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Overview

XRI Blue has requirements for Flowback Automation Systems for their Flowback Division.

XRI Blue has 10 Flow Back Trailers (3 Phase Separators on Trailer).  Each trailer has 1 Gas Meter Run,  2 Oil Meter Runs, 2 Water Meter Runs.  Only a single Oil and a Single Water is used at a single time.  The Gas Meter Runs use Cameron Scanner 2000 and Turbine Meter Runs Kimray Turbine Totalizers. Both the Scanner 2000 and Kimray BK3000X (some BK28000 are used) are battery powered.

XRI Blue Flowback Operations reads and report meters values hourly and daily during flow back operations. Meter values read include:

  • Gas Meter
    • Instantaneous dP, P, T,Flow
    • Gas Total
  • Oil Total
  • Water Total

Flowback Automation Requirements

For Flowback Automation they would like to have a system that can

  1. Automate Data Capture (Loading)
  2. Provide Local Display of Flowback Operation for Operator with Touchscreen  – all readings at one place.
  3. Provide Remote Wireless Communications for Flow Back Data to XRI Office from Remote Field Sites
  4. Provide Web Reporting of Flowback Data for XRI Blue and their Clients
  5. Provide Alarm Notification for Operational Alarms via Email, SMS, and Voice
  6. Integrate Sand Separator Weigh/Level Monitoring Into System – Current Weight and Trends
  7. Optional Integration of Wellhead Monitoring (Casing/Tubing Pressures, Temperature), Choke Pressures, and Tank Levels; and ESD

Flowback  Automation Approach

The approach we recommend to be taken for XRI Blue Flowback Automation implementation based on review of their existing systems.

  1. Use existing Scanner 2000 and Kimray Turbine Displays on Trailers.
    1. No Need to Buy different Instruments
    2. Manual Data recording can remain the same.
    3. On Some Trailers we will need to change Turbine displays as some turbine  displays are displays without Modbus connectivity.
  2. Wire all Instruments for Power and Communication and Terminate in JB
    1. Use Teck Cable – Class I Div 2
  3. Install New Modular RTU System
    1. Modular System would include –  Flow Back RTU and Wireless Gateway, and Power Supply
    2. Power Supply is 120VAC with Battery Backup and would powered by Generator/Light Tower. Solar and Wind Can be Added Optionally.
    3. System Equipment used in Modular RTU Systems same as Water Transfer Automation System
  4. Staged Deployment –  Prototype Deployment and Assess before Full Deployment
  5. Sand Separator Integration need to be Further Fleshed Out
  6. Casing/Tubing and Line Pressure Option can be easily integrated.

 

 

Gallery

Flowback Trailers

Scanner 2000

Cameron Scanner 2000 are used on XRI Blue flowback trailers. They are battery powered.

 

  

Kimray 3000

XRI Blue flow back trailers use Kimray 3000BX (round) and 2800 (square boxes). The Kimray 2800 have to be replaced with the explosion Kimray 3000BX.

RAVINDER – Check this

 

  

 

 

 

Architecture

 

 

SCADALink Well Test RTU Architecture

 

Proposed Flowback Panel Mounting Location

The HMI Panel is proposed to located at the highlighted location on the trailer on the left driver side of the trailer. This location is recommended as it is in Class I Div 2 zone.  With this location the HMI panel can be viewed without getting up on the trailer by an operator.

Sand Separator Monitoring

Overview

XRI Blue has a requirement for a Real Time Sand Separator Weigh Scale Interface. This is to be used with the Flowback Automation System and standalone operation.

Currently XRI Blue rents third party Separator Systems. The Sand Separator system that I inspected had a Load Cell System with a Display. The Display was mounted at the bottom of the Sand Separator and was not convenient for operations being it was not located at eye level.  It did not have a SCADA Interface.

XRI Blue needs a Sand Separator Load Cell system that can integrate into the Flowback Automation/SCADA System.

This section provides a brief preliminary design of a Sand Separator Load Cell System that can integrate into the Flowback Automation System.

  

Scale Equipment Options

Industrial Weighing Systems for Vessel Process Measurement typically comprise of the Display Unit,   Summer/Junction Box, and Load Cells Subsystems as shown.

 

Scale Displays

The Scale Display Units are use to display:

  • Gross Weight
  • Net Weight
  • Tare Weight  (Offset of Vessel and Water)

Displays can have Modbus Output in addition to 4-20 ma outputs in addition to the LCD/Keypad or LED Displays as shown for the Mettler Toledo IND780 (support multiple weighing lines) and IND570 Displays. It is recommended to use a single display per sand separator (i.e.  IND570).

 

 

Load Cells

Load cells are used to measure the load be attaching to frame of vessel.

Analog or Digital Load Cells are available.

Analog load cells use a Summer Box to sum total of the load cells use to measure weight.

Digital Load cells connect directly to the display device. An advantage of digital load cells is that they have intelligent  diagnostics so if 1 out 4 load cell has error  the other load cells can compensate intelligently.  A disadvantage is that the currently available Digital load cells are not Class I Div 2 or Class I Div 1 IS certified.

Analog load cells use a Summer Box to sum total of the load cells use to measure weight.

 

 

Costing

 

 

 

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