SBF-615 Operations V1 1 3842979 01

Stimulation Blender Truck
SBT-615 Operations Manual

Reference: InTouch content ID 3842979
Version: 1.1
Release Date: 18-May-2010
EDMS UID: 1653786795
Produced: 19-May-2010 15:13:21
Owner: Well Services WSD
Author: Hau Pham
Private SCD,SBT,615,SB T-615,operations,blending,pro ppant,Prop NET
Copyright © 2010 Schlumberger, Unpublished Work. All rights reserved.

SBT-615 Operations Manual / Legal Information
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This work contains the confidential and proprietary trade secrets of Schlumberger
and may not be copied or stored in an information retrieval system, transferred,
used, distributed, translated or retransmitted in any form or by any means,
Well Services WSD\Hau Pham\InTouch content ID 3842979\1.1\Release Date:18-May-2010\EDMS UID: 1653786795\Produced: 19-May-2010 15:13:21
electronic or mechanical, in whole or in part, without the express written

permission of the copyright owner.
Trademarks & Service marks
Schlumberger, the Schlumberger logotype, and other words or symbols used

to identify the products and services described herein are either trademarks,
trade names or service marks of Schlumberger and its licensors, or are the
property of their respective owners. These marks may not be copied, imitated
or used, in whole or in part, without the express prior written permission of
Schlumberger. In addition, covers, page headers, custom graphics, icons, and
other design elements may be service marks, trademarks, and/or trade dress
of Schlumberger, and may not be copied, imitated, or used, in whole or in part,
without the express prior written permission of Schlumberger.
A complete list of Schlumberger marks may be viewed at the Schlumberger

Oilfield Services Marks page: http://markslist.slb.com
Marks of Schlumberger include but may not be limited to DataFRAC, FracCAT,
POD, PodSTREAK, SBF-624, SUP-511, SUP-512.
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SBT-615 Operations Manual / Document Control
Document Control
Owner: Well Services WSD
Author: Hau Pham
Reviewer: Hau Pham
Approver: Juurong Hsieh

Contact Information
Name: Well Services WSD
LDAP Alias: scd-doc
Revision History
Version Date Description Prepared by
1.1 13-May-2010 Added the HiWAY information to the Unit Author: Marcos Kajita
Operations Section.
1.0 18-Aug-2005 Original issue date. Author:
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v SBT-615 Operations Manual / Table of Contents v
Table of Contents
1 Introduction ____________________________________________________ 1-1

1.1 Application overview _________________________________________ 1-1
1.2 General equipment overview and unit layout ___________________ 1-2
1.3 Specifications ________________________________________________ 1-4
1.4 Scope of this manual _________________________________________ 1-6
2 QHSE __________________________________________________________ 2-1

2.1 Safety standards and PPE ____________________________________ 2-1
2.2 Personnel safety _____________________________________________ 2-2
2.3 Equipment safety ____________________________________________ 2-2
2.4 Environmental safety _________________________________________ 2-4
2.5 Transportation _______________________________________________ 2-4
3 Unit operations _________________________________________________ 3-1

3.1 Power-up procedure _________________________________________ 3-1
3.2 Hydraulic and pneumatic system control _______________________ 3-8
3.3 Control cabin system overview _______________________________ 3-10
3.4 POD control software overview ______________________________ 3-16
3.5 Remote engine operation ____________________________________ 3-66
3.6 System plumbing and valve operation ________________________ 3-68
3.7 Header tank level control system operation ___________________ 3-84
3.8 Centrifugal pump operation __________________________________ 3-88
3.9 POD system operation ______________________________________ 3-90
3.10 Webasto winterization kit (optional equipment) _______________ 3-130
4 Job preparation ________________________________________________ 4-1

4.1 Pre-trip inspection ____________________________________________ 4-1
4.2 Unit spotting and hookup _____________________________________ 4-5
5 Job execution __________________________________________________ 5-1

5.1 Typical unit startup sequence on location during equipment
rig-up _______________________________________________________ 5-1
5.2 Mixer and triplex pump prime-up ______________________________ 5-3
5.3 Normal job operations ________________________________________ 5-4
5.4 Emergency manual mode of operation ________________________ 5-8
5.5 Normal shutdown procedure _________________________________ 5-10
5.6 Wash-up and drainage procedure ____________________________ 5-11
5.7 Service and maintenance ____________________________________ 5-11
6 Troubleshooting ________________________________________________ 6-1

6.1 Power, communication, and software troubleshooting __________ 6-1
6.2 Device troubleshooting _______________________________________ 6-4
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6.3 Circuits troubleshooting ______________________________________ 6-8

6.4 Electronics troubleshooting ___________________________________ 6-8
Appendices
A Forms and checklists __________________________________________ A-1

A.1 Driver’s trip report DS98-2-A __________________________________ A-2
A.2 STEMs forms ________________________________________________ A-4
B High-rate hopper gate position charts for various proppants ___ B-1
B.1 20–40 sand, SGU = 2.65, size factor = 1.0 _____________________ B-2
B.2 30–60 or 40–70 sand, SGU = 2.65, size factor = 1.17 __________ B-4
B.3 20–40 resin-coated sand, SGU = 2.53, size factor = 1.0 ________ B-6
B.4 30–60 or 40–70 resin-coated sand, SGU = 2.53, size factor =
1.17 _________________________________________________________ B-8
B.5 16–30 high-strength proppant, SGU = 3.55, size factor = 0.9 ___ B-10
B.6 20–40 high-strength proppant, SGU = 3.55, size factor = 1.0 ___ B-12
B.7 30–60 or 40–70 high-strength proppant, SGU = 3.55, size factor =
1.17 ________________________________________________________ B-14
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List of Figures
1-1 PodSTREAK roadside view ________________________________________ 1-3

1-2 PodSTREAK curbside view ________________________________________ 1-3
1-3 PodSTREAK underside view _______________________________________ 1-4
1-4 SBT-615 PodSTREAK performance envelope _______________________ 1-6
3-1 Shifting switch on transmission gear stick ___________________________ 3-1
3-2 Dashboard PTO switch locations ___________________________________ 3-2

3-3 Onan electrical generator for control cabin __________________________ 3-4
3-4 Control cabin power panel__________________________________________ 3-5
3-5 Switches on curbside battery box ___________________________________ 3-6
3-6 Shore power connection ___________________________________________ 3-7
3-7 Shore power pin diagram of power cable plug _______________________ 3-8
3-8 Apitech valves and backup control console _________________________ 3-10
3-9 Control cabin layout ______________________________________________ 3-11
3-10 Control cabin folding stairway deployment__________________________ 3-12
3-11 Location of power selector switch, junction box, and wireless box ____ 3-14
3-12 Control cabin with deployed satellite dish___________________________ 3-15
3-13 Satellite dish control panel ________________________________________ 3-15
3-14 Main screen ______________________________________________________ 3-17
3-15 Keypad dialog ____________________________________________________ 3-23
3-16 Zero setpoints dialog______________________________________________ 3-23
3-17 Backups Control screen___________________________________________ 3-24
3-18 Zero totalizers dialog______________________________________________ 3-27
3-19 Automated Diagnostics screen ____________________________________ 3-28
3-20 Wellsite Network Diagnostics dialog _______________________________ 3-32
3-21 Detailed Diagnostics screen _______________________________________ 3-33
3-22 Detailed Diagnostics screen functions with alternative (toggled) units 3-34
3-23 Calibration Control screen_________________________________________ 3-36
3-24 HiWAY Mode enabled_____________________________________________ 3-40
3-25 Advanced Calibration screen ______________________________________ 3-41
3-26 Configure DCU dialog_____________________________________________ 3-43
3-27 Gate calibration mode selection ___________________________________ 3-45
3-28 Manual gate calibration screen ____________________________________ 3-46
3-29 Automatic gate calibration screen __________________________________ 3-47
3-30 Gate opening point test in progress ________________________________ 3-48
3-31 Gate opening point test completed successfully_____________________ 3-50
3-32 Gate closing point test ____________________________________________ 3-51
3-33 Gate closing point test in progress _________________________________ 3-52
3-34 Gate closing point test completed successfully______________________ 3-53
3-35 Basic gate speed test _____________________________________________ 3-54
3-36 Basic gate speed test in progress __________________________________ 3-55
3-37 Basic gate speed test successful __________________________________ 3-56
3-38 Advanced gate velocity test _______________________________________ 3-57
3-39 Advanced gate velocity test in progress ____________________________ 3-58
3-40 Advanced gate velocity test successful_____________________________ 3-59
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viii SBT-615 Operations Manual / List of Figures viii
3-41 Gate response test screen ________________________________________ 3-60

3-42 Gate response test in progress ____________________________________ 3-61
3-43 Gate response test successful_____________________________________ 3-62
3-44 Engine Control screen (full version) ________________________________ 3-63
3-45 Major components of the plumbing system (curbside view) __________ 3-69
3-46 Major components of the plumbing system (roadside view) __________ 3-70
3-47 System plumbing diagram_________________________________________ 3-71
3-48 Valve layout diagram______________________________________________ 3-72
3-49 Valve operations from the POD Main Control screen ________________ 3-74
3-50 Close-up view of the backup console switches______________________ 3-75

3-51 Manual valve for header tank bypass ______________________________ 3-76
3-52 Flow diagram of DOWNHOLE operation with header tank ___________ 3-78
3-53 Flow diagram of DOWNHOLE operation without header tank ________ 3-79
3-54 Flow diagram of RECIRCULATE operation during pump prime-up ___ 3-80
3-55 Flow diagram of ISOLATE operation _______________________________ 3-81
3-56 Flow diagram of C-pump flow direct to discharge manifold___________ 3-83
3-57 Header tank with roadside ladder and storage basket _______________ 3-85
3-58 Back view of header tank assembly ________________________________ 3-86
3-59 Header tank level control from the Engine Control screen ___________ 3-87
3-60 Location of manual fill valve M1 for header tank ____________________ 3-88
3-61 C-pump PTO switch location on dashboard_________________________ 3-89
3-62 Location of 8x6 C-pump – bottom perspective ______________________ 3-89
3-63 Location of direct engine-driven 8x6 C-pump – profile perspective ___ 3-90
3-64 Mixer assembly components, part 1 of 3 ___________________________ 3-91
3-67 Internal mixer components (cutaway view) _________________________ 3-94
3-68 Main Control screen with activated proppant control_________________ 3-95
3-69 Zero Setpoints screen ____________________________________________ 3-97
3-70 Numeric keypad for manual entry __________________________________ 3-97
3-71 Main Control screen with activated mixer speed function ____________ 3-98
3-72 Proppant property entry fields on the Calibration screen ____________ 3-100
3-73 Calibrate gate procedure window _________________________________ 3-101
3-74 Dry add feeder modules__________________________________________ 3-104
3-75 Main Control screen with activated dry add control _________________ 3-106
3-76 Dry add screw factor entry fields __________________________________ 3-110
3-77 Location for marking conditioning screws of dry add feeders ________ 3-112
3-78 Fiber Feeder ____________________________________________________ 3-114
3-79 Main Control screen with activated fiber control ____________________ 3-116
3-80 Densitometer source ON _________________________________________ 3-120
3-81 Accessing the Densitometer Air Calibration screen_________________ 3-121
3-82 Densitometer Air Calibration Control screen _______________________ 3-122
3-83 Accessing the Densitometer Water Calibration screen______________ 3-123
3-84 Densitometer Water Calibration control screen ____________________ 3-124
3-85 Accessing the Zero on Pad screen________________________________ 3-125
3-86 Zero on Pad screen______________________________________________ 3-126
3-87 Main Control screen with activated LAS1 control ___________________ 3-127
3-88 Accessing the LAS Calibration window from the Calibration screen _ 3-129
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3-89 Liquid Add Tachometer Calibration screen_________________________ 3-130

3-90 Location of Webasto heater and auxiliary 80-gal fuel tank __________ 3-131
3-91 Location of Webasto timer control panel and Emergency Kill switch _ 3-132
4-1 Typical equipment setup on location ________________________________ 4-6
4-2 Configuration with one PCM and one LTM___________________________ 4-7
4-3 Configuration with one chemical float, one PCM, and one Sand Chief _ 4-8
4-4 2-in prime-up connection __________________________________________ 4-10
4-5 Typical LAS-to-offboard tank setup_________________________________ 4-11
5-1 Air-actuated valves ________________________________________________ 5-9
B-1 20–40 sand, SGU = 2.65, size factor = 1.0 __________________________ B-2
B-2 30–60 or 40–70 sand, SGU = 2.65, size factor = 1.17 ________________ B-4
B-3 20–40 resin-coated sand, SGU = 2.53, size factor = 1.0 ______________ B-6
B-4 30–60 or 40–70 resin-coated sand, SGU = 2.53, size factor = 1.17____ B-8
B-5 16–30 high-strength proppant, SGU = 3.55, size factor = 0.9 ________ B-10
B-6 20–40 high-strength proppant, SGU = 3.55, size factor = 1.0 ________ B-12
B-7 30–60 or 40–70 high-strength proppant, SGU = 3.55, size factor =
1.17 _____________________________________________________________ B-14
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xi SBT-615 Operations Manual / List of Tables xi
List of Tables
1-1 General Specifications _____________________________________________ 1-4

3-1 Proppant Controls ________________________________________________ 3-18
3-2 Liquid Add Controls _______________________________________________ 3-20
3-3 Dry Add Controls _________________________________________________ 3-21
3-4 Fiber Controls ____________________________________________________ 3-21
3-5 Mixer Controls____________________________________________________ 3-22

3-6 General Controls _________________________________________________ 3-22
3-7 Backup Controls __________________________________________________ 3-24
3-8 Automated Diagnostics Screen Function Descriptions _______________ 3-28
3-9 Detailed Diagnostics Screen Function Descriptions _________________ 3-33
3-10 Detailed Diagnostics Screen Alternative Display Units_______________ 3-35
3-11 Calibration Controls_______________________________________________ 3-37
3-12 Advanced Calibration Controls ____________________________________ 3-41
3-13 Engine Controls __________________________________________________ 3-63
3-14 Toggled Units in Engine Diagnostics Display________________________ 3-65
3-15 Valve Description _________________________________________________ 3-73
3-16 Valve Configurations for Major POD Functions______________________ 3-74
3-17 Proppant Control Screen Details___________________________________ 3-95
3-18 Mixer Speed Relationships for Selected Engine Speeds_____________ 3-97
3-19 Mixer Speed Control Function Descriptions_________________________ 3-98
3-20 Dry Additive Main Screen Functions _____________________________ 3-106
3-21 Screw Size Chart (English Units) _________________________________ 3-108
3-22 Screw Size Chart (Metric Units)___________________________________ 3-108
3-23 Dry Add Feeder Modes of Operation ______________________________ 3-111
3-24 Fiber Feeder Main Screen Functions______________________________ 3-117
3-25 Screw Size Selection for Two Major Fiber Types ___________________ 3-118
3-26 Fiber Feeder Modes of Operation _________________________________ 3-118
3-27 Functions of the Liquid Additives Main Screen _____________________ 3-127
6-1 Absence of Communication Between the Equipment and FracCAT____ 6-1
6-2 Computer(s) Will Not Power On ____________________________________ 6-2
6-3 Touchscreens Will Not Power Up ___________________________________ 6-2
6-4 POD Control Software Problems____________________________________ 6-3
6-5 Engine Will Not Start, Or Runs With Low Output Power ______________ 6-4
6-6 Mixer Gearbox Not Working Correctly _______________________________ 6-6
6-7 The Gate Does Not Move Correctly _________________________________ 6-7
6-8 No Power for an Electrical Device __________________________________ 6-8
6-9 No Densitometer Signal ____________________________________________ 6-9
6-10 No Flowmeter Signal______________________________________________ 6-10
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1-i SBT-615 Operations Manual / Introduction 1-i
1 Introduction
1.1 Application overview ___________________________________________ 1-1
1.2 General equipment overview and unit layout ___________________ 1-2
1.3 Specifications __________________________________________________ 1-4
1.3.1 Specifications ________________________________________________ 1-4
1.4 Scope of this manual ___________________________________________ 1-6
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1-1 SBT-615 Operations Manual / Introduction 1-1
1 Introduction IPC,SBT,615,SBT-615,blender,stimulation,POD,proppant,operations,Introduction
1.1 Application overview

The PodSTREAK Stimulation Blender Truck Model 615 (SBT-615, also known as
SBT-615 6x4 PodSTREAK) is a truck-mounted, direct engine-driven fracturing
service blender that blends and pumps fracturing slurry in well stimulation
applications.
An integrated deck-mounted control cabin with FracCAT software provides the

same control of all essential functions as the full-sized FracCAT unit including
job design and monitoring functions, programmable optimum density (POD)
operations, and remote control of stimulation pumps.
The onboard POD computers precisely control the solid-to-liquid ratio of the
proppant-laden slurry at design values in either ramp or stair-step incremental
mode. The operating system can run in a fully automated mode with setpoints
received from the operator or from a host system, such as FracCAT.
A 10-bbl capacity header tank, working in conjunction with an 8x6 direct-driven

centrifugal pump, supplies fluid to the mixer suction intake. An automatic variable
valve system controls the header tank fluid level to maintain suction head
pressure to the mixer inlet.
The standard SBT-615 POD configuration features an elevated gate and hopper
system that is similar in design to the SBF-624. The calibrated gate system,
actuated with a hydraulic cylinder, regulates the flow of proppant passing through
the gate and into the mixer. The elevated height of the high-capacity hopper
requires a Sand Chief or sand belt to dispense proppant into a hopper at a height
of about 8.5 ft from the ground and mounted directly above the gate. The gate
system utilizes slurry proppant concentration feedback from a densitometer and
a flowmeter to automatically regulate gate position.
The 500-BHP Caterpillar C-15 engine on the SBT-615 directly powers the
blender driveline, hydraulic systems, centrifugal pump operation, and on-road
motoring functions.
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The unit comes standard with the following:
• one Fiber feeder

• two dry additive feeder modules
• two SUP-511 liquid additive system (LAS) modules
• one SUP-512 LAS module
• provisions for storing suction and discharge hoses (hoses not supplied with
the unit) and miscellaneous fittings.
Optional configurations available include:
• winterized unit version for cold climate operation

• any combination of LAS modules ranging from none to up to four modules,
with no more than two SUP-512 modules because of hydraulic system
limitations
• room for up to two optional tote tanks, depending on space availability due to
the number of LAS modules selected.
1.2 General equipment overview and unit layout

• Peterbilt heavy-version 357 6x4 chassis (11 5/8-in high chassis rails) with
conventional front cab
• deck-mounted control cabin with FracCAT system
• work platform with provisions for LAS installation and cargo storage
• Caterpillar C-15 diesel engine
• direct-driven 8x6 centrifugal pump (C-pump)
• direct-driven POD mixer
• two dry additive feeder modules
• Fiber feeder
• Onan diesel electric generator
• suction manifold flowmeter
• discharge manifold slurry densitometer
• right-angle mixer gearbox with independent lubrication circuit and built-in
lubrication pump, driven directly by the gearbox itself
• POD operator touchscreen panel
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• 10 bbl-capacity header tank/hydraulic fluid tank assembly integrated within a

heavy-duty rollover protection frame
• patented dual-jack screw-based forklift-type system for raising and lowering
the mixer assembly to respective on-road and frac job positions
• elevated high-capacity hopper and gate system
• two SUP-511 LAS modules
• one SUP-512 LAS module.
Figure 1-1: PodSTREAK roadside view
Figure 1-2: PodSTREAK curbside view
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Figure 1-3: PodSTREAK underside view
1.3 Specifications
1.3.1 Specifications
Table 1-1: General Specifications
Truck Chassis Peterbilt 357 heavy version

Truck Engine Caterpillar C15 diesel
500 BHP @ 2,100 rpm
515 BHP @ 1,500 rpm
1650 LB-FT @ 1,200 rpm
Transmission Fuller FRO16210C 10 speed
Remote PTO MVG2000SD
Hydraulics Parker hydraulic pump, filters, and fittings
– Apitech valve cluster
– Chelsea PTO mounted on transmission
Drive Train 6x4 with Spicer 1810 series driveshafts
Length 516 in
Width 102 in
Height 161 in
Wheelbase 310 in
Weight - Front Approximately 18,000 lbm*
Weight - Rear Approximately 34,950 lbm*
Total Weight Approximately 52,950 lbm*
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Tires – Front (2) Bridgestone M-844F

