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Calfrac Hydration Unit Operator's Manual
Record of Revisions
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Calfrac Hydration Unit Operator's Manual
Conventions Used
All screen names and navigation icons in the following screen descriptions will be in
Bold Text.
Notes especially of interest to the user are offset slightly from surrounding text and are
highlighted with a light gray background.
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Calfrac Hydration Unit Operator's Manual
Table of Contents
About this Manual...............................................................................................4
Conventions Used ..............................................................................................4
Table of Contents ...............................................................................................5
List of Figures.....................................................................................................7
List of Tables ......................................................................................................8
1 Equipment Description................................................................................ 9
1.1 Introduction.................................................................................................9
1.2 Hydrator Components.................................................................................9
1.2.1 Trailer Chassis .....................................................................................10
1.2.2 Control Cab ..........................................................................................11
1.2.3 Deck Engine .........................................................................................11
1.2.4 Hydraulics System................................................................................11
1.2.5 Manifold Systems .................................................................................11
1.2.6 Centrifugal Pumps................................................................................12
1.2.7 Hydration Process Components...........................................................12
1.3 Principle of Operation ...............................................................................13
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Calfrac Hydration Unit Operator's Manual
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edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
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grant or registration of a product or design patent are reserved.
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Calfrac Hydration Unit Operator's Manual
List of Figures
Figure 1 Hydrator Components..........................................................................10
Figure 2: Typical ECAMS™ Screen Layout ........................................................16
Figure 3 ECAMS™ Main Menu Screen .............................................................19
Figure 4 Hydration Process Screen ...................................................................24
Figure 5: Engine Information Screen ..................................................................26
Figure 6 Hydraulic Performance Screen ............................................................28
Figure 7 Digital Data (Gauges) Screen ..............................................................29
Figure 8 Suction Flow Meter Screen..................................................................30
Figure 9 Hydration Tank Discharge Flow Meter.................................................32
Figure 10 Calmixer Flow Meter Screen..............................................................34
Figure 11 Pump Pressure Setpoints Screen......................................................36
Figure 12 Alarms Screen ...................................................................................38
Figure 13 Hydrator Calibration Menu Screen.....................................................42
Figure 14 Process Pressure calibration Screen .................................................45
Figure 15 Hydraulic Pressure Screen ................................................................46
Figure 16 Temp/Fuel Calibration Screen ...........................................................47
Figure 17 Tank Inlet Valve Calibration Screen...................................................49
Figure 18 Hydrator Data van Rate Calibration Screen.......................................51
Figure 19 Calmixer Flow Rate Calibrations Screen ...........................................53
Figure 20 Wits/ Flash Log Output Setup Screen................................................56
Figure 21 Alarm Screen .....................................................................................63
Figure 22 Hydrator Deck Engine Rig Saver .......................................................66
Figure 23 Hydration Unit Control Panel .............................................................69
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Calfrac Hydration Unit Operator's Manual
List of Tables
Table 1 Metric and US Units ..............................................................................67
Table 2 Centrifugal Pump Troubleshooting Guide ..............................................68
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Calfrac Hydration Unit Operator's Manual
1 Equipment Description
1 Equipment Description
This section provides an overview of the Calfrac Hydrator major components:
1.1 Introduction
The Calfrac Hydrator is a trailer mounted unit that has been designed for gel preparation
and chemical blending of frac fluids that are the fracturing base for proppants used to
stimulate existing, completed oil or gas wells.
The Hydrator can be controlled manually or automatically with ECAMS™ (Enerflow
Control And Measurement System) which provides touch screen access to Hydrator
controls and operating information.
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1 Equipment Description
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Calfrac Hydration Unit Operator's Manual
1 Equipment Description
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1 Equipment Description
The suction and discharge manifolds are fitted with electric/air operated butterfly valves
with actuators. The crossover manifold allows the suction pump to discharge directly to
the discharge manifold.
Suction Pump
• Gorman Rupp VG8HD3-B 10” x 8” centrifugal pump with a closed 5 vane impeller.
• Powered by a hydraulic motor with independent variable speed drive.
• Maximum pump output is 100 BPM.
Mix Pump
• Goulds 2 x 3 x 11 with closed impeller and mechanical seal.
• Powered by a hydraulic motor with independent variable speed drive.
• Maximum output is 15 BPM at 250 psi.
• The mix pump is supercharged from either the main suction pump or the auxiliary
suction pump.
