Table of Contents

Blender Operator Calibration and

QA/QC Procedures

Halliburton Energy Services, Inc.

Internal Document

i
 Table of Contents

All information contained in this publication is confidential and proprietary property of

Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings, or
photographs without the express written permission of an officer of Halliburton Energy
Services, Inc. is forbidden.

Copyright 2002, Halliburton Energy Services, Inc.

All Rights Reserved. Printed in the United States of America.

Halliburton Internal Document

Printing History:
First Release (February, 2002)

ii
 Table of Contents

Introduction .......................................................................... 1

LA Pump Calibration (Bucket Test) ...................................... 2

LA Pumps ......................................................................... 2

Micro Motion Mass Meter ............................................. 2

Tach Drive .................................................................... 4

ARC .............................................................................. 4

ACE .............................................................................. 4

Alternate Bucket Tests Procedures.................................. 5

Seraphin Test Measure Company .................................... 7

Radioactive Densometer High- and Low-Pressure

Cementing and Fracturing ................................................... 8

Field Calibration Procedure ............................................. 8

Reference Documents ..................................................... 8

pH Meter Calibration ............................................................ 9

Procedure pH Probe Calibration (ARC Blenders) ........... 9

Other Solutions ............................................................ 11

Procedure pH Probe Calibration (Unipro II) ..................... 12

iii
Blender Operator Calibration
and QA/QC Procedures
Introduction
This manual contains procedures for calibrating and maintaining QA/QC
procedures on ARC and ACE slurry processors. The procedures are divided into
three areas:

LA Pump Calibration (Bucket Test)

Radioactive densometer high- and low-pressure cementing and fracturing
pH meter calibration

The on location, prejob calibration of the blender instruments is critical to the

overall success of the stimulation treatment and the ultimate productivity of the
customers well. It is extremely important that you do your part in ensuring the
success of Halliburton and our customers by executing these calibration proce-
dures before each job.

December 2001 Blender Operator Calibration and QA/QC Procedures 1

 LA Pump Calibration (Bucket Test)
The following calibration procedures are used for ARC and ACE blending
equipment.

LA Pumps
Bucket testing is the most critical step in ensuring that the liquid additive (LA)
pump system is accurate and functioning correctly. The Halliburton Management
System (HMS) procedures and the Gold Medal Quality standards require an
accurate bucket test performed on the LA pumps before the fracturing job
begins. A proper bucket test before the job usually means accurate chemical
delivery during the job and an accurate final strap matching job design.

Proper pump selection is also an important variable in assuring accurate chemi-

cal delivery. The blender operator should have the job chemicals already as-
signed to specific pumps before bucket testing.

A calibrated bucket is also required before a bucket test is performed. Use a

purchased calibrated volumetric device for measuring liquid volumes and
calibrating LA pumps.

Note To show consistency between blending units and locations, we have

established a standard calibration bucket, SAP Part No. 101290246.
This is a rectangular 5-gal bucket with 1-gal increments and a
Halliburton logo.

An optional volumetric device is available from Seraphin Test Measure Company.

These devices offer extreme accuracy, but must be handled with care to maintain
this accuracy. More information on the Seraphin devices is listed on Page 7.

Each LA Pump will have a bucket-test manifold consisting of a tee and valve
arrangement, which allows (1) recirculating the LA back to its storage container,
(2) pumping the LA through a hose to the measuring container, or bucket, and
(3) pumping to the suction side of the discharge centrifugal or to the suction side
of the suction centrifugal. An additional tee, valve, and hose that allow you to
pump to either centrifugal are recommended.

The LA pump test should be displayed and monitored in the data acquisition unit
to ensure that the rates can be displayed and recorded within 5% variance.

Performing the bucket test procedure and calibration is recommended.

Micro Motion Mass Meter

Perform the following procedure to calibrate the LA pump with the Micro
Motion mass meter.