425/65R22.5 LRL-20PR
Tires – Rear (8) Bridgestone M-843
11R22.5 LRH-16PR
Mixer Patented Dowell vortex mixer with high-rate
hopper and trapezoidal gate orifice
Maximum Discharge Pressure 100 psi
Maximum Slurry Rate at 100% Engine See performance envelope graph (Figure 4)**
Load
Additive Systems
Liquid Add Systems 3 LAS modules:
- (2) SUP-511 modules (standard with unit)
- (1) SUP-512 module (standard with unit)
- (1) tote tank optional
Fiber Feeder System One fiber feeder comes standard with unit. Fiber
metering rate ranges from 17.5 lbm/min to 350
lbm/min, depending on motor speed and metered
fiber material.
DryAdd Systems Two dry add feeders come standard with unit.
Dry add metering rate per feeder ranges from
0.62 lbm/min to 65.8 lbm/min depending on motor
speed, screw type, and metered material.
Gauges English and Metric
Control Cabin 120-in long cabin
Electrical Generator Onan 7.5 kW diesel generator
* Weights are without hoses, connections, chemicals, and/or miscellaneous

materials included.
Note
The SBT-615 6x4 PodSTREAK unit is overweight on all front and rear axles
according to US D.O.T. regulations and requires a yearly permit to work and
travel in the United States. Observe and comply with the regulations of the
regions the unit is intended to work in with regard to weight restrictions, and
obtain the proper permits wherever applicable.
** The performance envelope is extrapolated based on test data using 20–40

sand flowing through the high-rate gate at about 10,500 lbm/min and 1,400
rpm POD mixer speed at close to 100% engine load. Data points achieved
during testing were: 37.0 bbl/min at 9.6 PPA and 97.3 % engine load; and 42.4
bbl/min at 5.5 PPA and 98.9% engine load. Since data is lacking to define higher
PPA values and corresponding bbl/min rates along the 10,500 lbm/min 20–40
sand rate curve, bbl/min rates for PPA values significantly higher than 10 PPA
should be met with caution due to triplex pump limitations and other equipment
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considerations. Additionally, the chart stops at 42.4 bpm at 5.5 PPA; however,
this does not necessarily mean that higher rates and correspondingly lower PPA
values cannot be achieved up to the ultimate horsepower limit of the engine.
Further data is necessary past 42.4 bbl/min to define the maximum bbl/min and
corresponding PPA achievable as advertised limits for the unit.
Figure 1-4: SBT-615 PodSTREAK performance envelope
1.4 Scope of this manual

The SBT-615 Maintenance Manual includes these additional topics:
• QHSE
• General specifications
• Circuit descriptions
• Maintenance
• Spare parts list
• Bills of material and drawings
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2-i SBT-615 Operations Manual / QHSE 2-i
2 QHSE
2.1 Safety standards and PPE ______________________________________ 2-1
2.2 Personnel safety _______________________________________________ 2-2
2.3 Equipment safety ______________________________________________ 2-2
2.3.1 Pre-trip safety inspections ____________________________________ 2-2
2.3.2 Pre-job safety checklist _______________________________________ 2-4
2.4 Environmental safety ___________________________________________ 2-4
2.5 Transportation _________________________________________________ 2-4

2.5.1 Driving to the location ________________________________________ 2-4
2.5.2 On location __________________________________________________ 2-4
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2-1 SBT-615 Operations Manual / QHSE 2-1
2 QHSE SCD,SBT,615,SBT-615,operations,QHSE
Due to the many hazards in the oilfield industry, all Schlumberger employees
must be familiar with the appropriate safety regulations and precautions
described in Well Services Field Safety Handbook, InTouch content ID#

3038407. Anyone who feels that an operation is unsafe has the right, and the
duty, to stop the operation.
Note
The Well Services Field Safety Handbook is the current safety standards
document, replacing the Safety and Loss Prevention Manual (SLPM).
2.1 Safety standards and PPE

Before handling chemicals, take the time to review the applicable Material Safety
Data Sheets (MSDS) regarding personal protective equipment (PPE) and
handling procedures. PPE is important, but does not in itself prevent accidents;
that is the responsibility of the individual – you. It is vital that you have a working
knowledge of Well Services Safety Standard 5, Safety Standard 9, and Safety
Standard 11, and that you put into practice the information contained in these
standards.
You should also be familiar with the following:
• Motor vehicles and utility trailers, a part of the QHSE S001: Journey
Management and Driving, InTouch content ID# 3051691
• QHSE S002: Reporting, InTouch content ID# 3260257
• QHSE S007: Management System Audit, InTouch content ID# 3260262
• Well Services Safety Standard 4: General Facility and Workshop, InTouch
content ID# #3313678
• Well Services Safety Standard 15: Lockout/Tagout, InTouch content ID#
3313691
• Well Services Safety Standard 17: Storage and Handling of Oxidizers,
InTouch content ID# 3313693
• Well Services Safety Standard 18: Chemical Hazard Communication
(HAZCOM) and Material Handling, InTouch content ID# 3313694
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• Well Services Safety Standard 30: Pumping Combustible and Flammable

Fluids, InTouch content ID# 3313709
• Radiation Safety Manual, InTouch content ID# 3311641
2.2 Personnel safety

Ensure that all relevant procedures and standards are followed at all times.
Make certain that personnel always wear the required PPE when around the unit.
It is important to remember the dangers of heat generated by this unit. The

exhaust system and other parts of the engine become extremely hot during
operation, and can cause severe burns.
Be aware of all moving parts on the unit while it is in operation. All nonessential
personnel should stay away from the unit during operation. If it is necessary to
climb up on the unit, exercise extreme caution.
Potential Severity: Serious

Potential Loss: Personnel
Hazard Category: Human, Temperature
Do not climb on the engine while it is in operation.
2.3 Equipment safety

Equipment should be maintained according to the standard equipment
maintenance (STEM) system (see Appendix A). In addition, complete the
following Schlumberger preventive maintenance checklists, samples of which
are available in Appendix A.
• Driver’s Trip Report DS-598-2-A

Appendix A.1 Drivers Trip Report DS-598-2-A
• Auxiliary Equipment Check (STEMs forms) Auxiliary Equipment Check Sheet
DS-587-E
2.3.1 Pre-trip safety inspections

Perform the following safety inspections before the truck leaves the district:
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• Schlumberger 15-point checklist, as applicable for the unit. This is part of

QHSE Standard S001.
• The four-point brake checklist, also found in the Safety Standards for Well
Services Operations.
• Verify that radioactive sources are locked in the OFF position and/or secured.
• If fuel is added before leaving the district, refer to Well Services Safety
Standard 30, InTouch content ID# 3313709.
• Review deficiencies recorded on the unit from the previous job.

• Review all appropriate MSDS, and place them in the tractor cab.
• Properly store or tie down all loose equipment.
• Ensure that a first aid kit is present.
• Check the capacity and condition of the fire extinguisher.
• Check the eye wash bottle. Fill it if the level is low, or clean and refill it if
the water looks unsafe.
• Check that the LAS access platform is secured in its stowed position.
• Check that the cable reel compartment access platform is secured in its
stowed position.
In addition, check the following items on the unit:
• water coolant level

• engine oil level
• hydraulic oil tank level
• gearbox lube oil level
• fuel tank level (when filling the fuel tank)
• the presence of oil or air leaks.
Before leaving the district, the operator should complete the following steps:
1. Run the engine at idle for approximately 5 minutes.

2. Throttle the engine to full.
3. Run the unit for approximately 10 minutes to circulate the hydraulics and
ensure there are no abnormal sounds to the unit.
4. Walk around to check for any air, hydraulic, and lube oil leaks.
5. Throttle down the engine to idle.
6. Allow the engine to idle for 5 more minutes.
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7. Shut down the unit.
2.3.2 Pre-job safety checklist

Always be alert for emergency situations. Failure to spot signs of trouble can
result in equipment damage and/or personal injury.
• Conduct a pre-job safety meeting with Schlumberger employees and the

customer’s employees at the field location.

• Review each person’s responsibilities to be performed during the job.
• Tag or mark off any hazardous areas if this is required by the Schlumberger
district or field location.
• While the unit is being warmed up before the job, the operator should perform
a quick walk-around inspection of the unit.
2.4 Environmental safety

Any chemical spill must be contained, cleaned up, and reported according to
local procedures. Refer to Well Services Safety Standard 17, InTouch content
ID# 3313693 and Well Services Safety Standard 18, InTouch content ID#
3313694 for more information.
Dispose of oils, filters, and batteries in an environmentally acceptable way and

in accordance with local regulations.
2.5 Transportation
2.5.1 Driving to the location

You may proceed to the job location only after completing the requirements of
the pre-trip inspection. Travel must comply with the QHSE Standard S001.
2.5.2 On location
Position the unit on location as instructed by the supervisor. Once on location,
you are required to comply with Schlumberger Well Services Safety Standard 5,
InTouch content ID# 3313681.
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3-i SBT-615 Operations Manual / Unit operations 3-i
3 Unit operations
3.1 Power-up procedure ___________________________________________ 3-1
3.2 Hydraulic and pneumatic system control _______________________ 3-8
3.3 Control cabin system overview ________________________________ 3-10
3.3.1 Cabin layout ________________________________________________ 3-10
3.3.2 Cable reel connection _______________________________________ 3-12
3.3.3 Satellite dish operation ______________________________________ 3-14
3.3.4 FracCAT software operation _________________________________ 3-16

3.4 POD control software overview ________________________________ 3-16
3.4.1 Main Control screen _________________________________________ 3-16
3.4.2 Backups Control screen _____________________________________ 3-24
3.4.3 Diagnostics Control screens (Automated and Detailed) ________ 3-27
3.4.4 Calibration Control screens (General and Advanced) __________ 3-36
3.4.4.1 HiWAY gate calibration __________________________________ 3-44
Manual HiWAY gate calibration _______________________ 3-45
Automatic HiWAY gate calibration _____________________ 3-46
3.4.5 Engine Control screen _______________________________________ 3-62
3.5 Remote engine operation ______________________________________ 3-66
3.5.1 Manual engine speed control ________________________________ 3-67
3.6 System plumbing and valve operation _________________________ 3-68
3.6.1 Plumbing layout _____________________________________________ 3-68
3.6.2 Valve layout ________________________________________________ 3-71
3.6.3 Valve operations from the POD Control touchscreen __________ 3-73
3.7 Header tank level control system operation ___________________ 3-84
3.8 Centrifugal pump operation ___________________________________ 3-88
3.9 POD system operation ________________________________________ 3-90
3.9.1 Mixer module operation _____________________________________ 3-94
3.9.1.1 Proppant control _________________________________________ 3-94
3.9.1.2 Mixer speed control ______________________________________ 3-97
3.9.1.3 Gate system operation ___________________________________ 3-99
3.9.1.4 Lifting system operation _________________________________ 3-102
3.9.1.5 Hopper cover operation _________________________________ 3-102
3.9.1.6 Digital camera __________________________________________ 3-102
3.9.2 Dry add feeder operation ___________________________________ 3-103
3.9.2.1 Hazards _______________________________________________ 3-105
3.9.2.2 Initial setup ____________________________________________ 3-105
3.9.2.3 Normal operation _______________________________________ 3-110
3.9.2.4 Backup operation (Emergency procedures) ______________ 3-111
3.9.2.5 Typical problems _______________________________________ 3-113
3.9.3 Fiber Feeder _______________________________________________ 3-114
3.9.3.1 Hazards _______________________________________________ 3-115
3.9.3.2 Initial setup ____________________________________________ 3-116
3.9.3.3 Normal operation _______________________________________ 3-118
3.9.3.4 Backup operation (Emergency procedures) ______________ 3-119
3.9.4 Densitometer operation ____________________________________ 3-120
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3-ii SBT-615 Operations Manual / Unit operations 3-ii
3.9.4.1 Air calibration __________________________________________ 3-120

3.9.4.2 Water calibration _______________________________________ 3-122
3.9.4.3 Zero on Pad ___________________________________________ 3-124
3.9.5 Liquid additive system (LAS) operation ______________________ 3-127
3.9.5.1 LAS tachometer calibration ______________________________ 3-129
3.10 Webasto winterization kit (optional equipment) _______________ 3-130
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3-1 SBT-615 Operations Manual / Unit operations 3-1
3 Unit operations Operations ,blender,LAS,proppant

IPC,SBT,615,SBT-615,operations,Unit
3.1 Power-up procedure

The first step in operating the unit prior to the start of a job is to perform a proper
power-up procedure. The following are important points to bear in mind relative
to unit operation:
1. When using the shifting switch on the transmission gear selector stick (Figure
3-1) to shift the transmission from low gear to high gear, or vice versa, it
is extremely important to toggle the shifting switch while the gear selector
stick is in neutral position, and to listen for a “clank” sound during toggling
before setting the gear selector stick in gear. Toggling the shifting switch with
the gear selector stick in neutral and listening for a “clank” sound indicates
that the mechanical synchronizer in the transmission gear is properly set for
changing gears.
Figure 3-1: Shifting switch on transmission gear stick
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Note
Always toggle the shifting switch before setting the gear selector stick from
low gear to high gear, or vice versa. Absence of the “clank” sound indicates
improper synchronizer engagement, which results in severe damage to the
synchronizer and an inability to run the transmission in high gear. This will
cause a major operating failure on location.
2. After the unit has been set up on location, the hydraulic system is engaged
to lower the mixer to the ground. Use the hydraulic power take-off (PTO)
switch on the dashboard inside the truck cab to engage the hydraulic pump.
While the engine is running, press the clutch pedal down completely before
toggling the PTO switch, then smoothly release the clutch. Refer to Section
3.2 Hydraulic and pneumatic system control (p. 3-8) for more system details.
Figure 3-2: Dashboard PTO switch locations
3. Once on location, be sure to toggle the transfer case PTO switch from the
ROAD position to the PUMP position while the transmission stick is still in
neutral. Keep the stick in NEUTRAL until it is time to run the POD mixer.
When ready to run the mixer, set the transmission stick in 9th gear and turn
on the REMOTE switch on the dashboard to control the engine remotely from
the POD control touchscreen in the control cabin. You must use 9th gear to
obtain the correct maximum mixer speed of approximately 1,400 rpm at full
engine throttle (2,100 rpm engine speed).
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Potential Loss: Assets, Personnel
Hazard Category: Human, Machinery equipment hand tools
It is a safe and best practice to never set the transfer case PTO to PUMP
position before lowering the mixer to the ground; however, no damage will
occur if the transfer case PTO is set to PUMP position before lowering the
mixer as long as the truck engine is at IDLE speed. NEVER RUN THE
ENGINE AT FULL THROTTLE BY STEPPING ON THE ACCELERATOR
PEDAL WHILE THE TRANSFER CASE PTO IS IN PUMP POSITION AND
THE MIXER IS NOT FULLY LOWERED TO THE GROUND. Serious damage
to the equipment and possible injury to personnel can occur when running
the mixer at high speed due to severe driveshaft angularity when the mixer is
in the fully raised position.
4. To engage or disengage the C-pump while the engine is running, press the
clutch pedal down completely before toggling the C-pump PTO switch on
the dashboard inside the truck cab, and then smoothly release the clutch.
Do not engage the C-pump until water supply lines are connected to the
suction manifold of the unit and water is inside the suction piping. Running
the C-pump without water flowing through it will accelerate wear on the
inner C-pump seals. See Section 3.8 Centrifugal pump operation (p. 3-88)
for more information.
5. When powering up the control cabin, the Onan diesel electric generator can
be started using the Start/Stop button either on the Onan generator housing
(Figure 3-3) or on the electrical control panel inside the control cabin (Figure
3-4). Be sure the AC line switch to the right of the START/STOP button
on the Onan generator is set to ON.
It is a good practice to always keep the AC line switch set to ON to save
wear and tear on this switch, since it will be exposed to harsh outside
environmental conditions throughout its operational lifetime.
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Well Services WSD\Hau Pham\InTouch content ID 3842979\1.1\Release Date:18-May-2010\EDMS UID: 1653786795\Produced: 19-May-2010 15:13:21 3-4 SBT-615 Operations Manual / Unit operations 3-4
Figure 3-3: Onan electrical generator for control cabin
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Figure 3-4: Control cabin power panel
6. After starting the generator, switch on the master AC power switch on the
control cabin power panel, along with any other switches required. Make
sure the AC line voltage display shows a reading of about 118 volts indicating
that power is being produced by the generator.
7. Switch the Electronics breaker switch on the passenger-side battery box
to the ON position (Figure 3-5) after turning on the generator and switching
on AC power. Switches for HVAC, which powers systems such as heating,
ventilation, and air conditioning, can also be switched on or off as needed.
Turning on the electronics breaker switch allows the generator to keep the
battery charged via the power inverter. If the generator fails, the inverter will
instantly convert battery power to emergency backup AC power for use by
the control cabin computers.
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Figure 3-5: Switches on curbside battery box
Note
To run the air conditioning system inside the control cabin, the hydraulics PTO
must be engaged and running because the AC compressor is hydraulically
driven. Use the thermostat controls located inside the control cabin to adjust the
cabin temperature as desired.
8. When powering down the control cabin, follow this short procedure:
a. Power down all the computers using the appropriate shutdown for each
particular control software (e.g., SHUTDOWN COMPUTER option on
POD touchscreen and FPC computer).
b. Switch off the main AC power switch on the power panel.
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c. Shut down the Onan generator.

d. Shut off the Electronics switch on the curbside battery box. Make sure
the Electronics switch is shut off to avoid draining the curbside battery.
e. Toggle the Remote switch back to CAB position to prevent the CHECK
ENGINE light from appearing.
9. An external 220 VAC shorepower connection that can be used in place of the
Onan generator is located on the inside of the platform frame (Figure 3-6).
This connection may be needed to perform troubleshooting at the district.

