zero procedure:
Step Action Commentary

1 Ensure the viscometer system is
off.
2 Open the ACE viscosity
calibration dialog box
3 Does the raw viscosity indicate -
1.2 cP?
If ... Then ...

Yes Unit is zeroed
No Adjust offset to -1.2 cP
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How to Calibrate the Viscometer, Continued
Performing a To perform a water circulation test to confirm viscometer calibration, use

Water the following procedures:
Circulation Test
Step Action Commentary
1 Perform zero procedure
2 Provide fresh water to the Use a boost pump or ensure
viscometer pump hydrostatic head for
complete prime
3 Ensure the air valve is fully open
4 Open the ACE viscosity
calibration dialog box
5 Turn on viscometer system
6 Monitor the ACE raw viscosity
output and review water
viscosity table.
If ... Then ...

Reading is Circulation test
within range is complete
Reading is Perform zero
not within procedure
range (1st try) again and
retest
Reading is Perform gel
not within circulation test
range (2st try)
Note Using water may result in turbulent flow causing a

misreading of the raw viscosity value. Using a gelling
agent and performing the test will help reduce this
turbulence and ensure a good circulation test of the
viscometer.
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How to Calibrate the Viscometer, Continued
Water Viscosity Use the following table to validate the raw viscosity reading for the water
Table circulation test:
Water Temperature Model 2006 Raw Acceptable Range (cP)

(F) Viscosity (cP)
55.00 1.00 0.80 - 1.20
60.00 0.92 0.72 - 1.12
65.00 0.84 0.64 - 1.04
70.00 0.77 0.57 - 0.97
75.00 0.70 0.50 - 0.90
80.00 0.65 0.45 - 0.85
85.00 0.60 0.40 - 0.80
90.00 0.56 0.36 - 0.76
95.00 0.52 0.32 - 0.72
If it Fails the If the capillary viscometer fails to fall within the acceptable range on the 1st
Tests and 2nd test, use the procedures listed in the course appendix to perform a
gel circulation test and test validation.
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Unit 5: Preparing for the Job
Unit Overview
Introduction In the last unit you learned how to calibrate the equipment for accurate
metering. In this unit you will learn how to prepare the surface equipment to
pump the treatment.
Course
Roadmap
ACE and Equipment
Blending Rig Up and
Equipment Startup
Systems Systems
Topic See Page

Lesson 5-1: Preparing Blending Equipment 5-3
Lesson 5-2: Priming Horsepower Equipment 5-15
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Lesson 5-1: Preparing Blending Equipment
Lesson Overview
Introduction In this lesson you will learn how to prime the downhole blender before the
job.
Course
Roadmap Preparing Blending Equipment
Preparing for Priming Horsepower Equipment
the Job

Objectives
Prepare liquid additives and pumps
Prepare dry additives and feeders for the job
Topic See Page

Preparing Liquid Additives for the Treatment 5-4
Blender Upright Tanks 5-6
Preparing Dry Additives for the Treatment 5-10
Priming and Function Testing the Blender 5-12
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Preparing Liquid Additives for the Treatment
Introduction In this topic you will learn about the importance of preparing LA pumps
before the job.
Priming of While the LA pumps are primed up due to the bucket test, most often the
Pumps with pumps and hoses are full of a fluid that is not the chemical to be pumped
Additive during the job (i.e. LCA-2).
Ensuring that the equipment is full of the additive to the injection point will
ensure that the needed additives are delivered when the job begins. It is
suggested to circulate out the fluid used to bucket test to achieve this at the
injection point.
Selection of Selecting the correct injection points for additives for the correct metering
Injection Points and mixing of chemicals is something that needs some consideration. Use
technology bulletins, best practices and experience when selecting injection
points.
To formalize a selection process involves too many variables for the injection
point of additives, but the following guidelines can be used to aid in the
selection process:
Guidelines
Use progressive cavity pumps on the discharge side of the blender; avoid
styles of pumps not effective in pumping against pressure
Avoid injecting friction reducers into the blender tub; they require an
adequate amount of shear, and tend to float on top of the tub due to
being oil-based additives.
Additives that require substantial mixing energy should be injected into
the eye of a centrifugal pump for proper dispersion
Avoid mixing additives with the tendency to foam into the blender tub. It
can cause a misreading of the K-Tech style tub level sensors
Avoid placing additives that are drawn from long distances on the
discharge side: the pump will not keep up with the needs
Confidential
Preparing Liquid Additives for the Treatment, Continued
Injection Point Injection points on the blender will be dependent on the liquid additive type.
Information Injection points are in the suction side, in the tub, in the eye of the discharge
boost pump or in the discharge manifold.
Conductivity enhancers such as SandWedge or Expedite are injected into the

