Project background
The client is one of oilfield service companies that is into hydraulic fracturing. They increase well flow rates. Hydraulic fracturing Fleet usually consists of 7-8 or more units of equipment. Its basis is a hydraulic fracturing plunger pumping unit installed on the truck chassis. (up to 5 pumps are simultaneously connected to the well via special adapters), which can make pressure up to 1000 atmospheres. For example, the tire pressure of a passenger car rarely exceeds 3 atmospheres.
The client suffered from high costs due to enormous fuel consumption (according to thew crew member of one unit, was more than 200 liters of diesel per hour). This was considered to be overruns and difficult working conditions - cold weather and low temperature of chemical mixture.
They tried to double-check the process, conduct field tests and measurements, but did not come up with the solution. It was needed to create the system that would work reliably and efficiently in the North harsh conditions.
Challenges
- Monitor engine parameters
- Receive data from sensors of mixture flow rate and control pressure in the well
- Monitor fuel, avoid draining
Solution
The client needed to obtain data on the of the Mercedes-Benz Actros engine parameters and control one more engine, mounted on the truck to supply a plunger pump (by MTU or Detroit Diesel from 2000 hp).
Frac fleet is a complex operation with large number of sensors and heating lines, even in fuel tanks. It was difficult to reach tanks as there were many wires, pipes, metal platforms and other communications. This made it tricky to install fuel level sensors.
Integrator specialists opted for Galileosky 7x tracking units with two CAN buses support. After FLS calibrating, specialists began to parse data from CAN buses of 2 engines: RPM, coolant temperature, mileage, gas and brake pedals position, headlights, seat belt, instant and general fuel consumption and data from two Webasto units.
During the CAN bus reverse engineering of the equipment, specialists used the J1939 protocol with 29 bits at a speed of 500,000 kbit / s. They got data about engine speed, temperature, pressure of antifreeze and oil. Moreover, they managed to monitor Allison automatic transmission parameters: gears shifting and chemical mixture consumption.
Test runs took place in the GSM coverage area. The client wanted to make sure that the Wi-Fi solution will work reliably when the equipment goes to the quarry or to hard-to-reach object. For this, the integrator specialists disabled all SIM-cards at the devices and reproduced conditions close to reality. The equipment worked properly and transmitted data via Wi-Fi stably, without any losses.
After the company top-management was convinced the system is reliable, the remaining machines were equipped and sent by ferry to the area of the airport, where temperature is sometimes -55 ° C.