Make sure the pin connections on the power cable match the pin diagram
(when looking at the end of the cable plug), as shown in Figure 3-7.
When using the Onan generator for electrical power, set the power
changeover switch located inside the cable reel compartment of the control
cabin (see section on the control cabin) to GEN. When using shorepower, set
the switch to SHORE.
Figure 3-6: Shore power connection
Refer to the Onan generator operations manual in the SBT-615 Vendor

Maintenance Manual, InTouch content ID# 3882239, for additional
information.
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Figure 3-7: Shore power pin diagram of power cable plug
3.2 Hydraulic and pneumatic system control

The following systems on the SBT-615 require hydraulic power for operation:
• both dry add feeders

• Fiber feeder
• POD hopper cover
• POD lifting system
• POD high-rate gate
• LAS modules
• AC compressor for controlling cabin air-conditioning system (located just
forward of the Onan electrical generator on the driver’s side).
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Engaging the hydraulic system PTO switch on the dashboard inside the truck
cab engages the hydraulic pump, which powers the hydraulic system of the
SBT-615. When engaging or disengaging the PTO while the engine is running,
press the clutch pedal down completely before toggling the PTO switch, and then
smoothly release the clutch. The hydraulic system PTO must be engaged during
the entire job operation to supply power to all the systems that utilize hydraulic
power, including the air-conditioning system for the control cabin.
Use the Apitech valves, mounted on the curb side of the mixer to manually
control these functions:
• raising and lowering the POD assembly

• opening and closing the POD high-rate gate
• opening and closing the POD hopper cover
• regulating motor speed of dry add feeders
• regulating motor speed of fiber feeder.
For more details about the foregoing POD operations with the Apitech valves,
refer to POD operation in this chapter.
The POD computer control system automatically controls the pneumatic

air-actuated valves under normal circumstances. In the event of computer
system failure, the POD operator can control the air-actuated valves manually
using the backup control console mounted on the curb side of the mixer
assembly. The tip of an object, such as a ballpoint pen, is inserted into recessed
buttons associated with major valves in the plumbing system to manually actuate
these valves. For more details about the operational context of the backup
control console, refer to system plumbing and valve operation in this chapter.
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Figure 3-8: Apitech valves and backup control console
3.3 Control cabin system overview
3.3.1 Cabin layout

Figure 3-9 shows the basic layout of the control cabin. Major features include:
• computer tray for housing the computers that run software for FracCAT
(Version 4.3 or higher), POD, FPC, and satellite link-up system
• dual monitors for operating FracCAT in split-screen mode
• POD control system touchscreen panel for controlling the POD, dry add
feeders, fiber feeder, header tank level, LASs, etc.; the SBT-615 operator
practically runs the entire unit from the POD touchscreen
• frac pump control (FPC) touchscreen panel for remote control of frac pump
units by cable connection or through wireless communication
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• hopper camera monitor for monitoring the amount of proppant inside the
POD hopper at any given time
• power control panel (used in unit startup procedure)
• main DCU box for housing electronics interface between various unit sensors
and the computers in the control cabin
• chair for client company representative
• optional FracCAT viewing monitor for client company representative
• video ports for making electronic connections to the optional FracCAT

viewing monitor.
Figure 3-9: Control cabin layout
To deploy the curbside folding stairway mounted just inside of the cabin curbside
door, first climb up the curbside rear deck ladder and then enter the cabin
through the rear door. Once inside the cabin, open the main cabin door and
then carefully lower the stairway, making sure that no personnel are below to
avoid possible injury to others. To stow away the folding stairway at the end of
a job, enter the control cabin and pull up the stairway to bring it into its folded
upright position; close the main door afterwards. Next, exit the cabin through
the rear door and then climb down from the workdeck using one of either side
ladders mounted to the workdeck.
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Figure 3-10: Control cabin folding stairway deployment
To modify the temperature environment inside the cabin, use the controls located
on the air-conditioning unit mounted to the cabin ceiling. Make sure to have
the hydraulic power running in order to drive the AC compressor that supplies
pressurized refrigerant to the air conditioner air handler unit.
3.3.2 Cable reel connection

Cable reels are provided for conventional cable connection between stimulation
pump units and the control cabin to allow FPC touchscreen control of the pump
units. The cable reels are located inside the lower driver-side compartment door
of the cabin, as shown in the following figure. Be sure to extend the auxiliary
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platform before opening and lowering the reel door; extending the auxiliary
platform makes it easier to connect cable plugs to the junction box inside the
compartment.
Unlatch the cable reel compartment door, and lower the door until it hangs
straight down, exposing the mounted cable reels. Pulling down on the door to
open it may require some effort; you need also to be very careful when lowering
it because the door has stiff return spring tension that may cause it to suddenly
swing shut.

Be sure to connect the safety chain from the inside of the cable reel compartment
door to the eyebolt in the middle of the auxiliary platform frame to prevent the
door from swinging back shut when stringing cables from the reels.

Hazard Category: Machinery equipment hand tools
When closing the cable reel compartment door, exercise caution by carefully
raising the door in a controlled manner to prevent it from suddenly swinging shut
and possibly injuring yourself or others.
Cables from the cable reels are connected to junction box connections and
their respective pump units in a similar fashion to connections on conventional
FracCAT carrier units. The POD operator can then control frac pumps with the
FPC touchscreen.
The Phase 1 FPC system can control pumps in wireless mode, through
conventional cable connection, and through Ethernet connection. For more
information about FPC operation and configuration, refer to Fracturing Pump
Control System, InTouch content ID# 4098588, and Configuring the FracCAT
to Communicate with Fracturing Pump Control System , content ID# 4031155.
Additionally, refer to FracCAT Reference Page, content ID# 3272758 for general
information on cable connections between the conventional FracCAT unit and
other equipment.
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Figure 3-11: Location of power selector switch, junction box, and wireless
box. (Inside cable reel compartment)
3.3.3 Satellite dish operation
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Figure 3-12: Control cabin with deployed satellite dish
Figure 3-13: Satellite dish control panel
The satellite dish system is used primarily to transmit job data over the Internet
for off-location real-time monitoring of a job (for example, in one’s office) without
having to be actually on location for job observation. Power up the satellite
dish using the satellite dish control panel located inside the cabin. Press the
ACQUIRE button to have the satellite link-up system scan for a satellite link until
communication is acquired. This process may take several minutes.
When the job is finished, press the STOW button to lower the dish. After the
satellite dish is stowed, set the transfer case PTO to the ROAD position before
driving the truck.
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Potential Loss: Assets
Do not raise the satellite dish from its stowed position unless the transfer case
PTO is set to Pump position. Driving the truck unit with the dish deployed is likely
to cause damage to the dish. Additionally, a warning buzzer will sound if the PTO
is in ROAD position with the satellite dish in the RAISED position.
For more information on the satellite dish communications system, refer to the
Satellite Dish Operator Manual, InTouch, content ID# 4085490.
3.3.4 FracCAT software operation

The FracCAT software used by the SBT-615 must be Version 4.3 or higher for the
unit to function correctly. Refer to the FracCAT Software Operations Manual on
the Web at: http://wsd.sugar-land.oilfield.slb.com/wsn/FluidsQaQc/default.htm.
3.4 POD control software overview

The major control screens featured in the SBT-615 POD control touchscreen
software are:
• Main Control
• Backups Control
• Diagnostics Control – Automated and Detailed
• Calibration Control – General and Advanced
• Engine Control
These control screens are accessed from the Main Control screen.
3.4.1 Main Control screen

The POD operator will use the Main Control screen most of the time during
normal job operation, as shown in Figure 3-68 Main Control screen with activated
proppant control (p. 3-95). This screen provides control of the following:
• proppant
• up to four liquid add modules (LASs)
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• two dry add feeders

• fiber feeder
• mixer.
Figure 3-14: Main screen
Select which additive device to control by pressing one of the buttons at the
top of each additive block, (i.e., Prop, LAS1, LAS2, Mixer). When an additive
device is activated, the Mode, Valve and Setpoint controls are associated with
that particular additive.
Valve operations for going downhole, recirculation, mixer isolation, header-tank

flow/bypass, and C-pump discharge flow regulation are also controlled from the
Main Control screen. POD suction rate, discharge rate, and the header tank
level are also monitored on this display.
Beware of any indicators that turn red. Red indicators may suggest a serious
problem demanding immediate attention.
Note that only one active parameter at a time can be manipulated on the Main
Control screen.
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Table 3-1: Proppant Controls
Control Description
During normal operation, this is the %PPA, as calculated from the
densitometer. During backup operation (See the Backups Control
Actual display screen section for more details), green backup tags are displayed
next to the Prop button. This display represents the PPA calculated
from the gate position.
When the Prop is in MANUAL mode, this displays the manual gate %
setpoint as entered by the operator.

When the Prop is in AUTO mode, this displays the PPA setpoint as
Setpoint display
entered by the operator.
When the Prop is in REMOTE mode, this displays the PPA setpoint
coming from FracCAT.
Gate Position display Displays the measured position of the gate.
Displays the current mode for the Prop, either MANUAL, AUTO, or
Mode display
REMOTE.
Displays the current position of the Prop valves, either DOWNHOLE,
RECIRC, or ISOLATE.
Valves display
Note
The valve position display will read NONE if the air pressure has not
reached 60 psi or if the I/O board is not online.
Puts the Prop in MANUAL mode so the operator can enter manual
gate % setpoints. This does not control the position of the gate based
Manual mode button
upon the density; it will only hold the position of the requested gate
% setpoint.
Puts the Prop in AUTO mode so the operator can enter PPA setpoints.
Auto mode button The system automatically adjusts the position of the gate to maintain
the requested PPA.
Puts the Prop in REMOTE mode. This mode is exactly the same as
Remote mode button
AUTO mode, except that the PPA setpoints are supplied by FracCAT.
Sets the Prop valves as follows:
- Suction valve: OPEN
- Discharge valve: OPEN
- Recirc valve: CLOSED
Downhole button
Note
To fire these valves, the air pressure must be greater than 60 psi and
the I/O board must be online. See the Advanced Calibration screen
for more details.
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Control Description
- Suction valve: OPEN
- Discharge valve: OPEN
- Recirc valve: OPEN
Recirc button
Note
To fire these valves, the air pressure must be greater than 60 psi and
the I/O board must be on line. See the Advanced Calibration screen
for more details.

- Suction Valve: CLOSED
- Discharge Valve: CLOSED
- Recirc Valve: CLOSED
When the Prop is in ISOLATE, the gate should not be opened.
When ISOLATE is activated, all additives are either stopped or put
into RECIRC, and access to the dry-adds and fiber is not allowed.
REMOTE mode is unavailable when the Prop is in ISOLATE.
Isolate button
Note
The air pressure must be greater than 60 psi and the I/O board must
be online to fire these valves. See the Advanced Calibration screen
for more details.
C-Pump-Header
These buttons will either Open or Close the C-pump to header valve.
Open/Close buttons
C-Pump-Disch These buttons will either Open or Close the C-pump to discharge
Open/Close buttons valve.
When the Prop is selected as the current additive, either STANDARD
GATE or LOW-RATE GATE is displayed below the keypad button. This
indicates if the Low-Rate insert has been selected for this particular
gate.
Standard
Gate/Low-Rate Gate
display
Note
STANDARD GATE must be selected for the SBT-615 6x4 PodSTREAK.
LOW-RATE GATE applies only for the SBT-626 6x6 PodSTREAK and
must never be used with the 6x4.
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Table 3-2: Liquid Add Controls
Control Description
When the LAS is in MANUAL or AUTO-RATE mode, this displays the
actual rate in gal/min, as measured by the LAS flowmeter.
When the LAS is in AUTO-CONC or REMOTE mode, this displays the
Actual display actual concentration in gal/mgal, as measured by the LAS flowmeter.
In backup operation, green backup tags are displayed next to the
LAS button, and the display represents values measured by the LAS
tachometer.
When the LAS is in MANUAL mode, this displays the % setpoint, as
When the LAS is in AUTO-RATE mode, this displays the rate setpoint
as entered by the operator.
Setpoint display
When the LAS is in AUTO-CONC mode, this displays the
concentration setpoint as entered by the operator.
When the LAS is in REMOTE mode, this displays the concentration
setpoint that is coming from FracCAT.
If the tachometer is not reading a value, a Tach Off icon is displayed.
Tach display Otherwise, there is an icon indicating that the tachometer is reading
a value.
Displays the current mode for the LAS, either MANUAL, AUTO-RATE,
Mode display
AUTO-CONC, or REMOTE.
Displays an icon for the current position of the LAS valves, either
Valves display DOWNHOLE or RECIRC. No indicator is displayed if the operator has
not selected DOWNHOLE or RECIRC.
Puts the LAS in MANUAL mode so the operator can enter manual
Manual mode button
% setpoints.
Puts the LAS in AUTO-RATE mode so the operator can enter rate
Auto-Rate mode
setpoints. The system automatically controls the LAS to maintain
button
the requested rate.
Puts the LAS in AUTO-CONC mode so the operator can enter
Auto-Conc mode
concentration setpoints. The system automatically controls the LAS
button
to maintain the requested concentration.
Puts the LAS in REMOTE mode. This mode is exactly the same as
Remote mode button AUTO-CONC mode, except the concentration setpoints come from
FracCAT.
Sets the LAS valves to pump DOWNHOLE.
Downhole button
Note
Air pressure must be greater than 60 psi to fire the valves. See the
Advanced Calibration screen for more details.
Sets the LAS valves to RECIRCULATE. The air pressure must be

Recirc button greater than 60 psi to fire the valves. See the Advanced Calibration
screen for more details.
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Table 3-3: Dry Add Controls
Control Description
When the Dry-add is in MANUAL or AUTO-RATE mode, this displays
the actual rate in lbm/min as measured by the tachometer.
Actual display
When the Dry-add is in AUTO-CONC or REMOTE mode, this displays
the actual concentration in lbm/mgal as measured by the tachometer.
When the Dry-add is in MANUAL mode, this displays the % setpoint
When the Dry-add is in AUTO-RATE mode, this displays the rate

setpoint as entered by the operator.
Setpoint display
When the Dry-add is in AUTO-CONC mode, this displays the
When the Dry-add is in REMOTE mode, this displays the
concentration setpoint from FracCAT.
Puts the Dry-add in MANUAL mode so the operator can enter manual
Manual mode button
% setpoints.
Puts the Dry-add in AUTO-RATE mode so the operator can enter
Auto-Rate mode
rate setpoints. The system automatically controls the Dry-add feeder
button
to maintain the requested rate.
Puts the Dry-add in AUTO-CONC mode so the operator can enter
Auto-Conc mode
concentration setpoints. The system automatically controls the
button
Dry-add feeder to maintain the requested concentration.
Puts the Dry-add in REMOTE mode. This mode is exactly the same
Remote mode button as AUTO-CONC mode, except that the concentration setpoints come
from FracCAT.
Table 3-4: Fiber Controls
Control Description
When the Fiber is in MANUAL or AUTO-RATE mode, this displays
the actual rate in lbm/min as measured by the tachometer.
Actual display When the Fiber is in AUTO-CONC or REMOTE mode, this displays
the actual concentration in %PPA (or lbm/mgal for FAT fibers) as
measured by the tachometer.
When the Fiber is in MANUAL mode, this displays the % setpoint as
When the Fiber is in AUTO-RATE mode, this displays the rate setpoint
Setpoint display
When the Fiber is in AUTO-CONC mode, this displays the
When the Fiber is in REMOTE mode, this displays the concentration
setpoint coming from FracCAT.
If the tachometer is not reading a value, a Tach Off icon is displayed.
Tach display Otherwise, there is an icon indicating that the tachometer is reading
a value.
Displays the current mode for the Fiber, either MANUAL,
Mode display
AUTO-RATE, AUTO-CONC, or REMOTE.
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Control Description
Puts the Fiber in MANUAL mode so the operator can enter manual
Manual mode button
% setpoints.
Puts the Fiber in AUTO-RATE mode so the operator can enter rate
Auto-Rate mode
setpoints. The system automatically controls the Fiber feeder to
button
maintain the requested rate.
Puts the Fiber in AUTO-CONC mode so the operator can enter
Auto-Conc mode
concentration setpoints. The system automatically controls the Fiber
button
feeder to maintain the requested concentration.
Puts the Fiber in REMOTE mode. This mode is exactly the same as
Remote mode button AUTO-CONC mode, except the concentration setpoints come from
FracCAT.
Table 3-5: Mixer Controls
Control Description
RPM display RPM of the mixer calculated directly from the engine rpm.
Table 3-6: General Controls
Control Description
Discharge Rate
This display represents the discharge rate as calculated by FracCAT.
display
Discharge Pressure
Pressure measured on the discharge side
display
During normal operation, this is the rate measured by the flowmeter.
Suction Rate display During backup operation, this display represents the suction rate as
calculated by FracCAT. (See the Backups screen, Figure 3-17).
Suction Pressure
Pressure measured on the suction side
display
FracCAT Slurry Rate This displays the slurry rate as calculated by FracCAT (usually from
display the Pump rates).
Header Tank % This displays the current level of the header tank. There is also a
display graphical representation of the header tank.
Enters a setpoint for the currently selected module (Prop, LiqAdd1,
Keypad button Dry-add, mixer). The keypad dialog appears when the keypad button
is selected for manual input. (Figure 3-70).
Toggle the setpoint up and down by small increments. Holding down
Up/Down arrows
the arrows increases the rate at which the setpoint will change.
Activates the Zero Setpoints screen, providing the operator with the
following options:
- Current Selection: only the currently selected additive (Prop, LAS)
Stop button is stopped (all setpoints for that additive will go to zero)
- Zero All: all additives (except the mixer) is stopped with the setpoints
for all additives going to zero
- Cancel: cancels the zero request.
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Control Description
Activates the Backups screen. When any backup mode is active,
Backups button
green flags are displayed on either side of this button.
Activates the Automated Diagnostics screen. When there are
Diagnos. button
identified warnings, red flags are displayed on either side of this button.
Calibrate button Activates the Calibration screen.
Activates the Engine screen. When there are identified engine
Engine button
warnings, red flags are displayed on either side of this button.
Figure 3-15: Keypad dialog
Figure 3-16: Zero setpoints dialog
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3.4.2 Backups Control screen

The SBT-615 is equipped with multiple control sensors for each system. For
example, each LAS has a flowmeter and a tachometer, both of which can be
used to control its operation. In the event of sensor failure, the operator can
select an alternative sensor to be used from the Backups screen. The Backups
screen is also where the operator can specify the Master Rate for each additive
and where totalizers can be viewed and reset.
To access the Backups screen, press the Backups button on the Main Control
screen display.
Figure 3-17: Backups Control screen
Table 3-7: Backup Controls
Control Description
Prop Densitometer
Displays the proppant concentration as measured by the densitometer.
display
Prop Gate position Displays the proppant concentration as calculated from the position
display of the gate.
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Control Description
Prop Densitometer This is the default setting when the densitometer is used for the
button automatic density control.
This forces the automatic density control to use the proppant
concentration as calculated by the position of the gate. This mode
should be used in the event of densitometer failure.
Prop Gate position

button
Note
When this mode is active, there are green flags on either side of the
Prop button and the Backups button on the Main screen.
LAS Flowmeter
Displays the LAS rate as measured by the LAS flowmeter.
display
LAS Tachometer
Displays the LAS rate as measured by the LAS tachometer.
display
Default setting when the LAS flowmeter is used for the automatic
LAS Flowmeter button
rate/concentration control.
This forces the automatic rate/concentration control to use the LAS
tachometer, and should be used in the event of LAS flowmeter failure.
To prepare for this, calibrate the LAS tachometer before every job (see
section on Calibration Control screen).
LAS Tachometer
button
Note
When this mode is active, green flags are displayed on either side of
the LAS button and the Backups button on the Main screen.
Suction Rate
Displays the suction rate as measured by the suction flowmeter.
Flowmeter display
Suction Rate From Displays the suction rate as calculated by FracCAT (CFLD_RATE
FracCAT display variable)
Suction Rate Default setting when the suction rate from the flowmeter is used as
Flowmeter button the main suction rate for the unit.
This forces the main suction rate for the unit to be the calculated rate
from FracCAT, and should be used in the event of suction flowmeter
failure.
Suction Rate From

FracCAT button
Note
When this mode is active, green flags are displayed on either side of
the Backups button on the Main screen, and the Suction Rate display
is green.
Discharge Rate Displays the discharge rate as calculated by FracCAT (SLUR_RATE

Calculated display variable)
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Control Description
Displays the total of fluids/materials pumped since the most recent zero.
The Prop, Clean Fluid, and Slurry are totalized only when the PROP
Totals displays is DOWNHOLE.
The LAS are totalized only when they are DOWNHOLE.
The Dry-adds and Fiber totalize whenever the screw is turning.
Displays a dialog allowing the operator to individually zero the
Zero (totalizers) totalizers. After the operator sets the totalizers to zero, press the OK
button button to confirm this action. The Cancel button results in no action
(Figure 3-18).
These allow the operator to specify the master rate to be used for
each LAS during concentration mode. The default setting is LOCAL,
which means the currently selected suction rate, either Flowmeter or
LAS Master Rate From FracCAT.
Selection buttons
When the FracCAT option is selected, the master rate is the suction
rate, as calculated by FracCAT, regardless of the main suction rate
selection.
This allows the operator to specify the master rate to be used for the
fiber during concentration mode. The default setting is PROPPANT,
which means the fiber is injected as a percentage of Proppant
Fiber Master Rate concentration (i.e., %PPA).
Selection button
When CLEANFLUID is selected, the fiber is injected as a ratio to the
suction rate (i.e., lbm/mgal). CLEANFLUID selection should be used
when using FAT fibers.
Turns off the computer after a job. After confirmation, the computer
shuts down and informs the operator when it is safe to turn off the
power to the computer.
Shutdown Computer
button
Note
If the computer is shut down improperly, for example, by killing the
power without following the shutdown procedure, data on the computer
can become corrupted, leading to job failure.
This button allows the operator to open all air-actuated valves (including
Open All Valves
Prop valves, C-Pump-Header, and C-Pump-Discharge valves) for
button
drainage at the end of a job.
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Figure 3-18: Zero totalizers dialog
3.4.3 Diagnostics Control screens (Automated and