sand screw at various distances in the sand screw housing. The exact
placement is area specific.
Confidential
Blender Upright Tanks
Introduction In the last topic you learned about selecting additive injection points for the
job. In this topic you will learn about preparing the Hal Tanks on the blender.
Blender Upright It is important to ensure that if you are using the blender upright tanks that a
Tanks nominal volume is loaded into the totes for immediate usage. However it is
not recommended to fill to capacity in case the well does not receive the
treatment fluid; that is all the more chemical that you would need to pump
back into the tote or transport vehicle.
A nominal volume of around 10 gallons is recommended to be preloaded.

This amount should generally last long enough until an injection rate is
established into the formation. Once flow rate is established the tanks can
be filled as necessary.
Opening the
Transfer Pump
Menu in ACE 1. Click on
the Tanks
tab in ACE
2. Select
desired
tank
Loading the When loading the upright tanks care must be taken not to overflow the
Uprights tanks. Overflowing of the blender upright tanks can cause first of all a mess,
potential environmental impact as well as being a cause of cost of poor
quality.
It is recommended to have someone monitor the levels and assist you in all
loading and reloading operations in order to avoid said issues, especially if
the tanks are not equipped with level sensors.
Confidential
Blender Upright Tanks, Continued
Chemical Review the following image of the window:

Transfer and
Tanks Window
Components of Review the following description of the buttons in the window:

the Window
Image Description
This area describes:
Upright tank number
Status of the pump filling the tank (ON
or OFF)
Control Mode Status (Auto or Manual)
Clicking on the image of the tank will also
allow you to adjust the slope if necessary
This area describes:
The current volume in the tank
The transfer pump that is to fill the tank
Allows you to select the control status mode
of either Auto or Manual.
Confidential
Components of Image Description

the Window Instructs the controller to only fill the tanks
(continued) one time when it is placed in Auto mode.
The High and Low indicators are used when

level switches are installed instead of float
sensors.
The ON button turns on the chemical

transfer pump. The pump will turn on
if the control is in auto or manual.
The OFF button turns off the chemical
transfer pump. The pump will turn off if
the control is in auto or manual.
The OFF ALL TRANS PUMPS button will turn
off all chemical transfer pumps.
The max volume function will allow you to

reduce the maximum amount you want to fill
to when using the automatic filling functions.
Note Only one chemical transfer pump can be assigned to a

tank. If chemical transfer pump #1 is assigned to tank
#6 then the controller will automatically assign pump
#6 to tank #1. The assignments will change back to
default value on the next application start up.
Automatic Be certain to verify the blender you work with is equipped with equipment
Functions for automatic filling before using these functions in the window.
Otherwise manual loading is required, and extra caution is needed to not

overflow the containers.
Confidential
How to Load Use the following procedure to load the upright blender tanks.
Upright Tanks
Step Action
1 Configure bucket test manifold to load desired tank
2 Verify tank and transfer pump combination is correct
3 Determine the volume to load
4
If ... Then ...
Using Auto Mode Set max value
Place in Auto Concentrate
Use either Auto Fill Once
or turn pump on to fill to
needed level
Using Manual Mode Turn pump on
Fill to desired level
Turn pump off
Note If using equipment capable of automatic filling,

