250 BBL Hydrator

RZ

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THESE ARE NEW UNITS AVAILABLE FOR SHIPMENT NOW 1.0 General Unit Specification This technical specification covers the construction and design requirements for a 250 BBL Trailer-Mounted Hydrator unit capable of delivering homogeneous liquids required for oilfield fracturing and stimulation services in ambient conditions of 24 degrees F minus 4.5 degrees C to 120 degrees F 49 degrees C The unit will be equipped to draw in and mix fracturing water and liquid chemical products to the process liquids through a well-designed and maintainable fluid handling system. Manual and automated controls will be installed on the unit to allow complete operator control and customized programming for job specific applications and treatment plans. 1.1 Unit Dimensions & Permitting The unit dimensions(excluding the customer supplied tractor will be approximately Length: 48’ 0” 14 meters Width: 8’ 6” 2.6 meters Height: 13 6” 4.1 meters Weight empty 70000lbs 31750 kgs estimated The unit/tractor combination will comply with all US & TX DOT regulations for unit dimensions, but could exceed the standard 80,000lbs vehicular weight allowed depending on customer tractor selection. Axle loading will be properly distributed to allow overweight/oversize permitting in the continental United States and compliance with US Federal Bridge Law. 2.0 Equipment Systems 2.1 Trailer Specifications The trailer will be a heavy duty, mobile, multi-purpose platform that will include the following features and compliances: US and TX DOT Compliant for On-Road Transportation A36 Steel Beam/Frame Construction (at minimum) w/ frame members Heavy duty 2” King Pin with 3/8” Bolster Plate mounted to receive a fifth-wheel Standard tractor air “glad-hands” and electrical connectors accessible at the front of trailer Sealed electrical wiring and protected air-lines Dual Axle w/ 25,000lb rated axles and 50,000lb rated Monopivot Air-Ride Suspension 16 1/2” x 7” S Cam Brakes w/ ABS system installed on both axles Eight 11R22.5 Tires Eight 8.25 x 22.5, 10-Hole, Hub Piloted Wheels Four hydraulic stabilizing cylinders with landing feet Holland Mark V Heavy Duty Landing Gear, manual 2-speed gearbox crank DOT compliant vehicle lighting and conspicuity marking Heavy duty Rubber Mud-Flaps installed on rear axle Steel Fenders 2.2 Power Unit 2.2.1 Hydraulic Drive Engine To supply hydraulic power requirements, installed on the trailer front deck area will be one (1) 580HP Caterpillar C-15 Diesel Engine. It will be supplied in a standard configuration to allow ease of access to oil-fill ports, filters, and service points. The engine will be accessorized and installed to drive the hydraulic power system as follows: 24 VDC ECM and electronics 24 VDC Alternator SAE Flywheel housing w/ clutch drive 24 VDC Starter Spin-on Fuel Filtration System Spin-on Water Filtration System Spin-on Lube Oil Filtration System Safety derates included in Engine Calibration Heavy duty air cleaner pair w/ high filtration pre-cleaners and restriction indicator Carbon steel muffler w/ spark arrestor and carbon steel rain cap Heavy duty muffler brackets suitable for rough terrain Stainless steel flex connector from turbo exhaust connection to muffler intake Durst Style or Equivalent Pump Drive installed directly to the flywheel housing Vertically mounted Radiator/Cooling Assembly (120F) with sections for the following: Engine Jacket Water System (Air to Water) Hydraulic Cooler Core (Air to Oil) Fuel Cooler Core (Air to Fuel) 2.2.2 Fuel System This unit will be equipped with a diesel fuel storage and distribution system with the following specifications: One 200 Gallon Fuel Tank configured as follows: Aluminum construction Cylindrical build w/ capped ends Inline fuel heater for cold weather operations 2” Drain valve on the tank Tank breather fitting Filtration screen installed in fill neck Fuel level sender unit Tank fill neck accessible from the ground for filling on road-side Tanks “soft” mounted to unit via rubber lined straps and cradles 2.2.3 Hydraulics System Hydraulic power will be installed on this unit with circuits to drive the following items: One closed loop circuit to power the unit suction pump Five hydraulic powered mixing agitators in the main tank Two Liquid chemical metering pumps for gel Two Chemical tote agitators Four unit stabilizer / level control cylinders Three hydraulically controlled Weir gates in main tank Hydraulic Oil cooling loop Hydraulically Driven Process Valve Actuators as needed Features of the hydraulic system to include: Pressure compensated piston hydraulic pump technology Hydraulic valve stack(s) to control hydraulic flow to open loop components Common hydraulic reservoir equipped as follows: Steel construction Internal baffling to stabilize hydraulic fluid returns and suctions Removable suction strainer assemblies Tank mounted filters and common inlet/outlet manifolds Heat exchanger for cold weather service – Optional Equipment Level gauge visible from the side of the unit Oil temperature sensor Filtered fill port Filtered breather cap Clean out covers/man way access All hosing, fittings, and tubing necessary to complete the system. All standard cleanliness and “pigging” procedures will be followed in hose construction and installation. 2.3 Fluid Handling System 2.3.1 Discharge Piping & Manifold The discharge manifold will be installed on the road-side of the unit. The discharge manifold will be connected to the main tank outlet and flow to the manifold will be controlled via a hydraulic actuated butterfly valve. The discharge manifold shall be constructed with twelve (12) 4 inch Fig 206 union, thread half connections. Each Fig 206 union will be equipped with a 4” butterfly valve and cap with chain. 2.3.2 Suction Pump Installed on the curb-side of the unit will be a hydraulically driven suction centrifugal pump. 2.3.3 Suction Piping & Manifold Installed on the curb-side of the unit shall be an integrated manifold assembly consisting of the low pressure inlet piping, centrifugal pump, and discharge piping to the main hydration tank. The inlet piping shall consist of twelve (12) 4 inch Fig 206 union, wing half connections. Each union connection shall include a 4” butterfly valve. The centrifugal pump shall be installed at the outlet of the suction manifold. The pump discharge piping includes a Turbine flow meter and a magnetic flow meter for accurate measurement of flow rate. After the flow meters, the pump discharge piping runs to the main hydration tank inlet. All piping shall be constructed with appropriate Victaulic and flanged connections to facilitate removal for service. 2.4 Hydration / Liquid Additive Tanks and Systems 2.4.1 Main Tank The following documentation will be provided with each unit: One electronic copy on CD of the Unit Operations and Service Manual One hard copy of the Unit Operations and Service Manual

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