Detailed)
When problems occur, it is often helpful to compare the inputs from multiple
sensors when trying to determine the source of the problem. This comparison is
most easily made on the Diagnostics screen.
The Automated Diagnostics screen will appear first when the Diagnos button is
pressed, and provides the operator with a quick check of all critical components
of the control system. To get an accurate, up-to-date status of the components,
the operator should always perform a System Scan. This will run through all of
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the tests and provide a current snapshot of the system. A green light indicates
that the component is OK, while a yellow light indicates a potential problem. A
red light may indicate a serious problem that requires immediate attention.
Figure 3-19: Automated Diagnostics screen
Table 3-8: Automated Diagnostics Screen Function Descriptions
Control Description
Make sure the PodSTREAK computer has at least 500 MB of free
Free Disk Space
disk space.
Verifies that the proper touchscreen driver has been installed on the
Touchscreen Driver
computer (monmouse.cpl).
PodSTREAK
Displays the last version loaded of PodSTREAK software.
Software Version
Displays the current work area for the PodSTREAK software. This is
Current Work Area
where all job data files and configuration files are stored.
Virus Protection
Displays the latest version of all applied virus protection updates.
Updates
Indicates the status of the network cable connection. Possible errors
Cable Plugged In include an unplugged computer network cable or a problem with the
hub connection/power.
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Control Description
Indicates that the IP address of the PodSTREAK computer is in the
IP Address
proper format/range of 192.168.1.XX.
Indicates that the FracCAT computer can be “pinged” from the
Ping FracCAT PodSTREAK computer. This runs a “ping 192.168.1.2” command, and
indicates success or failure of the attempt.
Indicates the PodSTREAK computer can “ping” the router. This
Ping Router application pings the default gateway, which is typically IP address
192.168.1.1.
Indicates the ECM server operational status. This software component

allows communication between the FracCAT and PodSTREAK
ECM Server software.
If this component is not operating properly, the FracCAT computer will
be unable to acquire data from the PodSTREAK computer.
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Control Description
Displays the Wellsite Network Diagnostics dialog for advanced network
troubleshooting. (Figure 3-20)
Summary of controls:
– Current IP Address display: Shows the current IP address of the
selected network adapter.
– Current Connection display: Shows the current network connection
(adapter) in use.
– Network Status display: Shows the current status of the network

after the most recent network tests. Possible values are:
– Network OK: PodSTREAK computer can successfully ping router
(gateway) and FracCAT computer.
– No FracCAT: PodSTREAK computer can successfully ping router
(gateway) but cannot ping FracCAT computer.
– No Network: PodSTREAK computer cannot successfully ping router
(gateway).
– Ping Router display: shows result of the last attempt to ping the
router (gateway).
– Ping FracCAT display: shows result of last attempt to ping FracCAT
computer.
Advanced Diagnostics – ECM Server Test display: shows if the ECM server is running. This
component is necessary for FracCAT communication.
– DCOM Test display: Not available to run.
– Use DHCP button: Sets the computer to use DHCP in which the
IP address is automatically obtained from the router. This is the
recommended option.
– Use Static IP Address button: Sets the computer to use Static IP
addresses in which the IP address is set manually by the operator.
This option should be used in the event of router failure.
– FCT IP display: Shows the IP address of the FracCAT computer
used for the network tests.
– FCT IP Edit… button: Sets the IP address of the FracCAT computer.
The default setting of 192.168.1.2 should be used under normal
circumstances.
– Ping FCT button: Pings FracCAT and displays success or failure.
– Advanced… button: Specifies the network adapter to be used for
network testing.
– OK button: Applies any changes and closes the dialog.
– Cancel button: Cancels any changes and closes the dialog.
– Apply button: Applies any changes that have been made.
Certifies that the proper CAN card driver has been installed on the
CAN Card Driver
computer.
CAN Card Init. Indicates if the CAN card initialized properly.
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Control Description
Indicates the status of the DCU network as follows:
- GREEN: All DCUs (including all LAS) are ONLINE.
DCU Network - RED: One or more critical (non-LAS) DCUs are OFFLINE.
- YELLOW: All critical DCUs are ONLINE, but one or more non-critical
(LAS) DCUs are OFFLINE.
Discharge Rate Indicates that the signal from the discharge flowmeter is greater than
Flowmeter 3.9 mA (normal signal is 4–20 mA).
Indicates that the signal from the suction flowmeter is greater than 3.9
Suction Flowmeter
mA (normal signal is 4–20 mA).
Indicates that the signal from the suction pressure transducer is greater
Suction Pressure
than 3.9 mA (normal signal is 4–20 mA).
Indicates that the signal from the discharge pressure transducer is
Discharge Pressure
greater than 3.9 mA (normal signal is 4–20 mA).
Densitometer Indicates that the signal from the densitometer is greater than 0.0 V.
Gate Position Indicates that the gate position signal is greater than 0.0 V.
Indicates the status of the densitometer calibration as follows:
– GREEN: Calibration in the Master Calibration file and DCU match,
AND air calibration is approximately 3 times the water calibration.
– RED: Calibration in the Master Calibration file and DCU do not
match, AND/OR air calibration is not approximately 3 times the water
calibration.
– YELLOW: Either the calibration in the Master Calibration file and
DCU match, OR air calibration is approximately 3 times the water
Densitometer calibration, but not both.
Calibration
Note
Calibrations are stored to the Master Calibration file only if
MAINTENANCE mode (Figure 3-25) is ON while the calibration is
performed).
This indicates the status of the densitometer calibration as follows:

– GREEN: Calibration in the Master Calibration file and DCU match,
AND gate open calibration is greater than gate closed calibration.
– RED: Calibration in the Master Calibration file and DCU do not
match, AND/OR gate open calibration is not greater than gate closed
calibration.
– YELLOW: Either the calibration in the Master Calibration file and
Gate Calibration DCU match, OR gate open calibration is greater than gate closed
calibration, but not both.
Note
Calibrations are only stored to the Master Calibration file if
MAINTENANCE Mode () is ON while the calibration is performed.
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Control Description
Set the gate position setpoint to 0% and 100%, respectively, to test
the gate calibration.
Go to 0%/100%
buttons
Note
This works only if the PROP is already in MANUAL mode.
Runs through all tests, and provides a current snapshot of the system.
System Scan button To get an accurate up-to-date status of the components, the operator
should always perform a System Scan.
System Scan Status Displays the current status of the system tests, either In Progress or
display Complete.
Detailed Diagnostics
Displays the Detailed Diagnostics screen.
button
Figure 3-20: Wellsite Network Diagnostics dialog
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Pressing the Detailed Diagnostics button on the Automated Diagnostics

screen opens up the Detailed Diagnostics screen. The Detailed Diagnostics
screen provides the operator with detailed information to assist troubleshooting
activities. All values outside of normal operating ranges turn RED, and red flags
appear on either side of the Diagnostics button on the Main screen.
Figure 3-21: Detailed Diagnostics screen
Table 3-9: Detailed Diagnostics Screen Function Descriptions
Field Function Description

Prop Densitometer The Densitometer field displays the output from the radioactive densitometer.
The Mixer Speed field displays the current mixer speed and allows for speed
Mixer Speed
adjustment and setting.
Set Point The Set Point field displays the current setpoint achieved by the system.
The Suction Pressure field displays the mixer suction pressure. A red background
Suction Press
is displayed if the suction pressure is less than –7 psi.
Suction Rate The Suction Rate field displays the mixer suction rate.
Discharge Pressure The Discharge Pressure field displays the mixer discharge pressure.
Discharge Rate The Discharge Rate field displays the total mixer discharge rate (calculated).
The LAS Flowmeter field displays the LAS 1/2 flow rate. (measured from the
LAS Flowmeter
LAS flowmeter).
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The LAS Tachometer field displays the calculated LAS flow rate from the
LAS Tachometer
tachometer on the LAS motor.
The Header Tank field displays the status of the fluid level of the header tank
Header Tank
(from 0 to 100%).
Dry Add / Fiber The Dry Add/Fiber Tachometer field displays the calculated feed rate (calculated
Tachometer from the tachometer and the screw factor)
The Dry Add/Fiber RPM field displays the respective rpm of each of the dry add
Dry Add / Fiber RPM
feeders and fiber feeder (coming from the tachometer of each respective feeder).
The Screw factor for DryAdd and Fiber displays the status of the screw factor
Screw factor
chosen from the calibration screen.
C-pump Pressure The C-Pump Pres displays the centrifugal pump discharge pressure.
This field displays the status of all 7 DCUs.
Possible displays include:
- - -: Problem with DCU communication
DCU ***: The connection with the DCU has not been made (default before cables
Communication connected).
Status INIT: The connection is initializing.
ONLINE: Communication is working (during operation, this should be the normal
display).
OFFLINE: Communication was established previously but is no longer active.
Figure 3-22: Detailed Diagnostics screen functions with alternative (toggled) units
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Table 3-10: Detailed Diagnostics Screen Alternative Display Units

When toggled, this field displays a direct voltage from the densitometer
Prop Densitometer
electronics.
Mixer Speed No information displayed.
When toggled, this field displays for proppant control the signal sent to the gate
Setpoint (2 to 14 mA : 0 to 100%), and for the additives a calculated voltage represents
the output to the additive control valve.
When toggled, this field displays a measured current value for the suction
Suction Press
pressure (4–20 mA : 0 to 150 psi).
When toggled, this field displays a measured current value for the suction rate
Suction Rate
(coming from suction flowmeter).
When toggled, this field displays a measured current value for the displayed
Discharge Pressure
discharge pressure (4 to 20 mA = 0 to 150 psi).
Discharge Rate No information displayed.
When toggled, this field displays a measured current coming from the
LAS Flowmeter
tachometer and the pump characteristics.
When toggled, this field displays a measured frequency for the display of the
LAS Tachometer
LAS tachometer rate.
When toggled, this field displays the current signal coming from the sensor (4
Header Tank
to 20 mA: 0 to 100%).
Dry Add / Fiber When toggled, this field displays a measured frequency for the display of the
Tachometer feeder rate.
Dry Add / Fiber RPM No information displayed.
Screw Factor Fixed setting.
When toggled, this field displays the 4 to 20 mA signal coming from the C-pump
C-pump Pressure
discharge pressure sensor.
DCU Comm No information displayed.
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3.4.4 Calibration Control screens (General and

Advanced)
The Calibration Control screen calibrates the system equipment for use on a job;
to access the screen, press the Calibrate button on the Main Control screen.
Figure 3-23: Calibration Control screen
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Table 3-11: Calibration Controls
Control Description
Displays the Air Calibration dialog. See the instructions in Section
3.9.4 Densitometer operation (p. 3-120), for more information on how
to perform this.
Note that when MAINTENANCE mode is ON (Figure 3-25), all
calibrations are saved to the Master Calibration file.
Use the Send Calibrations to DCU feature on the Advanced
Calibration screen to easily recover calibration data in the event a DCU

is reprogrammed or replaced.
Do Air Cal button – Current Air voltage stored in DCU display: Shows the Air Calibration
value that is currently being used by the DCU
– Current Densitometer Voltage display: Shows the current output of
the densitometer
– Start button: Starts the Air Calibration process. A 30-second timer
counts down the process and, at the end, displays the newly calculated
Air Calibration value.
– Accept button: Accepts the newly calculated Air Calibration value
– Cancel button: Cancels the Air Calibration
Displays the Water Calibration dialog See the instructions in Section
3.9.4 Densitometer operation (p. 3-120) for more information on how
to perform this.
Note that when MAINTENANCE mode is ON ( Figure 3-25 ), all
calibrations are saved to the Master Calibration file. The Send
Calibrations to DCU feature on the Advanced Calibration screen
provides a way to easily recover calibration data in the event a DCU is
reprogrammed or replaced.
Do Water Cal button – Current Water voltage stored in DCU display: Shows the Water
Calibration value that is currently being used by the DCU.
– Current Densitometer Voltage: Shows the current output of the
densitometer.
— Start button: Starts the Water Calibration process. A 30-second
timer counts down the process and, at the end, displays the newly
calculated Water Calibration value.
– Done button: Accepts the newly calculated Water Calibration value.
– Cancel button: Cancels the Water Calibration.
Displays the Zero on Pad dialog. See the instructions in Section 3.9.4
Densitometer operation (p. 3-120) for more information on how to
perform this.
Zero on Pad button – Start button: Starts the Zero on Pad Calibration process. A 30-second
timer counts down the process, and at the end displays the OK and
Cancel buttons.
– OK button: Accepts the Zero on Pad.
– Cancel Zero button: Cancels the Zero on Pad.
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Control Description
Displays the Gate Calibration dialog, which allows the operator to
setup the 0% and 100% positions of the gate. Follow the on-screen
instructions to perform the calibration.
The gate should not have to be recalibrated; however, if the gate is not
responding as desired, it may be necessary to repeat this process.
Calibrate Gate button
Note that when MAINTENANCE Mode is ON (Figure 3-25), all
calibrations are saved to the Master Calibration file. Use the Send
Calibrations to DCU feature on the Advanced Calibration screen to
easily recover calibration data in the event a DCU is reprogrammed

or replaced.
Displays the LAS Tachometer Calibration dialog, which calibrates the
tachometer using the flowmeter as a reference. See the instructions in
Section 3.9.5 Liquid additive operation (p. 3-127) for more information.
A new LAS calibration should be performed before every job, and the
LAS tachometer calibration factor should be reset to 1.0. This helps
ensure proper operation in the event of LAS flowmeter failure during
the job.
– Liquid Add Tachometer Cal factor currently stored in the DCU display:
Shows the current cal factor used by the DCU. (The default value is 1.0.)
Do LAS Cal button
– Auto-Calibrate button: Starts the LAS tachometer calibration process.
A 15-second timer counts down the process and, at the end, displays
the newly calculated value.
– Reset Default button: Resets the tachometer calibration value to 1.0.
– Custom Value button: Allows the operator to enter a custom
tachometer calibration value. (This should normally be between 0.8
and 1.2.)
– Accept button: Accepts the new tachometer calibration value.
– Cancel button: Cancels the tachometer calibration.
Calibrates all LAS tachometers at the same time. See the instructions in
Section 3.9.5 Liquid additive operation (p. 3-127) for more information.
New LAS tachometer calibrations should be performed before every
job and the LAS tachometer calibration factors should be reset to 1.0 to
ensure proper operation in the event of LAS flowmeter failure during
the job.
Calibrate All button – Current Tach Cal factor display: Shows the current cal factor used
by the DCU (default value is 1.0).
– Start Auto Calibration button: Starts the LAS tachometer calibration
process. A 15-second timer counts down the process, and at the end
displays the newly calculated value.
– Accept button: Individually accepts each new tachometer calibration
value.
– Done button: Closes the LAS Calibration dialog.
Displays the current screw factor used for the Dry-add. This factor
converts the RPM of the screw into a rate (i.e., lbm/min) or concentration
Dry-add Screw Factor
(i.e., lbm/mgal), and changes depending on the type of Dry-add being
display
used. See Section 3.9.2 Dry-add feeder operation (p. 3-103) for more
information.
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Control Description
Dry-add Screw Factor Allows the operator to specify the screw factor to be used for the
Keypad button Dry-add.
Dry-add Screw Factor
Allow the operator to toggle the Dry-add screw factor up or down as
Dry-addUp/Down
required.
arrows
Displays the current screw factor used for the Fiber. This is a factor
that is used to convert the rpm of the screw into a rate (i.e., lbm/min) or
Fiber Screw Factor
concentration (i.e., lbm/mgal), and changes depending on the type of
display
fiber being used. See Section 3.9.3 Fiber Feeder (p. 3-114) for more
information.
Fiber Screw Factor
Allows the operator to specify the screw factor to be used for the Fiber.
Keypad button
Fiber Screw Factor Allow the operator to toggle the Fiber screw factor up or down as
Up/Down arrows required.
Allow the operator to select the type of proppant being used, and
specify the following parameters:
– Proppant type (Sand, Bauxite, Custom)
Proppant Type – Size (20/40, 16/30)
controls – Calibration Factor (used to adjust proppant density for custom
situations)
All of the above parameters are used in the DCU to calculate the actual
proppant concentration.
Standard Gate-Type
This button must be selected when using the SBT-615 6x4 PodSTREAK.
button
Never select this button when using the SBT-615 6x4; it applies only for
Low-Rate Gate-Type the SBT-626 6x6 PodSTREAK. This feature exists because the current
button POD touchscreen software is used for both the SBT-615 6x4 and the
SBT-626 6x6 units, which have completely different gate systems.
Advanced button Displays the Advanced Calibration screen.
Enables the HiWAY mode if the HMI is connected to a DCU with valid
firmware. The PodSTREAK 1.1 HMI verifies if the firmware installed
in the Solids DCU is HiWAY-compatible. If it is, the HiWAY mode is
enabled, otherwise a corresponding error message displays. For
detailed information on HiWAY, refer to the HiWAY Reference Page
Enable HiWAY button (InTouch ID# 4926605) or the HiWAY Operational Guidelines (InTouch
ID# 4986058) on InTouch.
Once the HiWAY mode is enabled, the Calibrate HiWAY Values button
becomes visible (see Figure 3-24), which allows performing the HiWAY
gate calibration.
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Figure 3-24: HiWAY Mode enabled
Pressing the Advanced button on the Calibration screen opens up the

Advanced Calibration screen. The Advanced Calibration screen provides access
to advanced features that are typically reserved for maintenance or backup
operations.
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Figure 3-25: Advanced Calibration screen
Note
Earlier prototype SBT-615 6x4 units that were fitted with an integral gate must
have the POD3-style gate button selected.
Table 3-12: Advanced Calibration Controls
Control Description
Refresh IP Address
Refreshes the IP address displayed in the title bar.
button
Disabling this feature permits actuation of the valves even if the air
Air Pressure Checks
pressure is less than 60 psi. The software will not allow valves to be
button
actuated unless the air pressure is greater than 60 psi.
Allows saved densitometer and gate calibration data to be sent to the
DCU without having to perform the actual calibrations if the SOLIDS
DCU is replaced or reprogrammed.
Send Calibrations to
This sends the latest calibration data in the Master Calibration file. See
DCU button
MAINTENANCE Mode (Figure 3-25) for more information.
Note that MAINTENANCE mode (Figure 3-25) must be ON for this
feature to work.
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Control Description
Allows the operator to configure the address and type of each DCU.
This feature should only be used by qualified personnel with expert
training.
MAINTENANCE mode (Figure 3-25) must be ON to use this feature.
The operator must close the software and restart it after entering this
dialog.
– DCUs Currently on Network display: Shows the number of DCUs
found on the CAN network.