determine the volume you desire to keep in the tank
and leave the pump on in auto for on-the-fly filling.
Confidential
Preparing Dry Additives for the Treatment
Introduction In the last topic you learned about preparing liquid additives for the
treatment. In this topic you will learn the importance of preparing dry
additive feeders if necessary.
Importance Dry additives are typically breakers that are released with elevated
temperatures downhole. Many a times a blender operator has missed
getting breaker into the initial fluid going downhole, which while sounding
like a simple issue can cause multiple issues in formation.
HMS Process Map PM-GL-HAL-STIM-401 activity step 5.2 discusses the need
to prepare for the job by having all materials loaded.
Loading While the dry additive feeder is capable of holding a large mass of chemical,
Suggestions be conservative when you load it. Depending on what additive you are
loading, load for example 1 lb. of additive at a time. When it is running low
add another lb.
This will allow you to monitor the volume throughout the job and may
identify an issue in the delivered volume of the feeder.
Dry Additive Use the following guidelines when working with dry additive feeders:
Best Practices
Guidelines
Load only amounts that you can physically monitor the delivered amount
Keep the cover on the feeder if possible, especially if raining or snowing
outside
Do NOT ever place your hands, fingers or a tool in the feeder while it is
operating
Confidential
Preparing Dry Additives for the Treatment, Continued
Dry Additive Before the job, apply the following guidelines to correctly prepare dry
Preparation additives and feeders for the job:
Guidelines
Load the feeders with an appropriate volume
Ensure the total pounds of additive needed for the job or zone is brought
up onto the blender for efficient loading
If utilizing the 5 auger, stack the needed amount of additive in close
proximity
Ensure that when using multiple dry additive feeders that correct labeling
is used if needed to ensure the correct dry additive goes into the correct
feeder
Confidential
Priming and Function Testing the Blender
Introduction In the last topic you learned how to prepare the dry additive feeders for the
job. In this topic you will learn how to prime and perform a function test of
the blender before the treatment.
Importance Before priming up horsepower pumps is one of the last opportunities to

catch a potential before beginning the treatment. Taking a few extra
moments to ensure your downhole blender is to perform as necessary is a
critical job task.
Priming the While the suction side leading to the blender tub may be completely flooded
Blender and primed already, it is important to prime the other areas of the blender
that are to be used during the job including:
Tub Bypass
Both tub fill valve pathways
Discharge manifold
If you are not working in cold weather operations, circulating fluid in the
blender tub via recirculation valves is a good way to determine whether or
not the centrifugal pumps will perform as desired.
Checklist Use the following checklist to perform a pre-job function test:
Step Action X
1 The ACE system computer can drive all pumps, screws,
feeders, and agitators
2 Feedback from the mixing tub level sensor in ACE computer
system
3 Feedback from the suction and discharge flow meters
4 Feedback from LA flow meters in ACE computer system
5 The LA systems are connected as required by the job design
and routed to the
6 Correct injection location in the process manifold
7 Correct position of valves for each LA circuit
8 LA tank lids are open
Confidential
Confidential
Lesson 5-2: Priming Horsepower Equipment
Lesson Overview
Introduction In the last lesson you learned how to prepare the downhole blender for the
job. In this lesson you will learn how to prime up horsepower equipment on
the jobsite.
Importance HMS Process Map PM-GL-HAL-STIM-400 activity step 9.0 describes the
process for primining up and pressure testing lines. These procedures must
be followed for a safe and correct prime up.
Course
Roadmap Preparing Blending Equipment
Preparing for Priming Horsepower Equipment
the Job

Objectives
Understand the role of the blender operator during prime up
Safely supply fluid and prime up horsepower equipment
Topic See Page

Using the Rate Tab in ACE 5-16
Loading the Blender Tub 5-17
Supplying Discharge Pressure 5-21
Role of the Blender Operator in Prime Up 5-22
Confidential
Using the Rate Tab in ACE
Introduction In the last topic you learned about the importance of the role the blender
operator plays in priming up horsepower equipment. In this topic you will
learn about the rate tab in ACE.
Description The Rate Tab displays status information concerning the suction and
discharge pumps, the engine speed, fluid parameters; pH, viscosity,
temperature and stage information.
Due to the criticality of the above items, this tab is recommended to remain
open and visible throughout the job.
Press the
button to
select the
control window
for that
subcomponent
Staging Buttons The rate tab also includes in the current stage information. This button will
be discussed in detail later on in the course.
Confidential
Loading the Blender Tub
Introduction In the last topic you learned about the importance of the blender operator in
horsepower prime up operations. In this topic you will learn how to bring
fluid on board into the blender mixing tub.
Methods to Fill There are a few different ways to fill the blender tub. The methods discussed
the Tub include:
Setting each component up individually