1. Prime the LA pump with the fluid to be pumped during the job. Before
starting the pumps, check that all suction and discharge valves to the LA

2 Blender Operator Calibration and QA/QC Procedures December 2001

 pump are in correct position. Ensure that the Micro Motion meter is
reading a steady rate and that all air is out of the system.
2. Set the clean flowmeter rate to the manual position and establish a rate
in bpm equal to the lowest anticipated downhole rate.
3. Begin circulating the LA pump with the fluid to be pumped during the
job.
4. Set the LA pump to the lowest rate in gal/Mgal required in the job
schedule. Control the rate from the main control system, as you would
during the job.
5. Using a stopwatch, measure the time in seconds required to fill an
appropriately sized container (normally 1 or 5 gal).
6. Record rate and time information and perform the calculations in
Eqs. 1 and 2 below.
7. Set the clean flowmeter rate to the manual position and establish a rate
in bpm equal to the highest anticipated downhole rate.
8. Set the LA pump to the highest rate in gal/Mgal required in the job
schedule. Control the rate from the main control system, as you would
during the job.
9. Using a stopwatch, measure the time in seconds required to fill an
appropriately sized container (normally 1 or 5 gal).
10. Record rate and time information and perform the calculations in
Eqs. 1 and 2 below.
11. Calculate pump accuracy.
12. Repeat Steps 1 through 12 for each pump and additive.

Use the following calculation to determine the time in seconds to fill the calibrated
1-gal container.

Clean rate (bpm) LA Rate (gal/Mgal) 0.0007 = LA rate in gal/sec Eq. 1

1 / LA rate (gal/sec) = seconds to fill a 1-gal container (sec/gal) Eq. 2

Note If the calibration is out by 5%, the Micro Motion meter or

pump may require maintenance. If the Micro Motion meter does
not read correctly, use the Tach drive to meter the additive. A
5% error for the time in sec/gal should fall within 1.05
seconds and 0.95 seconds, using the seconds produced from
the Eqs. 1 and 2.

Note Micro Motion calibration numbers must be set per Micro

Motion documentation and should not be changed. If the meter
does not read correctly, it requires maintenance by an electrical
technician. LA rates of less than 0.2 gal/min cannot be accu-
rately measured because of the Micro Motion calibration setup
(slug flow unit is set at 0.2 gal/min).

December 2001 Blender Operator Calibration and QA/QC Procedures 3

 Tach Drive
The calibration of the tach drive is divided into two categories, ARC and ACE.
Each of these is discussed according to whether the Micro Motion meter
calibrated properly.

ARC
You can calibrate the ARC system to switch between Micro Motion and Tach
readouts.

Note See the ARC software versions according to Tech Bulletin SEQ-
01-009 http://halworld.halnet.com/HES/Hesps/hespspe/
hespspe_content/fracacid/equip/bulletin/seq01009.pdf. The
hardware modifications outlined in that document will allow
you to calibrate the ARC systems to switch between Micro
Motion and Tach readouts.

If the Micro Motion meter is calibrated properly, follow these procedures:

1. Change screen to Display 2.

2. Verify that Rate 2 is reading the Micro Motion meter properly.
3. Change the LA control loop to Manual (ARC only).
4. Change to Rate 1, Tach readout, and Pump is Still Circulating.
5. Rate 1 should be equal to Rate 2. If Rate 1 is NOT equal to Rate 2,
adjust the Rate 1 (Tach) calibration numbers to equal Rate 2.

If the Micro Motion meter is not reading properly, follow these procedures:

Note Use the Tach readout for job by selecting Rate 1 with the
toggle switch on the control panel (per modification in Bulletin
SEQ-01-009).

1. Change screen to Display 2.

Repeat Steps 1 through 11 in the Micro Motion Mass Meter section (Page 3).

ACE
If the Micro Motion meter is calibrated properly, follow these procedures:

1. Adjust the Rate 1 (Tach) calibration numbers to equal Rate 2 (Micro

Motion).

If the Micro Motion meter is not reading properly, follow these procedures:

Note Use the Tach readout for the job by selecting Rate 1 from the
ACE control system.

4 Blender Operator Calibration and QA/QC Procedures December 2001

 1. Change the screen to display Rate 1 (Tach).

Repeat Steps 1 through 11 in the Micro Motion Mass Meter section (Page 3).

Alternate Bucket Tests Procedures

Alternate procedures require the following steps.

Note The alternate bucket test procedures do not ensure that the
pump, meter, and display will work properly at the minimum
and maximum rates during the job.