– Address display: Shows the address of the currently selected DCU.
– Type display: Shows the type of the currently selected DCU.
– Version display: Shows the firmware version of the currently selected
DCU.
– Serial display: Shows the serial number of the currently selected
DCU.
– Re-Scan Network button: Scans the CAN network for DCUs.
Configure DCU button
– Application menu: Allows the operator to specify the application in
order to narrow down the list of potential DCU addresses.
– Desired Address menu: Allows the operator to select the new
address for the DCU.
– Desired Type menu: Allows the operator to select the new type for
the DCU.
– Configure DCU button: Configures the currently selected DCU with
the new address and type settings.
– Enable Event-Driven Mode button: Turns event-driven mode ON
for the selected DCU. All DCUs on the PodSTREAK must be set to
this mode.
– Factory Reset button: Performs a factory reset for the selected DCU.
This resets the DCU and all stored settings (such as Air Cal/Water
Cal values) to the factory default.
– Exit Application button: Exits the PodSTREAK software. (Figure
3-26)
LAS Fill Mode This mode does not apply to the SBT-615 6x4 unit.
Switch to 6x4
Configures the software for use with the SBT-615 (6x4 PodSTREAK).
PodSTREAK button
Switch to 6x6 Configures the software for use with the SBT-626 (6x6 PodSTREAK).
PodSTREAK button NEVER USE THIS FOR THE SBT-615 (6x4 PodSTREAK).
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Control Description
Allows the operator to turn MAINTENANCE mode ON or OFF. By
default, MAINTENANCE mode is OFF.
Maintenance Mode
button When MAINTENANCE mode is ON, the densitometer and gate
calibrations are saved to a Master Calibration file. In addition, several
advanced maintenance features are made available.
These buttons allow the operator to specify the type of gate installed
on the PodSTREAK. The following options are provided:
– POD3-style gate
– Fiber gate
– High-Rate gate
Note that the selected gate choice is saved in the DCU for all future
jobs, so this selection should only have to be made once. If the
SOLIDS DCU is replaced or reprogrammed, this selection should be
made again.
Gate Type Selection
Note
USE ONLY HIGH-RATE GATE AS THE GATE TYPE FOR THE
SBT-615 6x4 PRODUCTION UNIT AND NO OTHER GATE TYPE
OR ELSE IMPROPER GATE PERFORMANCE WILL RESULT AND
ADVERSELY AFFECT THE JOB. Earlier 6x4 prototypes that are
deployed in the field and have integral gates need to have POD3-style
selected as the gate type.
Figure 3-26: Configure DCU dialog
Follow the instructions that appear on the screen when performing calibrations
for each type of equipment.
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• Section 3.9.2 Dry-add feeder operation covers dry-add feeder screw

calibration in more detail.
• Section 3.9.3 Fiber Feeder covers Fiber screw calibration in greater detail.
• Calibration of the POD densitometer should always be done at the district
and not on location. Refer to Section 3.9.4 Densitometer operation for more
details.
The Calibration screen provides access to these functions:

• Densitometer air calibration (Section 3.9.4 Densitometer operation)

• Densitometer water calibration (Section 3.9.4 Densitometer operation)
• Zero On Pad (Section 3.9.4 Densitometer operation)
• Liquid add tachometer calibration (Section 3.9.5 Liquid additive operation)
• Dry add screw factor (Section 3.9.2 Dry-add feeder operation)
• Fiber screw factor (Section 3.9.3 Fiber Feeder)
• Proppant type (Section 3.9.1.3 Gate system operation)
• Gate Calibration (Section 3.9.1.3 Gate system operation)
3.4.4.1 HiWAY gate calibration

The HiWAY gate calibration can be run in Automatic or Manual mode (see Figure
3-27). Start the HiWAY gate calibration by clicking on Calibrate HiWAY Values
button to display the gate calibration mode dialog box.
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Figure 3-27: Gate calibration mode selection
Manual HiWAY gate calibration
Clicking the Manual button displays the Manual Gate Calibration screen as
shown in Figure 3-28. The screen displays the current gate opening offset,
closing offset, slope (m), and intercept (b) values on the DCU. If new values
are selected, they are only written to the DCU when the Save Values button is
clicked.
Note
In order to save the new calibration values, you must click the Save Values
button. If you click the Exit button without clicking the Save Values button first,
the new calibration values will NOT be saved to the DCU.
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Figure 3-28: Manual gate calibration screen
Automatic HiWAY gate calibration
Clicking the Automatic button displays the Step 1: Gate Opening Point screen,
as shown in Figure 3-29. The Gate Opening Point step is used to find the value
of the output at which the Apitech starts opening the gate.
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Figure 3-29: Automatic gate calibration screen
After clicking the Start button, the PodSTREAK HMI will automatically go through
the following steps to perform the Gate Opening Point calibration:
1. Set the Engine RPM to the operating range.

2. Wait until the hydraulic oil is within the operating specifications.
3. Send a command to DCU to start the step.
4. Wait until the DCU completes the step.
5. Restore the Engine RPM to the initial Engine RPM in Step 1.
Note
The operator should manually warm up the PodSTREAK unit before starting the
calibration sequence. PodSTREAK HMI will wait until the hydraulic oil pressure
and temperature are within the operating specifications for a maximum of 2
minutes; however, if these are not reached within this time, the calibration will fail.
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In order to check the status of the gate opening point calibration, a progress bar
is displayed on the Step 1: Gate Opening Point screen, as shown in Figure
3-30. To abort the current test, click the Abort button. To restart the test, click
the Start button again.
Figure 3-30: Gate opening point test in progress
Note
Once the calibration sequence is launched, the equipment cannot be operated
from the PodSTREAK HMI.
Note
At the beginning of every test (step), there is a hydraulic oil temperature and
pressure test. If either the temperature or pressure is out of range, the procedure
will not start. Make sure the unit is warmed up before performing the automatic
gate calibration (see Maintenance Bulletin 1234).
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Potential Severity: Light

The gate will move intermittently during the entire gate calibration test – stay
clear.
Note
The gate calibration procedure can take up to one hour to complete.
Note
Before performing a calibration on a SBT-616 ensure that maintenance bulletin
1234 has been performed.
Note
Ensure the gate has been calibrated at 0% and 100% prior to starting this test.
There are three possible outcomes to the Gate Opening Point calibration step:
1. Calibration Successful, as shown in Figure 3-31

2. Calibration Failed, which occurs when the hydraulic oil does not reach the
operational specifications within 2 minutes
3. Calibration Failed, which occurs when the gate does not open
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Figure 3-31: Gate opening point test completed successfully
If the calibration step completes successfully, the step outputs will be displayed
to the user (e.g., Starting Point), and the Next >> button becomes enabled to
allow proceeding to the next calibration step. The Start button changes to
Restart. Clicking the Restart button repeats the current test only.
Note
The Gate Opening Point calibration step will take approximately 4 minutes
to complete.
The next step in the calibration sequence is Step 2: Gate Closing Point, as
shown in Figure 3-32. This step is used to find the value of the output at which
the Apitech starts to close the gate.
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Figure 3-32: Gate closing point test
After clicking the Start button, PodSTREAK HMI will automatically go through
the following steps to perform the Basic Gate Velocity calibration:

In order to check the status of this step, a progress bar is displayed on the
screen, as shown in Figure 3-33. To abort the current test, click the Abort button.
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Figure 3-33: Gate closing point test in progress
There are three possible outcomes to the Gate Closing Point calibration step:

3. Calibration Failed, which occurs when the gate does not close
to the user (e.g., Starting Point), and the Next >> button will be enabled to allow
proceeding to the next calibration step.
Note
The Gate Closing Point calibration step will take approximately 4 minutes to
complete.
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Note
The gate speed test expects to have a value within certain range. If the time (in
sec) is not within the range, the step will fail.
Figure 3-34: Gate closing point test completed successfully
The next step in the calibration sequence is Step 3: Basic Gate Speed, as
shown in Figure 3-35. The gate speed step is used to characterize the velocity of
the gate given a certain output signal.
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Figure 3-35: Basic gate speed test
When the user clicks Start, PodSTREAK HMI will automatically sequence
through the following steps to perform the Basic Gate Velocity calibration:

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Figure 3-36: Basic gate speed test in progress
There are three possible outcomes to the Basic Gate Velocity calibration step:

2. Calibration Failed, which occurs because the gate response time is not within
specifications. Refer to Maintenance Bulletin 1236.
to the user (e.g., Response Time), and the Next >> button will be enabled to
allow proceeding to the next calibration step.
Note
The Basic Gate Velocity calibration step will take approximately 1 minute to
complete.
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Figure 3-37: Basic gate speed test successful
The next step in the calibration sequence is Step 4: Advanced Gate Velocity ,
as shown in Figure 3-38. The gate velocity step is used to characterize the
velocity of the gate given a certain output signal.
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Figure 3-38: Advanced gate velocity test
the following steps to perform the Advanced Gate Velocity calibration:

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Figure 3-39: Advanced gate velocity test in progress
There are two possible outcomes to the Advanced Gate Velocity calibration step:

to the user (e.g., Slope and Intercept), and the Next >> button will be enabled to
allow proceeding to the next calibration step.
Note
The Advanced Gate Velocity calibration step will take approximately 3 minutes
and 45 seconds to complete.
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Figure 3-40: Advanced gate velocity test successful
The last step in the calibration sequence is Step 5: Gate Response, as shown
in Figure 3-41. The gate response step is used to set the proper feed forward
response based on the velocity of the gate. The starting values for the test are
the slope and intercept values from Step 4: Advanced Gate Velocity.
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Figure 3-41: Gate response test screen
the following steps to perform the Gate Response calibration:

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Figure 3-42: Gate response test in progress
There are two possible outcomes to the Gate Response calibration step:

If the calibration step completes successfully, the new slope and intercept values
are displayed. At this point, the gate calibration is NOT completed. The new
calibration values are stored on the DCU only after the clicking the Save Values
button. If you click the Exit button without clicking the Save Values button first,
the new calibration values will NOT be saved to the DCU.
Additionally, the slope and intercept parameters can be manually modified using
the digital controls on the calibration screen, if necessary.
Note
The Gate Response calibration step will take approximately 11 minutes per
iteration to complete. The total time for this calibration step is a function of the
number of iterations required to find the optimum slope and intercept values.
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Figure 3-43: Gate response test successful
3.4.5 Engine Control screen

The Engine Control screen provides control of engine operation with Start/Stop
and Throttle Up/Down commands, and monitors important engine system
parameters such as oil pressure, component temperature, etc. This screen also
controls the level of the header tank.
To access the Engine Control screen, press the Engine button on the Main
Control screen.
Pay close attention to the information on this screen during operation, as any
display that changes to red may indicate a serious condition. If the warning
indicates an engine-related issue, shut down the engine immediately and correct
the problem.
The Engine Control screen first appears as a concise, reduced screen version;
the POD operator uses this screen the majority of the time to control the truck
engine speed and regulate POD mixer speed. Header tank control functions
along with engine control and performance information are displayed on this
screen (Section 3.7 Header tank level control system operation (p. 3-84)).
When the SHOW More Info button is pressed, the full control screen appears
(Figure 3-44) and displays more information.
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Figure 3-44: Engine Control screen (full version)
Table 3-13: Engine Controls
Control Description
This displays the current status of the engine distributed control unit
(DCU). The possible values are:
- - -: The CAN card has been initialized, but communication has not
been established with the DCU.
DCU Comm display * * *: The CAN card did not initialize properly.
– INITIALIZE: The DCU has just come online.
– ONLINE: Communication with the DCU is working as expected.
– OFFLINE: Communication with the DCU was working, but now it is
offline.
Displays the engine oil pressure from the Caterpillar Electronic Control
Oil Pressure
Module (ECM).
Coolant Temp. Displays the engine coolant temperature (from the Caterpillar ECM).
Gearbox Temp. Displays the lube oil temperature.
Displays the engine load as a percentage of maximum load (from
Load %
Caterpillar ECM).
Battery Volt. Displays the main battery voltage (from Caterpillar ECM).
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Control Description
Air Pressure Displays the pressure in the air circuit.
Gearbox Press. Displays the pressure in the lube oil circuit.
Hydraulics Main
Displays the pressure in the main hydraulic circuit.
Press.
Displays the temperature in the hydraulic oil tank (oil used for both
Hydraulics Oil Temp.
main and auxiliary circuit).
Displays the fuel consumption rate of the engine (from Caterpillar
Fuel Rate
ECM).
Fuel Press. Displays the fuel pressure of the engine (from Caterpillar ECM).
Fuel Temp. Displays the temperature of the engine fuel (from Caterpillar ECM).
Displays the percentage of throttle that is open, which corresponds

Throttle Pos.
to the RPM display.
Hours Displays the total run time of the engine (from Caterpillar ECM).
Inlet Temp. Displays the engine air inlet temperature (from Caterpillar ECM).
Boost Press. Displays engine turbo boost pressure (from Caterpillar ECM).
Displays the engine torque as calculated from known engine operating
Calc. Torque
parameters.
START Engine button Starts the engine at idle speed.
STOP Engine button Kills the engine.
Full Throttle button Sets the engine to run at full throttle (2,100 rpm).
IDLE button Sets the engine to run at idle (700 rpm).
Incrementally sets the engine to run at speeds between idle and full
Up/Down buttons throttle. Holding down the arrows increases the rate at which the
speed will change.
RPM display Displays the current rpm of the engine (from Caterpillar ECM).
Engine Diagnostic
Displays error codes and descriptions (from Caterpillar ECM).
Information display
HIDE/SHOW More Correspondingly hides or shows the information displayed in the
Info. Buttons Additional Diagnostics frame.
Toggles the displayed units for values acquired by actual sensors; i.e.,
not from the Caterpillar ECM. The displays affected by the Toggle
Units button are:
Toggle Units button – Gearbox temperature - Air pressure
– Gearbox pressure - Drop box pressure
– Hydraulic oil temperature - Hydraulic main pressure
This is the setpoint used to keep the level of the header tank at
Header Tank Setpoint a certain percent. The setpoint can be changed by pushing the
Setpointbutton, which will bring up a keypad display.
Header Tank % The current level of the header tank given in percent.
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Control Description
Header Tank Close This will CLOSE the air-actuated control valve that supplies fluid to
button the header tank.
Header Tank Open This will OPEN the air-actuated control valve that supplies fluid to the
button header tank.
This will use the header tank setpoint to automatically control the
Header Tank Auto
position of the air-actuated control valve that supplies fluid to the
button
header tank.
Displays the suction pressure when using Pressure Control mode

Suction Press*
(determined by pressure switch).
Pressure Control
This will CLOSE the air-actuated control valve.
Close button*
Pressure Control
This will OPEN the air-actuated control valve.
Open button*
Pressure Control Auto This will use the suction pressure to automatically control the position
button* of the air-actuated control valve.
*These controls will only appear when using Figure 3-53 (p. 3-79)
STRAIGHT-THROUGH mode and bypassing the header tank. The pressure
switch sends a signal to the DCU indicating which mode is being used (either
standard HEADER TANK CONTROL or PRESSURE CONTROL).
In similar manner to the Diagnostics screen, engine diagnostics and other

indicators on the Engine Control screen can be toggled to show the output
from various sensors as needed, which can be particularly useful when
troubleshooting.
Table 3-14: Toggled Units in Engine Diagnostics Display
Sensed transducer
Field Corresponding physical units
quantity
Gearbox Temperature
(Operating temperature
milliAmps (range: 4–20) degF
should be no more than
240 degF max.)
Air Pressure (Pressure
should be at least 60 psi
milliAmps (range: 4–20) psi
or more for air-actuated
valves to operate correctly.)
Gearbox Pressure (Normal
gearbox pressure usually
goes no higher than about milliAmps (range: 4–20) psi
30 psi, depending on how
fast the POD is run.)
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Sensed transducer
Field Corresponding physical units
quantity
Hydraulic Main Pressure
(Normal operating pressure
milliAmps (range: 4–20) psi
is at about 1,500 psi, +/-
100 psi.)
Hydraulic Oil Temperature
(Normal operating
temperature is about
milliAmps (range: 4–20) degF
130–160 degF, and should

go no more than 190 degF
max.)
3.5 Remote engine operation

The 500-BHP diesel cab engine of the SBT-615 drives the mixer and centrifugal
pump as well as the hydraulic and pneumatic systems in addition to powering
the vehicle on the road. A successful stimulation job with this unit depends on
reliable remote control of the engine from the POD control touchscreen.
Note
Make sure the transmission is set to 9th gear when running the POD mixer to
allow a maximum mixer speed of about 1,400 rpm (2,100 rpm engine speed) at
full throttle. Running the POD in a higher gear will likely cause POD discharge
fluid overpressure resulting in a potentially dangerous situation.

Hazard Category: Land transport, Machinery equipment hand tools
Lower the POD to the ground or as far down as possible before running the
mixer to avoid drivetrain damage from excessive driveline angularity.

Hazard Category: Land transport, Machinery equipment hand tools
Pay close attention to the warning at the beginning of Section 3.1 Power-up
procedure (p. 3-1) regarding proper transmission gear selector shifting. This is
critical to prevent damage to the transmission and avert a major job operating
failure on location.
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3.5.1 Manual engine speed control

The START Engine and STOP Engine buttons are self-explanatory.
Pressing the FULL THROTTLE button causes the engine to immediately run at
full 2,100 rpm, while pressing the IDLE button causes the engine to immediately
drop down to 700 rpm idle speed.
The up/down arrows to the right of the RPM display allow the POD operator to
manually adjust the engine speed to any setting between idle and full throttle.

NEVER RUN THE ENGINE AT FULL THROTTLE BY STEPPING ON THE

ACCELERATOR PEDAL WHILE THE TRANSFER CASE PTO IS IN PUMP
POSITION AND THE MIXER IS NOT FULLY LOWERED TO THE GROUND.
Serious damage to the equipment and possible injury to personnel can occur
when running the mixer at high speed due to severe driveshaft angularity when
the mixer is not fully lowered.
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3.6 System plumbing and valve operation
3.6.1 Plumbing layout

The system plumbing can be divided into the following sections:
• suction manifold (curb side of unit) consisting of five 4-in and one 8-in suction
hose connections on 8-in piping which leads into the suction inlet of 8x6
centrifugal pump
• 8x6 centrifugal with 6-in pipe discharge leading into header tank
• 10-bbl capacity header tank with electronically controlled proportional valve
system to regulate fluid level in tank
• 8-in piping leading from the header tank into the POD suction deck; contains
8-in suction flowmeter, a 4-in hose connection port just aft of the suction
flowmeter for cleaning out the suction piping, and 1-in connections for
plumbing LAS module discharge into the suction lines
• 6-in discharge piping leading from the POD discharge outlet to the discharge
manifold (road side of unit); includes a densitometer located at the POD
discharge outlet for measuring slurry density
• discharge manifold with four 4-in discharge hose connections
• 2-in recirculation hose from the discharge piping back to the suction piping
for recirculating fluid through the POD for short periods of time; includes a
2-in connection for use in priming pump units
• 6-in discharge crossover piping for diverting fluid from the discharge side to
the suction side of the unit; includes two 4-in discharge hose connections
and is useful for batch-mixing gelled water tanks using the centrifugal pump
to circulate fluid from the tanks through the suction manifold and back into
the tanks through the discharge crossover
• electronically and manually controlled valves systematically located to
regulate fluid flow according to programmed touchscreen operations.
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Figure 3-45: Major components of the plumbing system (curbside view)
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Figure 3-46: Major components of the plumbing system (roadside view)
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Figure 3-47: System plumbing diagram
3.6.2 Valve layout

The plumbing system valve layout is pictured in Figure 3-48.
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Figure 3-48: Valve layout diagram
Table 3-15 lists the valves referenced in Figure 3-47 and Figure 3-48.
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Table 3-15: Valve Description
Symbol Description Activation

M1 Backup header tank inlet valve Manual
M2 Prime-up valve Manual
M3 Secondary mixer recirculation line valve Manual
Deck sump-to-suction line discharge
M4 Manual
valve
M5 Deck sump discharge-to-ground valve Manual

M6 Crossover discharge cutoff valve Manual
Air (computer-controlled solenoid valve or
A1 C-pump-to-header tank valve
backup console-controlled)
A2 C-pump discharge valve
A3 Mixer discharge valve
A4 Mixer recirculate valve
A5 Mixer suction valve
A6 Header tank outlet valve Air-actuated manual
A7 Header tank-bypass flow valve Air-actuated manual
A8 Primary header tank inlet valve Air-actuated manual
Air (Electronically controlled proportional
A9 Header tank fluid level control valve
valve)
S1-S6 Suction manifold valves Manual
D1-D6 Discharge manifold valves Manual
3.6.3 Valve operations from the POD Control touchscreen
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Figure 3-49: Valve operations from the POD Main Control screen
The following are the main operating functions the POD operator will use on a job:
Term Definition
1) DOWNHOLE: This function closes the recirculation line valve A4 (if open), and
opens mixer suction valve A5 and mixer discharge valve A3.
2) RECIRC: This function opens mixer suction valve A5, mixer discharge valve
A3, and recirculation line valve A4 to help eliminate air in the lines
during prime-up.
3) ISOLATE: This function sequentially closes off mixer suction valve A5, mixer
discharge valve A3, and recirculation line valve A4 (if open) to
isolate the mixer.
4) CPUMP-HEADER: This function opens or closes valve A1 from the C-pump to the
header tank.
5) CPUMP-DISCH This function opens or closes valve A2 from the C-pump to the
discharge manifold.
Table 3-16: Valve Configurations for Major POD Functions
Suction Valve Discharge Valve Recirculation Valve

DOWNHOLE Open Open Closed
RECIRC Open Open Open
ISOLATE Closed Closed Closed
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Upon powering up the unit, the power-up status of all electronically controlled
valves is closed.
Use the backup console (below) to manually control valve operations in the
event of POD computer control system failure. Use an object such as a pen or
pencil to depress the buttons that operate the switches.
Figure 3-50: Close-up view of the backup console switches
MIXER SUCTION = VALVE A5

MIXER DISCHARGE = VALVE A3
MIXER RECIRCULATE = VALVE A4
C-PUMP HEAD TANK = VALVE A1
C-PUMP DISCHARGE = VALVE A2
Valves A6, A7, and A8 under the header tank are normally preset for flow to the
header tank from the C-pump. To set valves A6, A7, and A8 for header tank
bypass, move the manual switch located near the A6–A8 valve cluster just below
the header tank on the curb side of the truck into BYPASS position; be sure to
set this switch back to HEADER TANK position if the header tank is needed
for the next job performed by the unit.
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Figure 3-51: Manual valve for header tank bypass
Note
When pumping DOWNHOLE to triplex pumps on a job while bypassing the
header tank, a fluid hammer effect in the plumbing system (seen as a sudden
shuddering or noticeable acute vibration in the piping) may occur together with
splashing of fluid from the POD once the triplex pumps are shut down while the
POD is still trying to supply fluid for the pumps. To minimize the splashing from
the POD, connect one end of a 4-in suction hose to the 4-in suction cleanout
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connection aft of the 8-in suction flowmeter, and the other end to the unit suction
manifold or to the frac fluid tank to provide a relief pathway for fluid backup to
escape.
Figure 3-52 and Figure 3-53 show DOWNHOLE flow with and without header
tank, respectively.
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Figure 3-52: Flow diagram of DOWNHOLE operation with header tank
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Figure 3-53: Flow diagram of DOWNHOLE operation without header tank
Figure 3-54 and Figure 3-55 and depict the RECIRCULATE and ISOLATE
operations, respectively, with the POD unit.
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Figure 3-54: Flow diagram of RECIRCULATE operation during pump prime-up
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Figure 3-55: Flow diagram of ISOLATE operation
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The following example illustrates how multiple valve operations can be used for
a given pumping operation. In the example of DIRECT mode, fluid is pumped
directly from the suction manifold to the discharge manifold through the C-pump
while bypassing the header tank and POD; this DIRECT pump mode is suitable
for safely pumping acid to minimize unsafe splashing of acid from the POD and
header tank. To pump in DIRECT mode:
1. Place the POD in ISOLATE to prevent discharge flow back to the mixer.
2. Close CPUMP-HEADER (valve A1) to bypass the header tank.