Group commands
Fill Once function
Group commands and the Fill Once function are highly recommended for
use, but you must know what you are performing when using group
functions.
If someone deletes the saved data on the group function, are you
confident you know what to do to fill the tub?
Load Tub Group

Command Only once you
fully understand
the sequence of
events and the
manifolding and
piping on the
blender you are
operating should
you utilize group
commands.
Confidential
Loading the Blender Tub, Continued
Setting the Tub Before opening valves and bringing fluid onto the blender, determining the
Level volume you want in the tub should be the first step.
It is no coincidence that the blender generally wakes up with a tub set

point of 75%. A properly calibrated tub and tub leveler valve will operate
most effectively with a tub level set at 75%. To adjust the tub level set point:
Click the Set Point button Click Set Point and adjust as needed
Creating an Once you have determined the set point for the tub, the next logical step is
Open Flow Path to create an open flow path to move the fluid from the current location into
the blender tub. Once the source (tank) is opened, most downhole blenders
require the following two valves to be opened:
Master Suction valve

Tub Level valve
Master Suction Review the following image of the Master Suction valve and suction header
Valve of the FB4K blender:
Opening the master

suction valve allows
you to supply fluid to
the suction
centrifugal pump
Confidential
Tub Level While you can manually open the tub level valve to fill the tub, by placing the
Setting tub in auto you will allow it to fill until the desired volume is achieved and it
will shut itself down.
Turning on the Once the tub volume has been determined and the Master Suction valve is
Centrifugal opened the next step is to turn on the suction centrifugal pump.
Pump
Select the
suction
centrifugal
pump
Adjust the
set point if
necessary,
then AUTO
pressure
Confidential
Loading Using Based upon the previous steps that need taken to load the tub, you can
Group apply the same information by using a group command to fill the tub.
Commands
Click
LOAD TUB
Make selections as below
Using the Fill Using the Fill Once feature in ACE allows you to regulate the rate at which
Once Feature the tub is loaded the first time. You can perform the Fill Once feature on the
load tub group command screen, or in the tub set point screen:
Confidential
Supplying Discharge Pressure
Introduction In the last topic you learned how to fill the blender mixing tub. In this topic
you will learn how to supply boost pressure.
Definition Fluid is discharged from the blender by the discharge centrifugal pump which
is connected to the discharge manifold. The typical centrifugal is an impeller
type pump.
Boost in Auto When in Auto the ACE controller maintains a constant pressure by adjusting
the centrifugal pump speed. To drive this pump the controller will send a
command drive signal to the SDS Analog Out device module. The output of
the SDS Analog Out device module is sent to a valve that controls the speed
of the pump by controlling the amount of hydraulic fluid flow to the
centrifugal pump.
Feedback Loop The feedback sensor is a pressure transducer mounted on the discharge side
of the discharge centrifugal pump. The pressure transducer sends back an
electrical signal to the SDS Analog Input device module which in turn reports
the value to the controller. The controller will then make the necessary
adjustments to the command drive to achieve set point.
Group Like with the LOAD TUB group command, using the boost group command is
Commands recommended as long as you are certain of what you are about to do.
Confidential
Role of the Blender Operator in Prime Up
Introduction In this topic you will learn about the importance of your role during priming
up of horsepower equipment
Importance of Typically pumps are primed up through the blender prime up line back into
Returns the mixing tub. The blender operator is responsible for monitoring the flow
coming in and out of the blender tub.
Before a horsepower pump operator engages a pump returns, or flow back