1. Prime the LA pump with fluid to be pumped during the job. Before
starting the pumps, ensure that all suction and discharge valves to LA
Pump are in correct position. Ensure that the Micro Motion meter is
reading a steady rate and that all air is out of the system.
2. Set the clean flowmeter rate selection to manual and enter 23.8 bpm.
3. Circulate the LA pump in auto at 1 gal/1,000, which equals 1 gpm, with
the clean rate of 23.8 bpm. Though some instances may call for a lower
or higher set point depending on pump limitations, 1 gal/1,000 is a good
overall set point for a bucket test. For example, for a small amount of
LA with a minimum of 0.25 gpm and a job set point at 0.5 gpm, a bucket
test at a set point of 0.5 gpm could be required (1 gal/1,000 is normally
used for convenience).
4. Using a stopwatch, measure the time the pump requires to discharge a
given volume. For a set point of 1 gal/1,000, the pump should require 1
minute to pump 1 gallon. One minute is usually sufficient for a bucket
test. If there are doubts about a pump, pumping for 5 minutes with a 5-
gal container will help ensure that the pump is correct.
5. A bucket test should be performed on Tach generator as well as the
Micro Motion meter. Tach is the backup to Micro Motion and needs
to be accurate in case of Micro Motion failure. (On ARC systems,
change the LA control loop to Manual.)
6. If the tach generator does not bucket-test accurately, the meter factor for
the Tach reading will need to be adjusted until the pump bucket tests
accurately.
7. Repeat Steps 1 through 6 for all LA pumps. Table 1 (Page 6) lists
available LA pump assemblies.

December 2001 Blender Operator Calibration and QA/QC Procedures 5

 Table 1LA Pump Assemblies
Progressive Cavity Pump Assemblies (with 60 Tooth Tach Transducers for Feedback)
Manufacturer Series Halliburton Ratea Speed Calibrationb
Roper Moyno Tarby Assembly Pump Min. Max. Min. Max. Factor
Part No. Part No. (gpm) (gpm) (rpm) (rpm) (gal/rev)
61001 281.10395 70.87749 0.3 3 200 1,750 0.0017
62001 281.10349 70.81134 0.5 4.2 200 1,750 0.0024
62201 281.10351 70.81133 0.9 8.1 200 1,750 0.0046
HS61F 281.1036 70.8105 0.2 4.2 85 1,750 0.0024
733025 281.10415 70.22375 0.2 3.1 80 1,200 0.0026
73201 281.10414 70.22116 0.8 10.3 80 1,200 0.0086
71201 1L3 1TL3 281.00655 70.05053 0.8 10.3 90 1,200 0.0086
73201 3L3 3TL3 281.1037 70.8116 0.8 10.3 90 1,200 0.0086
71202 1L4 1TL4 281.25568 70.05054 1.2 24.2 60 1,200 0.0202
73202 3L4 3TL4 281.1038 70.0867 1.2 24.2 60 1,200 0.0202
71205 1L6 1TL6 281.10572 70.04544 3 46.8 60 900 0.0520
Gear Pump Assemblies (with 60 Tooth Tach Transducers for Feedback)
Manufacturer Series Halliburton Rate Speed Calibration
Viking Eco Liquiflo Assembly Pump Min. Max. Min. Max. Factor
Part No. Part No. (gpm) (gpm) (rpm) (rpm) (gal/rev)
L32 281.90123 350.1562 10.5 136.5 50 650 0.21
HL32 281.90121 350.134 3.6 25.2 200 1,400 0.018
H32 281.10201 350.1345 1.8 12.7 200 1,400 0.0091
G8 311fs-109 281.10362 70.80827 2 16.5 200 1,650 0.01
G6 37fs-108 281.10361 70.80826 1 7.9 200 1,650 0.0048
G4 35fs-107 281.10359 70.80825 0.4 3.1 200 1,650 0.0019
Gear Pump Assemblies (without Tach Transducers)
Manufacturer Series Halliburton Rate Speed Calibration
Oberdorfer Viking Bowie Assembly Pump Min. Max. Min. Max. Factor
Part No. Part No. (gpm) (gpm) (rpm) (rpm) (gal/rev)
Q125 145.60046 70.897 301.6 520 0.58
9000B 281.90399 940.01069 21.6 1,725 0.0125
11600 281.91601 70.02054 51.8 1,725 0.03
8100 281.90806 70.84736 45 800 0.0563
a
Min/max gpm
b
Default meter factor

6 Blender Operator Calibration and QA/QC Procedures December 2001

Seraphin Test Measure Company
Table 2 contains cost information for 5-gal test measures (buckets) from
Seraphin Test Measure Company. These test measures are built and calibrated to
NIST 105-3 standards. In addition to the test measure costs, the table includes
costs for some of the additional options. Because any damage to the buckets will
invalidate their calibration, using the carrying cases to protect the buckets when
they are being transported or not in use is recommended. More information
about Seraphin Test Measure Company can be found at
http://www.seraphinusa.com/.