3. Open CPUMP-DISCH (valve A2) to open fluid access to the discharge
manifold.
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Figure 3-56: Flow diagram of C-pump flow direct to discharge manifold
The scenarios shown in Figure 3-52 through Figure 3-56 illustrate the most
common procedures that a SBT-615 POD operator would normally encounter on
a job. Here are some additional key points to mention:
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• During job operation, usually either the CPUMP-HEADER valve is open

and the CPUMP-DISCH valve is closed or vice versa, but both should not
be open at the same time. If both valves are accidentally opened, some
discharge from the POD may enter the header tank and possibly clog the
header tank with proppant.
• Nothing adverse will happen when going straight from ISOLATE to RECIRC.
• Nothing adverse will happen when going straight from RECIRC to ISOLATE.
• Nothing adverse will happen when going from DOWNHOLE to ISOLATE

and vice versa.
• When the POD is in ISOLATE during a job, the POD gate should be closed
to avoid clogging the mixer when full of proppant.
• All additives are either stopped or put into their respective recirculation
modes when ISOLATE is activated, and access to the DryAdds and Fiber
functions is not allowed.
• REMOTE mode is also unavailable when the POD is in ISOLATE.
3.7 Header tank level control system operation

The process fluid coming from the 8-in suction line is stored temporarily in the
header tank. The tank is made of stainless steel, with access to the top of the
tank by means of roadside and curbside ladders for maintenance and cleaning.
A tank-mounted sightglass is a visual monitor of the fluid level inside the tank.
With a capacity of 10 barrels, the header tank maintains a constant positive
hydrostatic pressure and flow for mixer suction.
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Figure 3-57: Header tank with roadside ladder and storage basket
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Figure 3-58: Back view of header tank assembly
The constant pressure head is achieved by controlling the fluid level in the tank
by means of a header tank pressure sensor and the air-actuated control valve
(A9 in Figure 3-48 (p. 3-72)). The pressure sensor sends a 4 to 20 mA signal
to the POD control system via header DCU that is proportional to the fluid level
in the tank, and the POD control system commands an air-actuated valve to
regulate the header tank level.
The operator has four ways to verify the fluid level inside the header tank during
the job:
• POD control touchscreen

• FracCAT control monitor
• header tank sightglass
• visual inspection using ladder on either side of the header tank.
The header tank level can be controlled from the Engine Control screen by
pressing the Setpoint button to enter a desired header tank level as a setpoint.
Usually, a setpoint between 70% and 80% suffices for most jobs. Pressing the
Auto button allows the POD control system to automatically maintain header
tank level according to the entered setpoint.
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Manually override control valve A9 by pressing either Close (e.g., in the event
of header tank overflow) or Open (e.g., in the event of inadequate header tank
level) as needed.
Figure 3-59: Header tank level control from the Engine Control screen
During the job it is important to periodically verify that the level of fluid in the
header tank sightglass is within +/- 10% of the setpoint (70 to 80%) to ensure
proper suction intake fluid pressure to the mixer.
In the event of a computer system failure, it may be necessary to control the

level of the header tank manually using the manual valve M1 located on the
road side of the truck just underneath the header tank. Valve M1 is usually kept
closed during normal operation while the control system operates valve A9 to
regulate flow to the header tank. To manually override header tank control during
an emergency, press the Close button on the header tank section of the Engine
Control screen to close off valve A9, and then adjust valve M1 as needed to fill
the header tank while constantly monitoring the fluid level in the header tank
sightglass during the job.
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Figure 3-60: Location of manual fill valve M1 for header tank
3.8 Centrifugal pump operation

The direct engine-driven 8x6 centrifugal pump maintains flow to the header
tank to ensure steady fluid level within the tank, particularly when the mixer
discharges for high-rate pumping. Use the power take-off (PTO) switch inside
the cab of the truck to engage or disengage the C-pump. While the engine is
running, press the clutch pedal down completely before toggling the PTO switch,
and then smoothly release the clutch.
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Figure 3-61: C-pump PTO switch location on dashboard
During a frac job, the C-pump generally runs at varying speeds in direct relation
to variations in truck engine/mixer speed.
Figure 3-62: Location of 8x6 C-pump – bottom perspective
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Figure 3-63: Location of direct engine-driven 8x6 C-pump – profile perspective
3.9 POD system operation

The POD mixer assembly comprises the heart of the slurry blending operation of
stimulation work. The operation of the dry additive feeders and the fiber feeder
function directly with the mixer, and are located close together accordingly. The
SBT-615 500-bhp Caterpillar C-15 diesel engine powers the blender driveline
along with the hydraulic systems, centrifugal pump, and on-road motoring
functions.
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Figure 3-64: Mixer assembly components, part 1 of 3
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Figure 3-67: Internal mixer components (cutaway view)
3.9.1 Mixer module operation
3.9.1.1 Proppant control

POD mixer operations are controlled primarily from the Main Control screen
on the POD touchscreen. Activating the Prop field regulates slurry proppant
concentration during the PPA stages of a frac job. The following figure shows the
Main Control screen with Prop set as the active field in MANUAL mode.
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Figure 3-68: Main Control screen with activated proppant control
Table 3-17: Proppant Control Screen Details

The Prop button activates the mixer controls. When selected, all of
Prop the display windows in the Prop field have a white background and
the control buttons are activated.
The Actual field displays the actual proppant density concentration
being pumped. Normally, this is the density measured by the radioactive
Actual
densitometer. When in BACKUP mode, this field displays the density
calculated from gate position and flow rate.
The Setpoint field displays the proppant density setpoint. In REMOTE
mode, this setpoint is sent to the POD from FracCAT; otherwise, it
is entered using the Setpoint arrows or the numerical keypad on the
Setpoint
Mixer/Additives Control screen.
The unit refers to the chosen mode: Gate% in MANUAL, and PPA in
AUTO mode.
The Gateposition field displays the current gate position in percent open
Gateposition
from 0 to 100 percent.
The Mode field displays the current operating mode of the mixer, as
Mode
selected in the Mode field (MANUAL, AUTO, or REMOTE).
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The Valves field displays the current valve configuration of the blender
as selected in the Valves field (DOWNHOLE, RECIRCULATE, and
ISOLATE, as described in Section 3.6 System plumbing and valve
Valves operation (p. 3-68)).
C-pump header and C-pump discharge valve operations also take place
in this field, as described in Section 3.6 System plumbing and valve
operation (p. 3-68).
In the Mode field, the operator can select the mode of operation for the
blender. Each mode operates as follows:

MANUAL – The operator enters a setpoint in gate percentage, which
directly opens and closes the gate. There is no automatic control of
density. The densitometer output signal is not used to control density,
Mode only to display a density reading.
AUTO – The operator enters a setpoint in PPA or kg/m3 and the blender
controls the gate to achieve the setpoint, which it holds automatically.
REMOTE – A setpoint in PPA or kg/m3 is sent from FracCAT; the
blender controls the gate to achieve that setpoint, then holds the setpoint
automatically. The operator is not required to control the density.
The Setpoint field enables the operator to enter a setpoint (density)
for the mixer.
The STOP button activates the zero setpoint screen (see Figure 3-69):
Current Selection: Zeros only the current active setpoint.
Zero All: Zeros all setpoints except mixer speed.
Cancel: Cancels zero selection.
Setpoint Arrows UP and DOWN: Press the UP arrow to raise the density and
the DOWN arrow to lower it. To rapidly change the density, hold the
arrows down.
KeyPad: Allows typing the desired amount (either Gate% or PPA) (see
Figure 3-70). When finished typing, press OK to validate this new
setpoint. If the typed amount exceeds the physical maximum, then the
setpoint goes to the maximum allowed position (100% gate or 40 PPA)
Discharge Rate Displays calculated mixer discharge rate.
Discharge Pressure Displays discharge pressure.
Suction Rate Displays mixer suction rate.
Suction Pressure Displays suction pressure.
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Figure 3-69: Zero Setpoints screen
Figure 3-70: Numeric keypad for manual entry
3.9.1.2 Mixer speed control

Mixer speed can be controlled from either the Main Control screen or the Engine
Control screen. The relationship of engine speed to mixer speed is:
Engine Speed = 1.5 x Mixer Speed
Table 3-18: Mixer Speed Relationships for Selected Engine Speeds
Engine Speed (rpm) Mixer Speed (rpm)

1,650 1,100
1,800 1,200
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Engine Speed (rpm) Mixer Speed (rpm)

1,950 1,300
2,100 1,400
Figure 3-71: Main Control screen with activated mixer speed function
Table 3-19: Mixer Speed Control Function Descriptions

Mixer Speed The Mixer Speed button activates the mixer speed control.
The RPM field displays the actual mixer speed. This speed is calculated
Mixer Speed RPM
from the engine speed sensor.
Throttle the engine up or down as needed to control the speed of the mixer. It
is common procedure for a POD operator to run the mixer at a constant speed
close to full throttle during a typical job.
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NEVER RUN THE ENGINE AT FULL THROTTLE BY STEPPING ON THE

ACCELERATOR PEDAL WHILE THE TRANSFER CASE PTO IS IN PUMP
POSITION AND THE MIXER IS NOT FULLY LOWERED TO THE GROUND.
Serious damage to the equipment and possible injury to personnel can occur
when running the mixer at high speed due to severe driveshaft angularity when
the mixer is not fully lowered.
3.9.1.3 Gate system operation

The SBT-615 6x4 POD gate system regulates the flow of proppant passing
through the gate and into the mixer while a sand dispensing unit, such as a
Sand Chief or belt loader, feeds proppant into the hopper mounted directly
above the gate (Figure 3-66 (p. 3-93)). The gate control system utilizes slurry
proppant concentration feedback from a densitometer and a suction flowmeter
to regulate gate position by means of the POD control system, as described
in Section 3.9.1.1 Proppant control.
When not controlling the POD in AUTO or REMOTE mode, the gate position can
be entered in MANUAL mode on the Main Control screen as a percentage of
the maximum opening, using the gate calibration proppant charts in Appendix B
Proppant Gate Charts (p. B-1). For a given proppant, use the gate position value
from the appropriate proppant chart that matches the bbl/min and PPA needed.
In the event of loss of computer control over the hydraulic gate actuator, use the
gate control handle on the Apitech valve, along with the gate position indicator
shown in Figure 3-66 (p. 3-93) and the charts in Appendix B to manually position
the gate as needed. Such an emergency may also require using the backup
control console to operate the plumbing system valves to complete the job. Be
sure to disconnect the pulsar cables from the top and bottom of the Apitech
before attempting to control the gate with the handle to prevent the control
system from possibly overriding manual control of the gate.
To properly set up the gate control system prior to a job, first make sure that the
high-rate gate is selected as the gate type for the SBT-615 6x4 by opening the
Calibration screen, selecting the Advancedbutton, and then selecting High-Rate
Gate in the Gate Type selection field. Next, enter the property values of the
specific proppant to be used on the Calibration screen (Figure 3-72). Enter
proppant type (sand, bauxite, etc.), size (20/40, 30/60, etc.) and calibration factor
(size factor taken from sand gate calibration charts in Appendix B).
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Figure 3-72: Proppant property entry fields on the Calibration screen
Use the Calibrate Gate function (Figure 3-72) only if the solids DCU software
code is upgraded or if any repair or replacement has been made to the gate
position transducer rod or magnet. Make sure to press the Advanced button
first on the Calibration screen to select High-Rate Gate for Gate Type before
performing the gate calibration. When the Calibrate Gate button is depressed,
follow the instructions displayed on the screen to complete the Calibrate Gate
setup (Figure 3-73).
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Figure 3-73: Calibrate gate procedure window
To save the new calibration settings, press the Advanced button on the
Calibration screen and then press Maintenance Mode to update the settings
in the master calibration file.
Check periodically that the surfaces of the gate that come in contact with the
supporting rollers are relatively free of proppant and debris that can interfere with
gate movement. A pressurized cleaning air hose or canned air can be used to
blast particles clear of the gate rollers.
Note
Always make sure that High-Rate Gate is selected as the Gate Type for the
SBT-615 6x4 PodSTREAK prior to all jobs to prevent incorrect gate performance
and possible negative job consequences from occurring if some other gate type
is inadvertently selected.
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Note
If for any reason the gate has to be disassembled for servicing, the gate will have
to be realigned upon reassembly according to the alignment procedure in the
Part #100191611 gate module assembly drawing in the SBT-615 Maintenance
Manual, InTouch content ID# 3842981. Failure to realign the gate according to
the alignment procedure may result in severe damage to the gate position sensor
rod and possibly have negative consequences on a job.
3.9.1.4 Lifting system operation

The mixer support system uses a patented dual-jack screw-based lift mechanism
to raise and lower the mixer assembly to either on-road or pump positions,
respectively.
To lower or raise the mixer, press down or lift the handle labeled POD LIFT
(depending on the desired operation) on the Apitech valve until the mixer is in
the desired position. At the end of the job, the mixer must be lifted to its highest
position prior to driving back to the district. This position is approximately 18 in
from the bottom of the mixer tub to the ground. The mixer will automatically stop
traveling upwards when the highest on-road position is attained.
3.9.1.5 Hopper cover operation

The mixer system features a cylinder-actuated cover that shields against rain,
road mud, etc., and serves as a sand deflector when a Sand Chief is used (Figure
3-64 (p. 3-91)). To open or close the cover, lift up or press down on the handle
(depending on the desired operation) labeled POD COVER on the Apitech valve.
When opened, the hopper cover acts as a useful backstop for deflecting proppant
into the hopper by allowing a Sand Chief or belt loader unit to sling proppant
directly against the cover.
3.9.1.6 Digital camera

A digital camera mounted underneath the hopper cover points directly down
into the mixer when the cover is fully raised (Figure 3-64 (p. 3-91)). The digital
camera allows the POD operator to remotely monitor sand flow into and out of
the mixer hopper from inside the control cabin. A worklight mounted beside the
camera provides extra illumination into the hopper, which is particularly useful for
nighttime or dim-lighting conditions.
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The digital camera display monitor is located above the POD control touchscreen
so that the POD operator can monitor the amount of proppant going into and
contained inside the hopper at any given point during a job while performing POD
operations at the same time. The camera and display monitor turn on using the
same switch inside the control cabin that turns on the overhead fluorescent lights.
3.9.2 Dry add feeder operation

The two dry additive feeder systems utilize a precision metering screw with
a secondary upper conditioning screw that breaks up clumps in dry materials
to facilitate metering. The conditioning screw is driven by an integral gearbox
that rotates at 25 percent of the feed screw speed. Conditioned material is
discharged from the feeder by feed screw rotation, with flow being proportional to
screw speed. Interchangeable feed screws supplied with the feeder provide a
wide delivery rate range.
A 10:1 worm-reduction gearbox mounted at the rear of the feeder assembly

drives the feed screw, and a proportionally controlled hydraulic motor directly
mounted to the gearbox delivers primary power. The normal delivery speed
range for the feed screw is 10 to 200 rpm.
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Figure 3-74: Dry add feeder modules
Additional features of the dry additive system include a fixed hopper with built-in
guards.

Hazard Category: Human
Never operate the feeder with the hopper base and guard removed!
Non-standard screws can be obtained from the manufacturer and will require
calibration.
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3.9.2.1 Hazards
It is normal for a small amount of hydraulic oil to leak past the Apitech valve,
even when the valve is closed. The screw can turn slowly enough under these
conditions for it to appear not to be moving. It can also stop turning and then
break free for a quarter of a turn as oil builds up in the motor. The screws can
also turn unexpectedly if the manual control valve is open.
Potential Severity: Major

Exercise extreme care when servicing internal feeder components or changing

feed screws. Shut off the truck engine and relieve residual hydraulic pressure by
moving either the manual control valves or loosening hydraulic hose fitting(s)
prior to performing any work on the hydraulic system or any of its components.

Keep your hands out of the feed hopper. Never attempt to push additive material
into the screw with a bar; it may get caught in the conditioning screw.

Potential Loss: Assets, Personnel, Process
Hazard Category: Fire flammable, Human, Temperature
Some additives can catch fire if the feed tube is plugged and the screw continues
to grind and compress the material in the feed tube.

Potential Loss: Assets, Personnel, Process
Hazard Category: Explosives, Fire flammable, Human, Temperature
The dry-add feeder should be cleaned of any previous chemicals prior to each
job to prevent the possibility of undesired and dangerous reactions.
3.9.2.2 Initial setup
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Figure 3-75: Main Control screen with activated dry add control
Table 3-20: Dry Additive Main Screen Functions

The Dry Add button activates the dry additive system controls. When selected, all the
Dry Add display windows in the dry additive field have a white background and the control
buttons are able to activate the functions of the dry additive feeder.
The Actual field in the Dry Add function displays the current dry additive rate or
Actual
concentration according to the mode selection.
The Setpoint field displays the current setpoint. In the REMOTE mode, this setpoint is
Setpoint
sent to the POD from the FracCAT. Otherwise, it is entered using the Setpoint buttons.
The Tachometer field displays the dry additive feeder speed. Speed is always
Tachometer
displayed, regardless of the selected mode.
The Mode field displays the dry additive feeder’s current operating mode as selected in
Mode
the Mode field (MANUAL, AUTO-RATE, AUTO-CONC, REMOTE).
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The Mode field allows the operator to select the mode of operation. Each mode
operates as follows:
MANUAL: Pressing the Setpoint arrows increases or decreases the feeder screw
directly.
Automatic control is not used and the setpoint is shown as a percentage (%) of the
maximum screw rate.
AUTO-RATE: In this mode, the DryAdd injects a certain weight of additives per
minute (e.g., 6 lbm/min) regardless of the clean fluid rate going into the blender. The
tachometer control ensures that the desired rate is achieved.