into the mixing tub must be established. When a steady flow rate from the
blender discharge pressure is established the blender operator can
communicate that there are returns back into the blender tub. Correctly
monitoring the returns before pumps are brought online to prime up can
eliminate an otherwise hazardous situation if an inline valve was shut in.
Comparing During prime up the blender operator should compare the rate the pump
Rates operator is ramped to versus the discharge rate on the blender.
More often than not the rates will not be identical. Horsepower pumps do
not have a flow meter on them and are inherently less efficient than the ACE
output is reading.
Confidential
Role of the Blender Operator in Prime Up, Continued
What to Do If rates are not the same, use the following steps to troubleshoot the
When Rates Do problem:
Not Match
Step Action
1 Are rates within a tolerable range (0.1 0.2 bpm)?
If ... Then ...
Yes Prime up for truck is complete
No Proceed to Step 2
2 Verify the correct calibration setting (flow meter factor) on the
discharge flow meter
3 Have the pump operator verify the correct engine, transmission
and fluid end type and size in ACE
4 Verify the problem isnt a pump maintenance issue: i.e. valves
upside down or missing from fluid end
5 If following Steps 2-4 did not resolve the issue identify potential
electronic or mechanical issues on the pump or blender
Note Do NOT adjust the flow meter efficiency factor to

match the ACE pumps. The ACE readout on the pumps
is much less accurate than the blender flow meter.
Confidential
Unit 6: Performing the Job
Unit Overview
Introduction In the last unit you learned how to prepare the equipment for the job. In this
unit you will learn how to operate the downhole blender during the
treatment.
Course
Roadmap
ACE and Equipment
Blending Rig Up and
Equipment Startup
Systems Systems
Topic See Page

Lesson 6-1: Monitoring Additives 6-3
Lesson 6-2: Performing the Treatment: Planned Events 6-5
Lesson 6-3: Performing the Treatment: Unplanned Events 6-7
Confidential
Lesson 6-1: Monitoring Additives
Lesson Overview
Introduction In this lesson you will learn how to monitor the delivery of additives on the
blender.
Importance HMS Process Map PM-GL-HAL-STIM-400 activity step 10.2 states that we
must monitor and record all volumes, pressures, and rates throughout the
job.
While much of the monitoring will take place in the frac van, blender
operators must monitor the performance of their equipment.
Course
Roadmap Monitoring Additives
Performing the Treatment: Planned Events
Performing the Performing the Treatment: Unplanned Events
Job

Objectives
Monitor and validate additive delivery
Topic See Page

Importance of Monitoring Additive Delivery 6-4
Confidential
Importance of Monitoring Additive Delivery
Introduction In this topic you will learn the importance of accurately monitoring the
delivery of additives on the blender.
Importance You took the time to properly calibrate equipment on the blender including:
Liquid Additives
Dry Additives
Proppants
Densometer
Validating these blender subcomponents are functioning correctly by

delivering additives at the correct concentrations during the job is critical.
Why Monitor? The reasons for monitoring the delivery volume of additives will allow you to
anticipate among other things:
When to add more breaker to the dry additive feeder

When a tote swap is necessary for an additive
When it is time to refill the blender upright tank
Having a game plan for the Quality Assurance role you play must be done
during the job.
Confidential
Lesson 6-2: Performing the Treatment: Planned
Events
Lesson Overview
Introduction In this lesson you will learn how to handle planned events during the job.
Course
Job

Objectives
Operate downhole blenders during common planned job events
Topic See Page

Common Planned Events 6-6
Confidential
Common Planned Events
Introduction In this topic you will learn about some common planned events that will be
seen on the jobsite while operating downhole blenders.
What is a A planned event is something that you knew was going to happen before
Planned Event? you reached the change. Identifying planned events will help you anticipate
change and be prepared for the change.
Examples of Review the following table with some examples of planned events during the
Planned Events job:
Event Description
Change of sand concentration at stage change
Increase or decrease of chemical concentration following job design
Swapping totes or refilling blender uprights when necessary
Ensuring to add more dry additive to the hopper during the job
Turning the sand screws off when going to the flush stage
Going to tub bypass during the acid stage
There are numerous other situations that when planned for and anticipated
will make operating downhole blenders a relatively simple process.
Confidential
Lesson 6-3: Performing the Treatment: Unplanned
Events
Lesson Overview
Introduction In the last lesson you learned how to handle various planned events during
the job. In this lesson you will learn how to handle unplanned events during
the job.
Course
Job