Table 2Test Measure Cost Information

Field Standard Test Measures Quantity Quantity Quantity Vendor
1 to 2 3 to 9 9+ Part No.
($) ($) ($)
Model E 5-gal stainless steel 488 415 366 EESS0005GA
test measure
Model FS-282-5D2 carbon steel 352 299 264 EE810007A
test measure
Test Measure Cart
Dual test measure cart 333 299 299 E300117PT
Carrying Case for 5-gal Measure
Model 5MC metal carrying case 164 139 123 EE810009
Model PCC-1 plastic carrying case 100 85 75 EE810010
Funnel
Model 3 galvanized funnel 84 71 63 EE810030
w/ copper spout
Funnel extension 60 51 45 EE810035
Stainless steel funnel 194 165 145 EE810040
Repair Kits
Repair kit for FS-282-5D 100 85 75 E80083
test measure
Repair kit for Series E test measure 100 85 75 E80181

December 2001 Blender Operator Calibration and QA/QC Procedures 7

 Radioactive Densometer High- and
Low-Pressure Cementing and Fracturing
This section does not include information for the IAGS densometer.

Field Calibration Procedure

The densometer should be calibrated before each job. No special equipment is
required for this procedure.

1. Ensure that the densometer is empty and dry, and that the Hi Cal/Lo Cal
knob is in the operate (OPR) position.
2. Turn on electrical power to the densometer and associated electronic
readout equipment. Allow the equipment to warm up for 15 minutes.
3. Verify on the readout instrument (Unipro, ARC OIP/Unit Controller,
ACE computer, or TCC) that the density is 0.00 pounds per gallon.
Allowable tolerance is 0.00, 0.75 lb/gal.
4. Turn the knob on the densometer to the LOW position. Autocalibrate
according to the instruction manual for the particular electronic readout
equipment involved.
5. Turn the knob on the densometer to the HI position. Verify that the
density corresponds to that recorded for Hi Cal in the documentation
package included with the densometer DOT shipping papers. Allowable
tolerance is Hi Cal density 0.15 lb/gal.
6. Return the knob on the densometer to the OPR position.
7. If either of the two readings, air or Hi Cal, were outside their allowable
tolerance, the densometer should be marked Out of Calibration and
returned to the shop for calibration. Use another densometer that can
pass this field calibration procedure.

Reference Documents
Engineering Bulletin 40-91 Densometer Field Calibrations (Updated)
Engineering Bulletin 32-91 Decaying Sources for Radioactive Density
Sensors
Engineering Bulletin 28-91 Accuracy of Digital Density Sensors
Unipro I Operators Manual - Cementing (TDRAD) 458.32471 /
100061868
Unipro I Operators Manual - Fracturing (TDRAD) 458.30008 /
100061610
Unipro II Operation Manual 458.50084 / 100003461
Universal Blender Software and Operating Systems Manual 516.99013 /
100003907

8 Blender Operator Calibration and QA/QC Procedures December 2001

 ACE 500 Blender Manual. Download from HalWorld at the following
link:
http://halworld.halnet.com/hes/hesps/hespspe/hespspe_fracacid/
hespspe_fracacid_eqace/hespspe_fracacid_eqace.asp
Tech Command Center Operators Manual 458.01037 / 100007855

pH Meter Calibration
Figure 1 is an example of the ACE calibration procedure (on screen).

Figure 1pH probe calibration screen in the ACE OIP

Procedure pH Probe Calibration (ARC Blenders)

Calibrating the pH probe requires three different pH-level fluids: 4 pH, 7 pH,
and 10 pH.

4 pH is used for a zero value.

7 pH is used for a mid-range check value.
10 pH is used for a span value.

December 2001 Blender Operator Calibration and QA/QC Procedures 9

 Note Standard water or distilled water must be used to rinse the probe
tips between each pH value. The tips must be blotted dry to
remove excess water.