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1 Equipment Description
• Internal baffles also include one 12’ butterfly valve with a pneumatic actuator so that
the restriction through the tank can be minimized when running “slick water” at up to
100 bpm.
• Level transducer and high water level switches.
Shear Plates
There are four (4) shear plates in the Calmixer. The shear plates ensure proper mixing of
the gel solution and can be replaced with different types of shear plates depending on the
mixing differential pressure and flow rate requirements of the gel.
Retention Tubes
• Stainless steel retention tubes are sized to provide a three (3) minute hydration time
for gel within the hydration unit when pumping at 60 bpm. The flow through the
hydration tubes is 15% of the overall unit flow rate.
• The retention tubes have removable end connections to provide cleanout access.
• The retention tubes are in four (4) sections that can be isolated during pumping
operations so that the hydration time can be modified based upon current through
flow rates.
• The retention tubes discharge into the inlet of the suction pump as part of the
“Calmixer” system.
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1 Equipment Description
d. The solution then flows through up to four (4) retention tubes that are configured with
a specific volume and length. The retention tubes limit the solution to a flow rate that
allows it to thicken into a gel with a specific density before it is pumped to a Hydrator
where proppant is added.
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Calfrac Hydration Unit Operator's Manual
2 ECAMS™ Screen Descriptions
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2 ECAMS™ Screen Descriptions
2.1 Typical ECAMS™ Screen Layout
1. The menu bar located along the top of each screen displays the following navigation
buttons and information fields:
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2.1 Typical ECAMS™ Screen Layout
Navigation Buttons
The Main Menu button displays navigation buttons to the
ECAMS major screens and flow rate and pressures at critical
points in the hydration process.
Information Fields
The menu bar displays the following information
fields:
• Discharge Rate – where???
• Suction pressure before the hydration tank.
• Calmix Rate
• Shear Inlet Pressure.
• Shear outlet Pressure.
2. The main screen display area located below the top menu bar displays hydrator
control buttons, operating settings and transmitter output fields.
3. An alarm code bar located below the main screen display area displays a description
of the most recent system faults.
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2 ECAMS™ Screen Descriptions
2.1 Typical ECAMS™ Screen Layout
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2 ECAMS™ Screen Descriptions
2.2 Main Menu Screen
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2.2 Main Menu Screen
The Engine Info button displays deck engine performance data and
diagnostic indicators.
The Digital Data button displays fluid level, pressure and flow rates
at critical points in the hydration process.
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2.2 Main Menu Screen
The Calmixer Flow Meter button displays the Calmixer flow rate,
total volume and flow meter communication status.
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2 ECAMS™ Screen Descriptions
2.3 Hydrator Monitoring Screens
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2 ECAMS™ Screen Descriptions
2.3.1 Hydrator Process Control Screen
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2 ECAMS™ Screen Descriptions
2.3.1 Hydrator Process Control Screen
The Hydration Process Control screen displays the following control buttons valve icons
and input fields:
The Manual/Auto toggle button provides the option
to select manual or auto flow control of gel through the
Calmixer shear plates and retention tubes.
The Baffle Open and Baffle Close buttons control a
baffle in the hydration tank.
The % Setpoint input field is the hydration tank level
setpoint that controls flow through the tank’s 12” inlet
butterfly valve.
Each manifold valve icon is a control button that opens
or closes a valve. The icon is green when the valve is
open and red when it is closed.
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2 ECAMS™ Screen Descriptions
2.3.2 Engine Information Screen
The Engine Info screen display the following engine diagnostic indicators and screen
navigation buttons.
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2 ECAMS™ Screen Descriptions
2.3.2 Engine Information Screen
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2 ECAMS™ Screen Descriptions
2.3.3 Hydraulic Pressures Screen
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2 ECAMS™ Screen Descriptions
2.3.4 Digital Data Screen
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2 ECAMS™ Screen Descriptions
2.3.5 Suction Flow Meter Screen
The Suction Flow Meter screen displays the following output fields and control buttons:
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2 ECAMS™ Screen Descriptions
2.3.5 Suction Flow Meter Screen
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2 ECAMS™ Screen Descriptions
2.3.6 Hydration Tank Flow Meter
The Suction Flow Meter screen displays the following output fields and control buttons:
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2 ECAMS™ Screen Descriptions
2.3.6 Hydration Tank Flow Meter
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2 ECAMS™ Screen Descriptions
2.3.7 Calmixer Flow Meter
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2.3.7 Calmixer Flow Meter
The Calmixer Flow Meter screen displays the following output fields and control buttons:
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2 ECAMS™ Screen Descriptions
2.3.8 Pump Pressure Setpoints
The Pump Pressure screen displays the following centrifugal operating setpoints:
Suction Pump – draws clean mix water from either the driver side or suction side
manifold.