Objectives
Operate downhole blenders during unplanned job events
Topic See Page

Being Prepared for Unplanned Events 6-8
Examples of Unplanned Events 6-9
Confidential
Being Prepared for Unplanned Events
Introduction In this topic you will learn about the importance of being prepared for
unplanned events.
Unplanned Most unplanned events and lessons learned come from experience
Events operating downhole blenders. While being prepared with a contingency plan
for every potential event is probably not possible, understanding how to
react in the situation is a function of being a qualified downhole blender
operator.
Utilizing the ACE ACE software and automates much of what the blender operator must
Software perform. Proper pre-job calibration and monitoring during the treatment
allows the blender to proportion correctly and deliver a quality product.
However, ACE does not substitute for or replace the reasoning or ability of
an operator. An operator must know how the blender works including the
various subsystems in order to correctly and safely handle unplanned job
events.
Definition of Unplanned events are relative to wellbore conditions, equipment

Unplanned performance issues and improper blender calibration on the jobsite.
Events
While one of these event types (wellbore conditions) is completely out of
the control of the blender operator, the other two are contingent on the
blender operator performing:
Correct blender calibration

Maintenance
The phrase goes: If its broke, fix it.
Dont allow something that should be considered an unplanned equipment

failure become a planned event on the job.
For example: Yeah, LA 2 never seems to bucket test correctly, but we

make it work.
Confidential
Examples of Unplanned Events
Introduction In the last topic you learned about the importance of not only being
prepared for unplanned events, but the fact you need to be prepared to
handle the situations when presented. This topic will discuss some examples
of unplanned events.
Importance We must be prepared for problems by having contingencies in place. HMS

Process Map PM-GL-HAL-STIM-400 activity step 3.6 indicates that this should
be done prior to beginning the job.
Examples Review the following table with descriptions of some common unplanned
events that happen on the jobsite:
Event
Wellbore screen out
Liquid additive pump lost prime
Lost tub, or blender mixing tub went dry
Overflowed the blender tub
Lost communication with ACE
Suction or discharge pump cavitation
Volumes in ACE are not matching physical strap volumes
Sand screw is jammed or stuck and wont move
There are countless numbers of unplanned events or scenarios that may

happen on the jobsite, but this short list defined some of the common items.
Note Ensure to report all equipment issues or failures to a

service supervisor.
Analysis of Given the list of events above, identify whether the problem is within or out
Events of the control of the operator, and whether the issue could be caused by
blender operator error.
If blender operator error is possible, what could the root cause of the
problem be?
Confidential
Confidential
Unit 7: Post Job Activities
Unit Overview
Introduction In the last unit you learned how to operate downhole blenders during the
job. In this unit you will learn how to perform post-job activities.
Course
Roadmap
ACE and Equipment
Blending Rig Up and
Equipment Startup
Systems Systems
Topic See Page

Lesson 7-1: Pre-Shutdown Tasks 7-3
Lesson 7-2: Equipment Power Down 7-5
Confidential
Lesson 7-1: Pre-Shutdown Tasks
Lesson Overview
Introduction In this lesson you will learn how to properly flush and clean up equipment
after the treatment.
Course
Roadmap
Pre-Shutdown Tasks
Post-Job Equipment Power Down
Activities

Objectives
Safely and correctly clean up blending equipment
Topic See Page

How to Prepare the Unit for Power-Down 7-4
Confidential
How to Prepare the Unit for Power-Down
Introduction In this topic you will learn the items that are required to be performed prior
to shutting the blender down.
Chemical HMS Process Map PM-GL-HAL-STIM-400 activity step 13.1 states that you
Inventory must inventory the chemicals that ran through your blender. The
expectation is at least that you assist in this process if you have a person in
charge of chemicals on location.
Equipment You need to ensure to write down any mechanical issues with the blender.
Issues This way upon return to the service center you can inform the maintenance
department of issues; consistent with PM-GL-HAL-STIM-500 activity step 1.3.
Equipment Equipment needs to be cleaned up in a manner that avoids any unintentional

Clean Up draining of fracturing fluids onto the ground in order to maintain
environmental compliance.
HMS Standards PM-GL-HAL-STIM-400 activity step 9.0 and PM-GL-HAL-STIM-