Mode
AUTO-CONCENTRATION: In this mode, the operator sets a concentration: pounds of
dry additives for 1,000 gallons of clean fluid. The system adjusts this concentration
from the discharge flowmeters (curb, road, or both calculated suction rate according to
the backup set-up—see the clean fluid master rate information in the Backups section)
and the tachometer. So, the operator selects a concentration of additive to inject
(e.g., 3 lbm/1000 gal) and the DryAdd slaves the injection rate to the clean fluid rate
coming into the blender.
REMOTE – A concentration setpoint is sent from FracCAT and the DryAdd
automatically maintains this setpoint.
This Setpoint field enables the operator to enter or modify the DryAdd setpoint.
The STOP button activates the Zero Setpoint screen (see Figure 3-69):
Setpoint
Arrows UP and Down: Press the UP arrow to raise the flow-rate and the DOWN arrow
to lower it. To rapidly change the DryAdd rate, hold the arrows down.
KeyPad: Allows entry of the desired amount (in %, lbm/min or lbm/1,000gal) (see
Figure 3-70). When finished typing, press OK to validate this new setpoint.
If the typed amount exceeds the physical maximum (or minimum), then the setpoint
goes to the maximum (or minimum) allowed flow rate.
1. Determine the proper screw size according to treatment requirements using

the following tables.
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Table 3-21: Screw Size Chart (English Units)
Dry Add Screw Size Chart (English Units)

Coarse Screw Fine Screw
Material Screw Minimum Maximum Screw Minimum Maximum
Code lbm/rev lbm/min lbm/min lbm/rev lbm/min lbm/min
B001 0.129 1.28 25.76 0.061 0.62 12.20
J110 0.111 1.12 22.20 0.063 0.62 12.58
J353 0.292 2.92 58.48 0.156 1.56 31.20

J418 0.196 1.96 39.22 0.122 1.22 24.46
J464 0.212 2.12 42.42 0.141 1.42 28.24
J603 0.143 1.42 28.56 0.086 0.86 17.10
J475 0.250 2.50 50.04 0.140 1.40 27.96
J479 0.240 2.40 48.00 0.140 1.40 28.00
J218 0.221 2.21 44.20 0.109 1.09 21.80
J481 0.302 3.02 60.40 0.166 1.66 33.20
J490 0.329 3.29 65.80 0.166 1.66 33.20
Table 3-22: Screw Size Chart (Metric Units)
Dry Add Screw Size Chart (Metric Units)

Coarse Screw Fine Screw
Material Screw Minimum Maximum Screw Minimum Maximum
Code kg/rev kg/min kg/min kg/rev kg/min kg/min
B001 0.058 0.58 11.68 0.028 0.28 5.53
J110 0.050 0.51 10.07 0.029 0.28 5.71
J353 0.132 1.32 26.52 0.071 0.71 14.15
J418 0.089 0.88 17.79 0.055 0.55 11.09
J464 0.096 0.96 19.24 0.064 0.64 12.81
J603 0.064 0.64 12.95 0.039 0.39 7.76
J475 0.113 1.13 22.69 0.063 0.63 12.68
J479 0.108 1.08 21.77 0.063 0.63 12.70
J218 0.100 1.00 20.05 0.049 0.49 9.89
J481 0.137 1.37 27.40 0.075 0.75 15.06
J490 0.149 1.49 29.85 0.075 0.75 15.06
Note that these charts are not all-inclusive. New additives are continually being
developed, making it difficult to provide a comprehensive list of screw factors. In
addition, some districts have their own local additives.
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2. Screw calibration (perform this task at the district well in advance of a

upcoming job).
a. Disconnect the pipe chute leading from the dry add feeder outlet down
into the mixer cone.
b. Remove the pipe chute, and place a bucket inside the mixer cone directly
beneath the discharge outlet of the dry add feeder.
c. Run a known weight of additive through the feeder using several different
rpm settings to determine the number of lbm/kgal needed per revolution.

d. Repeat the calibration several times to calculate an average. Alternatively,
a calibration bucket can be placed directly below the dry add discharge
tube.
3. Change the feed screw, if necessary.
a. Turn off the engine.

b. Remove the retaining nut of the feed screw using a 3/4-in socket wrench.
c. To remove the feed screw, loosen it by turning it in a clockwise direction
(when facing the feeder).
d. To install the feed screw, tighten it by turning it counterclockwise (when
facing the feeder).
Note
The feed screw has a left-handed thread. To tighten the feed screw, turn it
counterclockwise.
4. Enter the desired dry additive screw factor on the Calibration screen.
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Figure 3-76: Dry add screw factor entry fields. (On the Calibration Control screen)
Although the dry additive system will operate in the MANUAL (RPM) mode using
any number entered as the screw factor, the proper screw factor is required to
take full advantage of the unit’s capabilities. The correct screw factor permits the
unit to operate in CONCENTRATION mode.
When running in lbm/kgal, the dry feeder rate is coupled to the clean fluid flow
rate in the master rate selection. The master clean fluid setting uses the same
principle as the LAS without FracCAT data.
All procedures described apply to both dry add feeders.
3.9.2.3 Normal operation

Modes of operation can be selected from the touchscreen – MANUAL,
AUTO-RATE, AUTO-CONC, REMOTE, and BACKUP (Table 3-23).
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Table 3-23: Dry Add Feeder Modes of Operation
Mode of
Unit Comment
Operation
Manual % Percent of the maximum flow rate
Auto-Rate lbm/min From 0 to 30 lbm/min depending on the screw factor
Concentration mode with the clean fluid suction rate
Auto-Conc lbm/1,000gal
as reference
Remote lbm/1,000gal Data sent from FracCAT

Emergency manual operation in case of electronics
Backup rev/min
failure
MANUAL dry add control
In MANUAL operation, the operator uses the setpoint arrow keys (0–100%)
to set the desired feeder rate. The feeder speed will not automatically adjust
to changing job requirements.
AUTO dry add control
In AUTO operation, the operator uses the setpoint arrow keys (lbm/min or
lbm/kgal) to set the desired feeder rate. The feeder speed will automatically
adjust to changing job requirements.
REMOTE dry add control
In REMOTE operation, the host computer controls the setpoints.
Note
Operation in either RATE or CONC mode is possible in AUTO mode, but only
CONC mode is possible in REMOTE mode.
3.9.2.4 Backup operation (Emergency procedures)

Backup control may be necessary as a result of electrical or mechanical failure.
The severity of the failure dictates the appropriate manual override.
Dry add feeder speed sensor failure
If the dry add speed sensor fails, there is no feedback for the system and the
AUTO and REMOTE modes will not function properly. Control is possible in
the MANUAL mode only, and some means of determining the speed of the dry
add feeder is needed.
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To be prepared for the possibility of having to use MANUAL mode to operate

the dry add feeders in an emergency, it is useful to put a visible mark on the
conditioning screw shaft (top shaft) of the feeder before going on a job. The
conditioning screw shaft should be used to determine feeder speed because its
slower rotational speed in relation to the bottom auger shaft makes it easier to
count the number of rotations in a given amount of time. The visible mark could
be a piece of reflective tape, a large dot made with a good visibility marker paint
pen, or some other means or marking. Before marking the conditioning screw,
make sure the engine is off and the hydraulics system is not engaged, and
apply the proper lockout/tagout procedure to ensure that no one can enter the
truck cab and start up the engine and hydraulics while marking the conditioning
screws of the dry add feeders.
Figure 3-77: Location for marking conditioning screws of dry add feeders
To use MANUAL mode:
1. Set the speed as usual in MANUAL.

2. Count the conditioning screw shaft (top shaft) revolutions for one minute by
counting each time the mark on the conditioning screw passes a given point.
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3. Multiply this number by four to determine the rpm.

4. Adjust the speed until the desired rpm is achieved.
Electronic control failure
In the event of electronic control failure, the dry additive feeder can be operated
manually using the associated knurled knob on the Apitech valve.
If the operator panel is displaying sensor inputs, adjust the knurled knob until the
proper rpm is achieved. If the operator panel is no longer displaying the sensor
inputs, the feeder speed must be determined in the same manner as described
above for sensor failure.
3.9.2.5 Typical problems

The most common problem is failure of the dry add speed sensor, which is
usually related to the adjustment of the proximity switch. Failure of the dry add
speed sensor can add an entire job’s worth of additive in a few minutes if the
feeder runs unchecked at the maximum rate. In case the sensor fails, it is
critical to have a stopwatch or a watch with a sweep second hand available to
determine the rpm from the dry add conditioning screw shaft. See the procedure
in the preceding section.
Sensitive control in MANUAL mode or unstable control in AUTO mode is

symptomatic of a bad pulsar on the Apitech control valve. Refer to the Apitech
supplement provided with the SBT-615 6X4 Vendor Maintenance Manual,
InTouch content ID# 3882299, for more detailed information.
Some additives are very corrosive, which means that the feeders should be
cleaned on location. If they are not, the additive will be dumped on the back end
of the truck, causing corrosion and slippery conditions. To clean out additive
buildup, run a small amount of sand through the feeder at the end of each job.

Hazard Category: Explosives, Human, Machinery equipment hand tools
Some chemicals metered by the dry add feeder are incompatible and can cause
explosive reactions if mixed. Verify the compatibility of additives prior to changing
additives, and always flush the feeder by running a bucket of proppant through it
to clean any residual chemical.
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3.9.3 Fiber Feeder

The Fiber feeder, a multi-screw feeder specifically designed to convey fiber
materials, operates from 10 to 200 rpm and can also be used to convey large
volumes of dry additives. The Fiber feeder discharges its load directly into the
mixer cone.
Figure 3-78: Fiber Feeder
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Note
CAUTION! Do not fill the Fiber feeder hopper with fiber before the feeder
screws are turning at a constant speed. Activating the feeder screws with a full
hopper may cause a surge in feeder screw speed after the initial static friction
is overcome in the drive system, resulting in the discharge of fiber at a high
enough rate to possibly impair the job.
3.9.3.1 Hazards
It is normal for a small amount of hydraulic oil to leak past the Apitech valve,
even when the valve is closed. The screw can turn slowly enough under these
conditions for it to appear to be stopped. It can also stop turning and then break
free for a quarter of a turn as oil builds up in the motor. The screws can also turn
unexpectedly if the manual control valve is opened.

Exercise extreme care when servicing internal feeder components. Shut off the
truck engine and relieve residual hydraulic pressure by moving either the manual
control valves or loosening hydraulic hose fitting(s) prior to performing any work
on the hydraulic system or any of its components.

Never operate the feeder with the guards removed.

Keep hands out of the feeder hopper. Never attempt to push fiber into the feeder
with an object of any kind. Objects may get caught in screws and cause personal
injury and/or equipment damage.
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This feeder is located in an extremely dusty area during operations. Review

all associated policies and procedures, and use proper personal protective
equipment (PPE).
Note
Do not leave residual fiber in the feeder from one job to the next. Old fiber may
hang up and cause plugging and/or bridging of the feeder.
3.9.3.2 Initial setup
Figure 3-79: Main Control screen with activated fiber control
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Table 3-24: Fiber Feeder Main Screen Functions

The Fiber button activates the fiber system controls. When selected, all the display
Fiber windows in the Fiber field have a white background and the control buttons are able
to activate the fiber feeder functions.
The Actual field in the fiber function displays the current fiber rate or concentration
Actual
according to the selected mode.
The Setpoint field displays the current setpoint. In the REMOTE mode; this setpoint is
Setpoint
sent to the POD from the FracCAT. Otherwise, it is entered using the Setpoint buttons.
The Tachometer field displays the fiber speed. Speed is always displayed, regardless
Tachometer
of the mode.
The Mode field displays the current operating mode of the fiber, as selected in the
Mode
Mode field.
MANUAL: Pressing the setpoint arrows increases or decreases the feeder screw
directly.
Automatic control is not used and the setpoint is shown as a percentage (%) of the
maximum screw rate.
AUTO-RATE: In this mode, the fiber feeder injects a certain weight of fibers per
minute (e.g., 6 lbm/min) regardless of the clean fluid rate going into the blender. The
tachometer control ensures that the desired rate is achieved.
Mode AUTO-CONCENTRATION: In this mode, the operator sets a concentration: pounds
of fibers for each percentage PPA or pounds of fibers for 1,000 gal of clean fluid
(operating side suction rate). The concentration reference is selected in the Backups
screen with a choice of Proppant (PPA as reference) or Cleanfluid (dedicated for
fat fibers operations). The operator selects a concentration of fibers to inject (e.g.,
30 lbm/%PPA or 30 lbm/1,000 gal) and the fiber slaves the injection rate to the total
proppant concentration running through the blender or to the clean fluid rate coming
into the blender.
REMOTE: A concentration setpoint is sent from FracCAT and the fiber automatically
maintains this setpoint.
This Setpoint field enables the operator to enter or modify the fiber setpoint:
The STOP button activates the Zero setpoint screen (see Figure 3-69):
Setpoint
Arrows UP and DOWN: Press the UP arrow to raise the rate or concentration and the
DOWN arrow to lower it. To rapidly change the fiber rate, hold the arrows down.
KeyPad: Allows entry of the desired amount (in %, lbm/min, lbm/%PPA or lbm/mgal)
(see Figure 3-70). When finished typing, press OK to validate this new setpoint.
If the typed amount exceeds the physical maximum (or minimum), the setpoint goes
to the maximum (or minimum) allowed flow rate.
At the beginning of the job, set the screw factor on the POD touchscreen control
panel according to Table 3-25.
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Table 3-25: Screw Size Selection for Two Major Fiber Types
Fiber Screw Size Chart

(English Units)
Material Code Screw Factor
J 501 1.75 lbm/rev
J 502 0.85 lbm/rev
Set the master rate based on one of the following parameters:
• Proppant – The rate in AUTO mode is expressed as a percentage (e.g., 1%)

of the proppant PPA.
• Clean Fluid – The rate in the AUTO mode is expressed as lbm per thousand
gallons of circulating clean fluid.
For information on FiberFRAC properties, including fiber feeder calibration

factors, refer to the Proppant Transport Additives J578/J579 Manual, Intouch
content ID# 4058678.
3.9.3.3 Normal operation

The fiber feeder can be operated in MANUAL mode, AUTO mode (AUTO-RATE
or AUTO-CONCENTRATION) or REMOTE mode. Emergencies involving the
failure of any of these operating modes may require the use of BACKUP mode
as a last resort.
Table 3-26: Fiber Feeder Modes of Operation
Mode of
Unit Comment
Operation
Manual % Percent of the maximum flow rate
Auto-Rate lbm/min From 0 to 300 lbm/min depending on the screw factor
%PPA or Depends on the master rate selection based on
Auto-Conc
lbm/1,000gal proppant rate or clean fluid rate (see above)
%PPA or
Remote Data sent from FracCAT
lbm/1,000gal
Emergency manual procedure in the event of
Backup rev/min
electronics failure
Manual fiber feeder control
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In MANUAL operation, the operator uses the setpoint arrow keys (0–100%) to
set the desired feeder rate. The feeder speed will not automatically adjust to
changing job requirements, and must be continuously monitored and adjusted
while in this mode.
Auto fiber feeder control
In AUTO operation, the operator uses the setpoint arrow keys (lbm/min for
auto-rate or %PPA - lbm-mgal for AUTO-CONC) to set the desired feeder rate.
The feeder speed will automatically adjust to changing job requirements.
3.9.3.4 Backup operation (Emergency procedures)

The following procedure may be necessary should an electrical or mechanical
failure occur.
Fiber feeder speed sensor failure
If the feed speed sensor fails, there is no feedback to the feeder control system
and the feeder will not function properly in AUTO mode. Control is possible
in the MANUAL mode:
• Set the speed, as usual, in MANUAL.

• Count the screw revolutions per minute and adjust as required.
Tip
Observing the motor shaft may be easier. The feeder hydraulic motor speed
runs 1.6 times faster than the feeder screw.
Electronic control failure
In the event of an electronic control failure, the feeder can be manually operated
using the knurled knob of the associated Apitech valve. If the feeder speed
sensor is operable, the rate may still be displayed on the operator panel.
However, if the speed sensor has also failed, use the method described for
dealing with speed sensor failure.
Refer to SUS-553 PropNET Feeder Operators Manual (571097000) for more

information about the fiber feeder unit. This document is also available in
InTouch, as part of the SBT-615 Vendor Maintenance Manual, content ID#
3882299.
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3.9.4 Densitometer operation

The POD densitometer is used to measure slurry density during a job and
provides feedback to the POD control system for automatic control of slurry
PPA. To operate correctly, the densitometer must be calibrated at least once a
week at the district and never on location. The densitometer is located on the
mixer discharge outlet piping.
Figure 3-80: Densitometer source ON
Both an air calibration and a water calibration are required for the densitometer
to operate effectively.
3.9.4.1 Air calibration

To perform an air calibration:
1. Verify that the densitometer is ON by verifying that the sliding plate has been
pushed inside (Figure 3-80).
2. Be sure no sand, chemicals or solids are inside the mixer. If the mixer is
not clean, blow-dry the mixer and discharge piping components clean with
this procedure.
a. Close all but one discharge valve on the discharge manifold.

b. Open the drain cap of the mixer (Figure 3-65 (p. 3-92)).
c. Set the mixer to RUN at full throttle without engaging the C-pump PTO.
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d. Allow the fan action of the mixer to blow through the discharge piping for
several minutes to clear debris and dry out the piping.
3. Go to the Calibrate screen on the POD touchscreen.
4. Press Do Air Cal button (Figure 3-82). The stored DCU value should be
between 9,300 mV and 9,600 mV. If the value displayed is significantly
different from the expected DCU value, verify that all cleaning and drying
operations were performed correctly, and that the source is in the OPEN
position.
5. To save the new calibration settings, press the Advanced button on the
Figure 3-81: Accessing the Densitometer Air Calibration screen
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Figure 3-82: Densitometer Air Calibration Control screen
6. To launch a new calibration, press Start and wait 30 seconds. If the value
remains in the same range with a value gap no greater than 300 mV, press
Accept to confirm this new value.
3.9.4.2 Water calibration

The best time to perform a water calibration is just after the air calibration, as
the pipes should be at their cleanest.
1. Put the mixer drain cap back in place.

2. Close the remaining discharge valve on the discharge manifold.
3. With an external (garden) hose, fill the mixer with clean water until the
level in the mixer reaches the spitring (Figure 3-67). This ensures that the
densitometer portion of the discharge pipe is completely full of water.
4. On the touchscreen, select Calibrate, then select Do Water Cal.
5. Verify that the current value is close to the value stored in the DCU. Normal
water values should be between 3,050 mV and 3,300 mV.
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Figure 3-83: Accessing the Densitometer Water Calibration screen
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Figure 3-84: Densitometer Water Calibration control screen
6. Press Start to begin the calibration.