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2.3.8 Pump Pressure Setpoints
Calmixer Suc Pump – This is an auxiliary clean mix water pump that can draw water
from an external source. For example: a water tank.
Note: On the drawing P&ID Hydration unit with Calmixer (part #33962) included in
the Enerflow parts and service manual, this pump is labeled Aux Suction Pump
Cal Mixer Boost Pump – This pump maintains a differential pressure across the shear
plates.
Note: On the drawing P&ID Hydration unit with Calmixer (part #33962) included in
the Enerflow parts and service manual, this pump is labeled Press Mix Pump.
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2 ECAMS™ Screen Descriptions
2.3.9 Alarms Screen
The Alarms screen displays the following alarm codes and navigation buttons:
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2 ECAMS™ Screen Descriptions
2.3.9 Alarms Screen
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Calfrac Hydration Unit Operator's Manual
2.4 Hydrator Calibration Screens
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2.4 Hydrator Calibration Screens
2.4.1 Hydrator Calibration Menu Screen
The Hydrator Calibration Menu screen displays the following navigation buttons:
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2.4 Hydrator Calibration Screens
2.4.1 Hydrator Calibration Menu Screen
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2.4 Hydrator Calibration Screens
2.4.1 Hydrator Calibration Menu Screen
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Calfrac Hydration Unit Operator's Manual
2.4 Hydrator Calibration Screens
2.4.1.1 Process Pressure Calibration Screen
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2.4 Hydrator Calibration Screens
2.4.1.2 Hydraulic Pressure Screen
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2.4 Hydrator Calibration Screens
2.4.1.3 Temperature and Fuel Calibration Screen
The Temperature and Fuel Calibration screen displays the following control and
navigation buttons;
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2.4 Hydrator Calibration Screens
2.4.1.3 Temperature and Fuel Calibration Screen
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Calfrac Hydration Unit Operator's Manual
2.4 Hydrator Calibration Screens
2.4.1.4 Tank Inlet Valve Calibration Screen
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2.4 Hydrator Calibration Screens
2.4.1.4 Tank Inlet Valve Calibration Screen
The Tank Inlet Valve Calibration screen displays the following control and navigation
buttons:
The Tank 1 Inlet Calibrate button enables an auto
calibration of the hydration tank inlet valve hydraulic
actuator using the factory set values displayed on this
screen.
The Open and Close buttons displayed on the right side
of the screen fully open or fully close the hydration tank
inlet valve when the valve is in manual mode (set on the
main control panel).
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2.4 Hydrator Calibration Screens
2.4.1.5 Slip Calculation and Data van Output Configuration Screen
The Hydrator/Data van Input Calibration screen displays the following selection buttons
and input configuration fields:
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2.4 Hydrator Calibration Screens
2.4.1.5 Slip Calculation and Data van Output Configuration Screen
Slip% The Slip% Current is a value for the gel flow rate
in the hydration tubes that is calculated from the
actual mix tub suction or discharge line flow meter.
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2.4 Hydrator Calibration Screens
2.4.1.6 Calmixer Flow Rate Calibration Screen
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2.4.1.6 Calmixer Flow Rate Calibration Screen
The Calmixer Flow Rate Calibration screen displays the following control and navigation
buttons:
Calmixer 4
Note: These setpoints need to be changed each
time the shear plates are replaced with different
types of plates to satisfy job mixing requirements.
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2.4 Hydrator Calibration Screens
2.4.1.6 Calmixer Flow Rate Calibration Screen
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
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2.4 Hydrator Calibration Screens
2.4.1.7 WITS / Flash Log Output Setup Screen
The WITS / Flash Log Output Setup screen displays the following control buttons and
navigation links:
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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2.4 Hydrator Calibration Screens
2.4.1.7 WITS / Flash Log Output Setup Screen
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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Calfrac Hydration Unit Operator's Manual
3 Hydrator Operating Procedures
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.1 Pre-Startup Equipment Check List
Note: We do not give detailed instructions on how to start up the Hydrator for safety
and legal reasons. But there are some general instructions that do not require any
specific instructions.