500 activity step 3.5 describe the need for this clean up.
Guidelines Review the following guidelines to perform prior to shutting the equipment
down:
Guidelines
Determine the quantity of chemical additives that were ran by performing
inventory.
Record any equipment issues or malfunctions to report to the
maintenance department.
Clean up the blender completely by using local work methods.
Confidential
Lesson 7-2: Equipment Power Down
Lesson Overview
Introduction In the last lesson you learned how to clean up equipment after the job. In
this lesson you will learn how to properly power down blending equipment.
Course
Roadmap
Pre-Shutdown Tasks
Post-Job Equipment Power Down
Activities

Objectives
Correctly power down blending equipment
Topic See Page

How to Power Down Equipment 7-6
Confidential
How to Power Down Equipment
Introduction In this topic you will apply the procedure to correctly power down blending
equipment.
Checklist Use the following checklist to power down equipment:
Step Action X
1 Allow the engine to cool at idle for 15 to 20 minutes
2 Check the engine oil pressure gauge
3 Check the hydraulic pressure gauges
4 Inspect the air, fuel, coolant, and hydraulic systems for leaks
5 Flush all LA circuits with the appropriate clean up fluid
6 Flush and drain the mixing tub
7 Flush and blow down the manifold
8 Empty the DA hoppers
9 Empty the sand screws and sand hopper
10 List all equipment issues experienced during operation and
address them with the appropriate maintenance personnel.
After Power Once the unit is powered down, perform rig down per HMS Standards, and
Down ensure that all hoses or other items are stowed in a highway-worthy manner
as stated in HMS Process Map PM-GL-HAL-STIM-500 activity step 3.4.
Confidential
Course Appendix
Overview
Introduction The following procedures and information are relative to downhole blenders
but not necessarily relevant to operating ACE with a downhole blender.
Contents This appendix contains the following topics:
Topic See Page

Performing a Gel Circulation Test (Capillary Viscometer) II
Bucket Test Procedure Time Relative IV
2013 Halliburton. All Rights Reserved I OPERATING ACE FOR DOWNHOLE BLENDERS
Confidential
Performing a Gel Circulation Test (Capillary
Viscometer)
Introduction If the water circulation test fails while calibrating the capillary viscometer on
the blender, perform a gel circulation test and validation as in the following
procedures.
Gel Circulation Use the following procedure to perform a gel circulation test of the
Test viscometer if needed:
Step Action
1 Mix and completely hydrate 3 gallons of a guar-based gel to 10-
20 cP.
2 Fill a 5-gallon bucket with the mixed gel.
3 Route short hoses as necessary to circulate fluid through the
bucket.
4 Elevate the bucket to at least three feet above the pump.
5 Perform zero procedure.
6 Ensure the air vent is open.
7 Open the ACE viscosity calibration dialog box and select the
appropriate base fluid system and temperature.
8 Turn the viscometer system on and observe and record the
temperature corrected viscosity.
2013 Halliburton. All Rights Reserved II OPERATING ACE FOR DOWNHOLE BLENDERS
Confidential
Performing a Gel Circulation Test (Capillary
Viscometer), Continued
Validating the After performing the gel circulation test if needed, you must validate the
Gel Circulation temperature corrected viscosity you recorded during the circulation test.
Test Use the following procedure to validate the gel circulation test with a Fann
35 viscometer:
Step Action
1 Inspect and calibrate Fann 35 per latest Global Lab Best
Practices
2 Use Fann 35 with:
.2-Spring (fifth spring)
R1 rotor
B1 bob
3 Set RPMs to 300.
4 Read the dial and divide by 5.
5 Measure the gel temperature with a -degree F accurate
thermometer.
6 Correct the viscosity reading using the gel-appropriate
temperature correction to 77 degrees F.
7 Compare the temperature-corrected viscosity readings from
the Fann 35 and blender viscometer test:
If ... Then ...
Results are within 0.75 Gel test was validated
cP
Results are not within Refer to capillary viscometer
0.75 cP troubleshooting procedures
Using a 1-spring on the Fann 35 viscometer will not allow for an accurate
reading as required by this procedure.
2013 Halliburton. All Rights Reserved III OPERATING ACE FOR DOWNHOLE BLENDERS
Confidential
Bucket Test Procedure Time Relative
Introduction In the last topic you learned about the bucket test menu. In this lesson you
will learn how to perform the bucket test procedure.
Procedure Step Action