Warning The rubber cover must be removed from the glass tips. The
glass tips are thin and can be easily damaged (cracked). After
a job, always reinstall the rubber cover over the tips to protect
the probe (Figure 2). Use extreme care when handling.

pH
pH Probe
Probe

The rubber cover must

always be kept on the
probe for storage, and
must be removed
to calibrate the
probe for job.

Be sure guard is
Tips that must turned towards flow
be kept moist to protect the tips
are fragile. during the job

Figure 2Protecting glass probe tips

Perform the following procedures when calibrating the HSR pH probe:

1. Place the probe tips into the 4-pH solution and allow a few seconds
to stabilize.
2. On the OIP screen (Figure 3, Page 11) enter 4 into the Zero field. Rinse
the probe tips.
3. Place the probe tips into the 10-pH solution and allow a few seconds
to stabilize.
4. On the OIP screen enter 10 into the span field. Rinse the probe tips.
5. Place the probe tips into the 7-pH solution and allow a few seconds
to stabilize.

10 Blender Operator Calibration and QA/QC Procedures December 2001

Note The OIP screen should now read a pH of 7.

6. To further verify proper calibration, place the probe tips into the 4- and
10-pH solutions.

Note Each time, the OIP screen should read the proper value.

7. Note the Recal value on the OIP screen for future reference.

Figure 3Display 8, ACE OIP screen

Other Solutions
Solution values below 4 pH and above 10 pH tend to be unstable. Other solu-
tions that can be used in pH probe calibration include the following:

Tap water pH = 6.7 to 6.8

Distilled water pH = 7.1 to 7.2

Note Do not mix pH solutions. Mixing a 7-pH with a 10-pH solution

will not give you an 8.5-pH solution. pH buffer solutions can be
made with the following tablets (Use 1 capsule per 100 mL of
distilled water.):

December 2001 Blender Operator Calibration and QA/QC Procedures 11

 590.02029 Buffer - 4 pH - 10 capsules/vial
590.02030 Buffer - 7 pH - 10 capsules/vial
590.02031 Buffer - 10 pH - 10 capsules/vial

The following are Part Numbers for the necessary solutions:

pH 4 100024334
pH 7 100024335
pH 10 100024336

Procedure pH Probe Calibration (Unipro II)

Calibrating the pH probe requires three different pH level fluids: 4 pH, 7pH, and
10 pH.

4 pH will be used for a zero value.

7 pH will be used for a mid-range check value.
10 pH will be used for a span value.

Note Standard water or distilled water must be used to rinse the probe
tips between each pH value. The tips must be blotted dry to
remove excess water.

Warning The rubber cover must be removed from the glass tips. The
glass tips are thin and can be easily damaged (cracked).
After a job, always reinstall the rubber cover over the tips to
protect the probe (Figure 2, Page 10). Use extreme care
when handling.

Perform the following procedures when calibrating the Unipro II pH probe:

Important Typical pH buffer solutions are truly at their nominal pH value

only at room temperature. Be sure that the calibration is per-
formed at room temperature, and that both the probe and the
buffer solutions are at room temperature.

1. Place the probe tips into the 4-pH solution and allow a few seconds to
stabilize.
2. On the Unipro II screen, press the Menu button where pH is displayed,
then Menu 8 (cal/tst), then Menu 3 (Display Counts). Write down the
counts. Rinse the probe tips.
3. Place the probe tips into the 10-pH solution and allow a few seconds to
stabilize.

12 Blender Operator Calibration and QA/QC Procedures December 2001

 4. Write down the counts. Rinse the probe tips.
5. Press the Menu button where pH is displayed.
Then press Menu 8(cal/tst),
Menu 4 (Recalibrate),
Menu 4 (Accept),
Enter twice,
Then 2 (for number of cal points).
Enter the frequency for PH of 4 (from Step 2).
Enter 4 (for PH).
Enter the frequency for PH of 10 (from Step 2).
Enter 10 (for PH).
Press Enter 3 times (reading PH).

6. Place the probe tips into the 7-pH solution and allow a few seconds to
stabilize.

Note The Unipro II should now read a pH of 7.

7. To further verify proper calibration, place the probe tips into the 4-pH
and 10-pH solutions.

The acceptable ranges for each buffer solution are as follows:

pH 4 = 3.9 to 4.1
pH 7 = 6.9 to 7.1
pH 10 = 9.9 to 10.1

Note Repeat the calibration if the values are not within these limits.

December 2001 Blender Operator Calibration and QA/QC Procedures 13