Deck Engines
• Check that the deck engine rig saver is in the ‘open’ position.
Note: The rig saver leaver is in the open position when it is parallel to the rig saver
body.
• Check the deck engine oil levels. Also check the visual indicators on engine oil filters.
• Check the deck engine coolant level using the sight glass located on the engine
radiator or by removing the cap on the overflow tank.
• Check the deck engine air filter by looking at the visual indicators mounted just below
the filter.
• Check the fuel level by simply opening the fuel tank cap.
Hydraulics Components
Check the following hydraulic components:
• Check the hydraulic oil level and temperature by viewing the sight glass mounted on
the front of the hydraulic oil tank.
• Check the centrifugal hydraulic oil filter flow visual indicators.
Control Valves
Ensure that all process control valves are in the closed position.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.2 How to Power-up the
1. Turn the 24 Volt battery disconnect switch to the On position. The battery box is
located above the passenger’s side rear tractor wheel.
Note: The 24 Volt battery provides DC power to the deck engine starter, transmitters,
engine display screens mounted in the control cab, and control cab for the limited
length of time before deck engine startup.
Note: The engine screen will display a default temperature of 32◦ F when there is no
engine communication.
Note: If the engine coolant is not at the minimum operating temperature, turn the
Webasto control switch located on the battery box to the On position. The switch
will illuminate green when the Webasto power is on.
5. Walk around the Hydrator to ensure that well site personnel are not in the operating
area.
6. Turn and hold the HPU Engine switch in the Start position until the engine is
running on its own power.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.2 How to Power-up the
Note 1: Do not hold the Engine switch in the Start position for more than 10
seconds.
Note 2: If the engine does not run after two starts, check the fuel level. Then use the
engine priming pump to build up enough fuel pressure for ignition. The minimum
fuel pressure is reached when the operator can no longer move the plunger.
7. Open the Engine Information screens for both deck engines and check the transmitter
values to ensure that they are operating correctly.
8. Turn the Siemens touch screen power switch to the On position then open the
ECAMS™ HPU Status screen to ensure that the centrifugal suction pump has
hydraulic pressure.
Note: The hydraulic drive pump oil pressures should be approximately 320-350 psi and
the auxiliary hydraulic oil pressure should be between 1500 and 1850 psi. Check with
Marius.
9. Press the Alarm button located on the ECAMS™ screen top menu bar to open the
Alarms screen and check for system faults.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.3 How to Acknowledge an Alarm Code
2. Select the active alarm code by touching the flashing red alarm code. The red alarm
code will change to steady blue with white text.
3. Select the Acknowledge button located on the bottom right corner of the screen. The
alarm code colour will change to white.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.3 How to Acknowledge an Alarm Code
Note: An Alarm code will not disappear after it is acknowledged. To clear an alarm
code, the alarm condition must first be rectified and then the alarm code acknowledged
by the operator.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.4 How to Calibrate the Siemens Touch Screen
The following procedure describes how to calibrate the control panel Siemens touch
screen:
1. Cycle power to the touch screen or press Control Panel button located on the main
menu screen.
2. Press the Control Panel button on the main menu screen.
3. Double press the OP button.
4. Open the Touch tab and select Recalibrate. The screen will display a prompt that
will take you through each step in the screen calibration.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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3 Hydrator Operating Procedures
3.5 How to Reset the Rig Saver
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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Problem Solution
The pump will not spin or is very Switch to automatic mode and look at the pump
erratic in manual mode. outputs. If the speed is smoother, the dial is likely to
blame. If it does not increase or decrease steadily as
you move the dial then the dial needs to be replaced.
If the dial works but there is no output then check
for alarms caused by a malfunctioning PLC.
The pump spins on its own when Disconnect power to the Strokers at the pump(s). If
the Pump Output is 0.0 the pump continues to spin, the pump Strokers will
need to be changed by a qualified mechanic.
Check for a failed suction pump RPM transmitter.
This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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This document is loaned, subject to return upon demand, and shall not be transmitted, reproduced, disseminated and/or
edited, as well as utilization of its contents and communication indirectly or directly thereof to others without express
authorization are prohibited. Offenders will be held liable for payment of damages. All rights created by copy right, patent
grant or registration of a product or design patent are reserved.
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