ACE Blender Operator Manual

Chapter 1 Introduction

CHAPTER 1 INTRODUCTION TO THE ACE

CONTROLLER AND GUI DISPLAY

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

1.1
BASICS ...................................................................................................................................... 1-2
1.1.1
Definition of Blender Terms ................................................................................................ 1-2
1.1.2
Control Loops and the Electronics ...................................................................................... 1-4
1.1.3
Display Monitor / Control functions.................................................................................... 1-5
1.2
SPECIFICATIONS ........................................................................................................................ 1-6

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

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1.1 Basics
1.1.1

Definition of Blender Terms

Clean rate also called suction rate, clean side, and master rate. Clean rate is defined as
the rate at which fluid is delivered to the blenders tub by the suction pump. Clean rate is
the main variable involved in good control for chemical and sand delivery to the well
bore. All of the additives are slaved to the clean rate; meaning additive rate follows the
clean rate. In some instances, we have slaved chemicals to the sand rate, but the sand rate
is still slaved to the clean rate. Clean rate is typically measured in Barrels per Minute
(barrel being 42 gallons). A blender operator should always monitor clean rate and insure
the clean rate is stable and not fluctuating.
Dirty rate also called slurry rate, dirty side and discharge. Dirty rate is defined as the
rate at which the fluid is taken from the blender tub and boosted by the discharge pump to
the high pressure pumps. Dirty rate is usually measured in BPM, same as clean. During
Pad or before sand is brought on the blender operator should insure the dirty rate and
clean rate are matched up. If the Clean rate is 30bpm then the dirty should be close to
30bpm with the tub at set point and maintaining a constant level. This check insures both
clean and dirty flow meters are working and that the end of job volumes will be correct.
After sand is started in the tub the clean rate will decrease due to the sand acting as clean
volume in the tub. As more sand is delivered to the tub it takes less clean rate to maintain
adequate tub level.
Suction pressure The pressure in PSI (pounds per square inch) that is maintained on the
suction manifold.
Discharge pressure also called Boost. Discharge pressure is defined as the pressure
in PSI that is maintained on the discharge manifold. Discharge pressure is needed to
insure proper high pressure pump operation and accurate Densometer operation relative
to the high-pressure pump operation and accurate Densometer operation.
Boost Boost is defined as the pressurized fluid that is being pumped from the blender to
the high pressure pumps.
High pressure pumps Fluid pumps such as Grizzly, HT2000, and HT400 that pump
sand laden fluids at high pressure.
Tub level The level of fluid that is in the blender tub. Tub level is very critical to many
different variables. The main variable being having enough fluid in the tub to insure the
pumps do not suck air. Tub level set point is usually 70% to 75%. Prior to the job the
blender should check for a 0% (+/-2%) tub level reading with an empty tub and a 105%
reading when the float is pulled to the top (+/-5%). Setting the top value to 105% allows
the controller time to stop the tub from overflowing.

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

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1.1.2

Control Loops and the Electronics

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

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1.1.3

Display Monitor / Control functions

The ACE control system can be used as a (remote) display. The control and
monitoring of the units on location can then be done through the ACE control Graphical
User Interface (GUI) and then data would be received and sent out via network
connections. For example, some of the stations in the INSITE Technical Command
Center (TCC) are GUIs only. As such, the ACE control system can replace the PCI in
the PSW/PCI TCC.
The ACE control window can be used to launch other GUIs; selecting one of the
menu items for that particular unit type does this. For example to start a pump GUI select
Pump on the menu then Pump truck.

The instructions for using the Pump GUI can be found in the ACE Pump Operator
Reference Manual, part number 101268133 or downloaded from the ACE Web site. The
instructions for using the Instrument Data Gathering System (IDGS) which is listed under
the Instrument unit menu can be found in the IDGS Manual part number 101310021 or
downloaded from the ACE Web site. The instructions for using the Sand GUI can be
located in the ACE Sand System Manual, which can be downloaded from the ACE Web
site.
Some functions of the ACE Control System are limited to what computer the GUI
display is running on. Thus some functions are not sent to other units and are local to
that computer only; refer to the list below for those functions.
Job Plan information
Local Only tab refer to chapter 3
Selected Additive Pump chosen, selected chemical chosen
Operator entered Additive names, valve names
Display Setup number of additives, units
Unique ACE items viscosity control, pH control, cross linker control, selected
Master rate from other blender units
Manifold selection
Edited Group Commands

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1.2 Specifications
The ACE Controller Blender supports the following

Built in error checking for job data entry

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

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NOTES

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