1 Select pump to bucket test
Determine minimum and maximum clean rates for treatment
2
from the blender schedule
Determine gallons per minute at the low and high end of job
3
clean rates
Determine the 2 points for the test:
# Description
4
1 Below the minimum needed gpm delivery rate
2 Above the maximum needed gpm delivery rate
Perform bucket test:
# Action
1 Open the bucket test manifold to circulate fluid and
establish flow loop in manual
2 Enter selected set point from Step 3
3 Place pump in Auto Concentrate
5 4 Allow Micro Motion reading to stabilize
5 Open bucket test menu
6 Simultaneously swap to an empty bucket and start timer
7 Monitor for a minimum of 60 seconds, or until an
identifiable volume is in the bucket at one of the gallons
marks
8 Stop timer and simultaneously return to circulation
Compare the volume in ACE with the physical volume in the
bucket:
If ... Then ...
The volumes Select the volume under the Micro Motion
6
are within 5% on the bucket test screen and accept new
calibration for the tach pickup
Volumes are Refer to the troubleshooting procedure
not within 5%
7 Repeat Steps 5 and 6 for the second gpm value
8 Repeat Steps 2-7 for remaining pumps
2013 Halliburton. All Rights Reserved IV OPERATING ACE FOR DOWNHOLE BLENDERS
Confidential
2013 Halliburton. All Rights Reserved V OPERATING ACE FOR DOWNHOLE BLENDERS
Confidential

Operating ACE For Downhole Blenders

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HALLIBURTON ENERGY OPERATING ACE FOR

SERVICES DOWNHOLE BLENDERS

BLENDER OPERATOR DEVELOPMENT PROGRAM | HALLIBURTON ENERGY INSTITUTE

Confidentiality All information contained in this document is the exclusive property of

Document Description Date

Brian Dodd Robert Howard Bernardo Montell

Continued on next page

John Adams Mark Adams Tokes Adoun

Course This course focuses on:

Intended Better trained personnel will result in:

References to the HMS documents utilized in the creation are throughout

Documents HMS Documents Referenced or Utilized

Course This course is written for:

Unit 1: ACE and Downhole Blenders ................................................................................................................... 1-1

Unit 2: Equipment Rig Up and Startup ................................................................................................................ 2-1

Unit 3: Calibrating Additive Delivery Systems ..................................................................................................... 3-1

Unit 4: Calibrating Process Fluids Systems .......................................................................................................... 4-1

Unit 5: Preparing for the Job ............................................................................................................................... 5-1

Unit 6: Performing the Job .................................................................................................................................. 6-1

ACE and Calibrating Calibrating

Selecting LA Selecting Priming

Additive Bucket Testing

Contents This unit contains the following lessons:

Topic See Page

Lesson Upon completion of this lesson, you should be able to:

Contents This lesson contains the following topics:

Topic See Page

Control Stand Review the image of the FB4K control stand:

Diesel Engine (Prime Mover)

Continued on next page

Hydraulic Hydraulic pumps convert mechanical energy to hydraulic energy by pushing

Accumulators An accumulator stores incompressible hydraulic fluids under pressure. As the

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Lesson Upon completion of this lesson, you should be able to:

Contents This section contains the following topics:

Topic See Page

Clean rate is typically measured in barrels per minute (bpm). A blender

The more proppant that is

Understanding the components and their function is a critical part of a

Centrifugal suction and discharge pumps

What is a A centrifugal pump consists essentially of one or more impellers equipped

Right-Hand Centrifugal Pump

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Suction and discharge manifold diameters

An important distinguishing feature is whether the pump is a right-hand or

The head or pressure developed by the centrifugal pump is entirely the

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Required NPSH is the amount of pressure that must be supplied to the

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Faster speeds produce more pressure or head and demand more

A typical water hammer break is characterized by a crack running around the

A surge chamber can be installed in the discharge line to reduce the

Blender suction header

Multiple 4-inch hose connections

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Review the following image of a Gorman-Rupp 12 x 12 centrifugal pump

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This should be of no concern, as there is essentially no increase in the flow

Review the following image of a Flowserve 10 x 12 centrifugal pump