7. After 30 seconds, if the proposed value is near the normal values, press
Accept. If the new value is not close to the value of the DCU value, review
all the steps of the procedure. Pay special attention to discharge pipe
cleanliness and the correct level of water.
8. To save the new calibration settings, press the Advanced button on the
Note
Water calibration should be done at the district ONLY, and never on a job. It must
be performed with clean, fresh water (approximately 8.34 ppg tap water).
3.9.4.3 Zero on Pad

This procedure allows the POD control system to compensate for the actual
density of the treating fluid, and is typically performed while pumping. If a Zero
on Pad procedure is not performed, the POD control system assumes that
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the previous job’s pad fluid is the treating fluid. If several pad fluids are used,
perform a Zero on Pad while pumping the fluid that is most like the frac fluid. If
water quality varies, perform a Zero on Pad every time it is possible to do so
when the sand rate is zero.
Note
It takes 30 seconds for the Zero on Pad to complete after starting, so plan
accordingly.
Figure 3-85: Accessing the Zero on Pad screen
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Figure 3-86: Zero on Pad screen
Press the Start button to begin the Zero on Pad process. The process requires
30 seconds, and a clock on the screen counts down the remaining time. When
the zero is complete, the Actual PPA on the main control screen in the Proppant
Control field should be zero, providing the fluid properties do not change.
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3.9.5 Liquid additive system (LAS) operation

The LAS modules meter various liquid chemical additives into the process fluid
during a job. The liquid chemicals that are metered are usually stored in tote
tanks or in large containers on board chemical transport units. The POD operator
normally runs the LAS modules using the POD touchscreen.
Access LAS control for any given LAS module using the Main Control screen
Figure 3-87.
Figure 3-87: Main Control screen with activated LAS1 control
Table 3-27: Functions of the Liquid Additives Main Screen

The LAS1 button activates the Liquid add system (LAS) controls. When selected,
LAS1 (LAS2,
all the display windows in the Liq Add field have a white background and the control
LAS3, etc.)
buttons can activate the blender functions.
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The Actual field displays the current additive rate. When running in AUTO-RATE,
Actual the value is shown in gal/min; when running in AUTO-CONC, the value is shown in
gal/1,000gal. In MANUAL mode, it shows a % of the maximum flow of the LAS.
The Setpoint field displays the desired setpoint. In the REMOTE mode, setpoint is
Setpoint sent to the POD from FracCAT. Otherwise, it is entered using the setpoint arrows or
keypad.
The Tachometer field displays the current additive rate as calculated from the
tachometer. The tachometer display always shows rate, even when the system is
Tachometer
running in AUTO-CONC. This serves as a good double-check of the system if the
required additive rate for each stage is noted before the job begins.
Mode The Mode field displays the current operating mode for a given LAS.
The Valve position field displays the current valve configuration (DOWNHOLE or
Valves
RECIRCULATE) of the additive system.
MANUAL: Pressing the setpoint arrows increases or decreases the speed of
the additive pump. Automatic control is not used and the setpoint is shown as a
percentage (%) of the maximum pump rate.
AUTO-RATE: In this mode, the LAS injects a certain volume of chemical per minute
(e.g., 6 gal/min) regardless of the clean fluid rate going into the blender. The
LAS-flowmeter control ensures that the desired rate is achieved.
Mode
AUTO-CONCENTRATION: In this mode, the operator sets a concentration: gallons of
liquid additive for 1,000 gallons of clean fluid. The system adjusts this concentration
from the discharge flowmeters (curb, road, or both according to the backup
set-up—see the Backup section) and the LAS flowmeter. The operator selects a
concentration of additive to inject (e.g., 3 gal/1,000 gal) and the LAS slaves the
injection rate to the clean fluid rate coming into the blender.
REMOTE: A concentration setpoint is sent from FracCAT and the LAS automatically
maintains this setpoint.
The operator can select the valve position.
Valves DOWNHOLE: Liquid additive is pumped downhole as directed by manual valves.
RECIRC: Liquid additive recirculates back to the tank.
This Setpoint field enables the operator to enter or modify the LAS setpoint:
The STOP button activates the Zero setpoint screen (see Figure 3-69):
Setpoint Arrows UP and DOWN: Press the UP arrow to raise the flow rate and the DOWN
arrow to lower it. To rapidly change the LAS flow rate, hold the arrows down.
KeyPad: allows entry of the desired amount (in %, gal/min or gal/1,000gal) (Figure
3-70). When finished typing, press OK to validate this new setpoint.
If the typed amount exceeds the physical maximum (or minimum), the setpoint goes
to the maximum (or minimum) allowed flow rate (e.g., maximum: 54 gal/min for the
SUP-512; minimum: 1gal/min) according to the type of LAS.
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3.9.5.1 LAS tachometer calibration

The liquid additive system (LAS) tachometer can be used to calculate the fluid
flow rate in the event of a MicroMotion flowmeter failure. The tachometer
must be calibrated to the flowmeter to store the tachometer cal-factor, which
compensates for differences in LAS pump efficiency.
The tachometer cal-factor is a function of suction, discharge conditions, and age

of the LAS pump. As a result, this calibration should be repeated whenever
switching injection points on the blender or whenever changing LAS chemicals.
To access the calibration screen for a given LAS, select which of four LAS
modules will be calibrated; i.e., Do LAS1 Cal, Do LAS2 Cal, etc., as shown in
Figure 3-88.
Figure 3-88: Accessing the LAS Calibration window from the Calibration screen
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Figure 3-89: Liquid Add Tachometer Calibration screen
Follow the instructions shown on the LAS calibration screen to perform this
procedure.
• Press Auto-Calibrate to begin the calibration procedure. The process takes

15 seconds, and a clock on the screen counts down the time.
• Reset Default resets the factor to 1.0.
• Custom Value allows the operator to set a custom calibration value.
Note
The normal value range is 0.8 to 1.2.
3.10 Webasto winterization kit (optional

equipment)
For SBT-615 6x4 PodSTREAK units intended to operate in arctic or extremely
cold climates, the optional winterization kit available with the unit consists mainly
of a Webasto diesel-fired heater (mounted to the right of the discharge crossover
manifold on the curb side of the unit) that circulates heated water at controlled
temperature through the SBT-615 truck engine and fuel system to keep them
warm for cold weather start-up. An 80-gal diesel fuel tank mounted beside the
Webasto unit provides fuel for the Webasto and additional fuel for the SBT-615
truck engine.
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Figure 3-90: Location of Webasto heater and auxiliary 80-gal fuel tank
The Webasto runs on a timer system so that the temperature and time at
which the Webasto automatically operates can be programmed using the
dashboard-mounted Webasto timer control panel located inside the truck cab. In
the event that the engine is overheated due to a malfunction with the Webasto
unit, the Emergency Kill switch near the timer control panel can be used to shut
down the Webasto.
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Figure 3-91: Location of Webasto timer control panel and Emergency Kill switch
For more information, refer to the Webasto operation and Roda Deaco kill switch
system literature in the SBT-615 Vendor Maintenance Manual.
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4-i SBT-615 Operations Manual / Job preparation 4-i
4 Job preparation
4.1 Pre-trip inspection _____________________________________________ 4-1
4.2 Unit spotting and hookup ______________________________________ 4-5
4.2.1 Unit spotting on location ______________________________________ 4-5
4.2.2 Sand Chief/sand belt speed and trajectory _____________________ 4-8
4.2.3 Suction manifold hookup _____________________________________ 4-9
4.2.4 Discharge manifold hookup ___________________________________ 4-9
4.2.5 Prime-up line connection ____________________________________ 4-10

4.2.6 Liquid additives and offboard tank hookup procedure __________ 4-11
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4-1 SBT-615 Operations Manual / Job preparation 4-1
4 Job preparation SCD,SBT,615,SBT-615,operations,J ob Preparation
This chapter discusses the pre-trip inspection, on-location startup procedure,

spotting and equipment rig-up on location prior to the start of a job.
4.1 Pre-trip inspection

A pre-trip inspection should be performed on the SBT-615 before leaving
the district yard for a job. This inspection should include a review and the
correction of any deficiencies reported by an operator or mechanic from the
previous job. Refer to the STEM 1 schedule in the SBT-615 PodSTREAK
Maintenance Manual, InTouch content ID# 3842981, for information on
equipment maintenance. Samples of these forms can be found in Appendix A.
Equipment should be maintained according to the standard equipment

maintenance (STEM) system. In addition, complete the following Schlumberger
preventive maintenance checks, samples of which are available in Appendix A.
• Appendix A.1 Drivers Trip Report DS-598-2-A

• Appendix A.2 Auxiliary Equipment Check Sheet DS-587-E(p. A-4)
Other forms that may be required for the trip are:
• material safety data sheets (MSDS) sheets

• loose equipment list (a list of components needed in addition to those
normally carried on the unit)
• Department of Transportation (DOT) log booklet.
Before leaving the district, the operator must perform a pre-trip inspection, which
takes approximately one hour.
1. Complete the following Schlumberger Safety checklist:
• Check the lights – headlights, clearance lights, and turn signals.

• Check the fuel, oil, engine coolant, and V-belts on both the tractor and
the trailer.
• Check tires for proper air pressure and condition.
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• Check safety equipment required by DOT and Schlumberger. This

includes inspecting the fire extinguisher, the eyewash bottle, and the
first-aid kit.
• Check for proper placarding.
• Remove all loose objects, such as drink bottles and garbage from the
cab interior.
• Ensure that the windshield and side windows are clean, and that the rear
view mirrors are clean and adjusted for proper vision.

• Start the cab engine and observe all instruments, gauges, and indicator
lights for proper operation.
• Determine that the brake systems are operating properly.
• Check the windshield wipers and horn.
• Check the diesel flush tank level and fill, if necessary.
• Check the lubrication oil and fill, if necessary.
• Check the hydraulic oil level in the hydraulic reservoir.
• Check the fuel level.
• Verify that radioactive sources are in the OFF position and locked.
2. Check the liquid additive tote tank lids and the screw-on caps, if applicable.
3. Verify that the header tank is drained of all fluid.
4. Make sure the mixer is empty of all fluid or sand. Check the hopper; it should
contain no sand and, especially, no wet sand.
5. Start the engine and engage the hydraulics power take-off (PTO) to circulate
hydraulic fluid. Make certain no abnormal sounds are coming from the
hydraulic pump.
6. Check to make sure the air pressure builds to about 105 psi.
7. Check that all temperatures and pressures are in the normal range. Pay
special attention to the gearbox pressure, which should be above 30 psi.
8. Check all external work lights.
9. If applicable, check the LAS. Check the additives manually also, using the
touchscreen.
10. Check that the MicroMotion flowmeter displays are all showing values.
11. Locate the Apitech valves on the curb side of the mixer assembly near
the suction hose. All manual hydraulic controls for the mixer gate, dry add
feeders, fiber feeder, hopper cover, and mixer lifting system are controlled by
means of the Apitech valves.
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12. Locate the handle on the Apitech valve labeled POD LIFT, and press down
on the handle to lower the entire mixer assembly to the ground. Release the
handle after the mixer is firmly on the ground.
13. Set the transfer case PTO to PUMP position to start turning the mixer
driveline, and run the engine at full throttle.


It is a safe and best practice to never set the transfer case PTO to PUMP
position before lowering the mixer to the ground; however, no damage will
occur if the transfer case PTO is set to PUMP position before lowering the
mixer as long as the truck engine is at IDLE speed. NEVER RUN THE
ENGINE AT FULL THROTTLE BY STEPPING ON THE ACCELERATOR
PEDAL WHILE THE TRANSFER CASE PTO IS IN PUMP POSITION AND
THE MIXER IS NOT FULLY LOWERED TO THE GROUND. Serious damage
to the equipment and possible injury to personnel can occur when running
the mixer at high speed due to severe driveshaft angularity when the mixer is
in the fully raised position.
Listen for any unusual noises, and watch for any abnormal vibration or
movement in the driveline. Throttle back to idle when the test is complete.
14. To test the cover on the hydraulic cylinder, open and close the cover of the
hopper by pulling up and down on the handle of the Apitech valve labeled
COVER.
15. Turn on the Onan electrical generator located on the road side of the chassis
beneath the control cabin.
16. Turn on the ELECTRONICS switch on the curbside battery box.
17. Turn on all computer systems inside the control cabin. Verify on the POD
control screen that all sensors are operational and that all devices are
working properly. Pay special attention to:
• mixer gearbox oil pressure, to make sure oil is circulating inside the
lube circuit
• hydraulic oil pressure
• air pressure, which should increase to about 105 psi
• communication with all sensors, including pressure, temperature,
flowmeter, densitometer, etc.
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If one of the pressure display fields on the control screen shows abnormal
pressure (either to high or too low), stop immediately and check the root
cause and correct before restarting.

If the gearbox pressure remains zero after engine startup, a failure has
occurred in the lube circuit (pump, hose). If corrective action is not taken,
very serious consequences will follow when operating the mixer. For
additional information about gearbox issues, refer to Table 6-6 (p. 6-6) in
the Troubleshooting section.
18. Walk around the unit to check for air, hydraulic, lubrication, or coolant leaks.
During the walk around, tie down any loose objects that could fall off the unit
or swing out beyond the allowed width of the unit while traveling.
19. Engage the C-pump PTO to verify that it is working properly.
20. Check the dry additive system(s) and fiber feeder, if applicable:
a. Set a low speed (10 rpm) from the touchscreen.

b. Set a high speed (100%) from the touchscreen.
c. Open the caps of these additives to see if the screw is turning.
d. Repeat the test by operating the manual backup knob on the Apitech
valve.
21. Raise the mixer back to its ROAD position, which is about 18 in off the
ground.
22. If applicable, check that all tote tank discharge valves are CLOSED, and that
the LAS hoses are in their proper parking positions.
23. Disengage the mixer, C-pump, and hydraulics PTOs.
24. Shut down the FracCAT, PodSTREAK, and FPC console computer systems.
25. Shut off the Onan generator.
26. Turn off the ELECTRONICS switch on the curbside battery box.
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27. Before driving the SBT-615 to location, make sure the rear axle air
suspension is fully inflated. Driving the unit with the suspension under-inflated
can result in serious damage to the rear tires and/or piping components, and
will alter the weight distribution between the axles.
28. Make sure the densitometer has been calibrated at the district before going
to the job site. NEVER calibrate the densitometer on location.
Fasten your seat belt and drive safely.

4.2 Unit spotting and hookup

This section presents the recommended procedures for setting up the SBT-615
on location and connecting it (rigging-up) to other equipment involved in a typical
frac job.
4.2.1 Unit spotting on location

Figure 4-1 represents a typical setup of equipment on location. The number,
type, and actual equipment used on any given job depends on the requirements
of that particular situation.
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Figure 4-1: Typical equipment setup on location
When the SBT-615 arrives on location, the operator or supervisor must decide
where to place the unit to minimize the length of hoses required to connect
upstream and downstream equipment.
The unit should be placed upwind of the well so that the wind blows away any
gas or fluid escaping from the well from the unit and the operator. These points,
plus Well Services Safety Standard 5: Location Safety, InTouch content ID#
3313681, must be followed for safe operation on each job.
Figure 4-2 shows a possible spotting scenario involving the use of a liquid
transport module (LTM) in conjunction with a precision continuous mixing (PCM)
unit. Figure 4-3 depicts a configuration involving a chemical float unit and a PCM.
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Figure 4-2: Configuration with one PCM and one LTM
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Figure 4-3: Configuration with one chemical float, one PCM, and one Sand Chief
4.2.2 Sand Chief/sand belt speed and trajectory

When using a Sand Chief or a sand belt to deliver proppant into the elevated
high-rate hopper, it is possible to inadvertently sling proppant short of the
high-rate hopper and into the bottom cone of the mixer if too low a belt speed is
used and/or the trajectory angle of the belt is not set properly. Slinging proppant
into the bottom cone and directly into the mixer must be avoided if possible
because the proppant bypasses the high-rate hopper sand gate and is thus
unregulated, which can cause a negative impact if it occurs during a job.
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When spotting the Sand Chief or sand belt prior to the start of the job, determine
the correct belt speed and angle by first closing the sand gate, completely
opening the high-rate hopper lid to use as a deflector, and then adjusting the
belt speed and trajectory so that the proppant stream strikes the inside of the
high-rate hopper lid at the center of the lid and deflects down into the high-rate
hopper. Note and be sure to use this same belt speed during the proppant
stages of the job.
4.2.3 Suction manifold hookup

The curbside suction manifold (covered earlier in Section ) consists of five 4-in
female connections and one 8-in connection on the piping leading into an 8x6
centrifugal pump. Additional piping plumbs out of the centrifugal pump into the
header tank, and from the header tank directly into the suction intake of the mixer.
The 10-bbl capacity header tank, a fluid reservoir maintaining a preset fluid level
within the tank during a job, provides consistent hydrostatic fluid pressure to feed
the mixer. The centrifugal pump feeds fluid from the suction manifold into the
header tank at sufficient rates to keep pace with the rate at which fluid exits the
header tank and goes into the mixer. As a result, a consistent fluid level exists in
the tank that is precisely regulated by means of an air-actuated valve controlled
by fluid pressure sensor feedback from the header tank.
The number of hoses used, the type of hose used (4-in or 8-in), and the manner
of connection depend on the nature of the job (conventional frac, slick water,
acidizing, etc.) and the requirements of the job (rate, fluid composition, etc.).
Low-pressure hoses with Weco Figure 206-type connections are used for
hookup; flow rates should not exceed 7 bbl/min per 4-in suction hose and 40
bbl/min per 8-in suction hose.
4.2.4 Discharge manifold hookup

The roadside discharge manifold (covered in Section ), consisting of four 4-in
hose connections, channels fluid from the mixer at a higher pressure than in the
curbside suction piping; thus, care should be exercised when working in the
proximity of high-pressure equipment on a frac job.
There are two important considerations for discharge hookup:
• Use 4-in high-pressure discharge hoses, with Weco Figure 206-type

thread-by-wing connections, to connect the discharge manifold to the missile
trailer.
• One 4-in discharge hose for every 10 bbl/min discharge rate is recommended.
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4.2.5 Prime-up line connection

Connect a 2-in hose from the prime-up pipe to the dedicated prime-up connection
on the missile, as shown in Figure 4-4 below.
Figure 4-4: 2-in prime-up connection
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4.2.6 Liquid additives and offboard tank hookup

procedure
The unit comes with two SUP-511 and one SUP-512 LAS modules installed with
piping already plumbed from the discharge of the LAS modules to the 1-in LAS
connection manifold in the suction piping of the unit’s plumbing system. When
connecting a tote tank to a LAS module, make a direct hose connection between
the tank and the 2-in LAS suction inlet using a 2-in hose. Additionally, connect a
2-in recirculation line from the recirculation outlet of the LAS back to the tank.
Figure 4-5: Typical LAS-to-offboard tank setup
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5-i SBT-615 Operations Manual / Job execution 5-i
5 Job execution
5.1 Typical unit startup sequence on location during equipment
rig-up __________________________________________________________ 5-1
5.2 Mixer and triplex pump prime-up _______________________________ 5-3
5.3 Normal job operations __________________________________________ 5-4
5.3.1 Operation mode recap _______________________________________ 5-4
5.3.2 Header tank use during pumping operation ____________________ 5-5
5.3.3 Pumping acid _______________________________________________ 5-5

5.3.4 Proper POD discharge pressure ______________________________ 5-6
5.3.5 Hydraulic system performance limitations ______________________ 5-6
5.3.6 POD ingestion rate limitations with sand and resin-coated sand _ 5-6
5.3.7 Engine power limitations with high-strength proppant (HSP) ____ 5-7
5.4 Emergency manual mode of operation _________________________ 5-8
5.4.1 Unit startup in MANUAL mode ________________________________ 5-8
5.4.2 Manual valve control _________________________________________ 5-8
5.4.3 Pumping operations __________________________________________ 5-9
5.4.4 Proppant control operation in MANUAL mode __________________ 5-9
5.4.5 Operating the LAS in MANUAL mode _________________________ 5-9
5.4.6 Operating the dry and fiber additive systems in MANUAL mode 5-10
5.5 Normal shutdown procedure __________________________________ 5-10
5.6 Wash-up and drainage procedure _____________________________ 5-11
5.7 Service and maintenance ______________________________________ 5-11
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5-1 SBT-615 Operations Manual / Job execution 5-1
5 Job execution SCD,SBT,615,SBT-615,operations,J ob Execution
This chapter covers key points and topics to keep in mind during job execution.
5.1 Typical unit startup sequence on location

during equipment rig-up
See Section for startup procedure details.
1. Run the truck engine at IDLE speed.

2. Turn on the hydraulic system by engaging the hydraulic pump power takeoff
(PTO) switch inside the truck cab.
3. Locate the Apitech valve on the curb side of the mixer assembly near the
suction hose. All manual hydraulics for the mixer gate, dry add feeder, fiber
feeder, hopper cover, and mixer lifting system are controlled by the Apitech
valve.
4. Locate the handle on the Apitech valve labeled POD LIFT and press the
handle down to lower the entire mixer assembly to the ground. Release the
handle when the mixer is firmly on the ground.
5. Open the cover of the hopper by pulling up on the handle of the Apitech
valve labeled COVER.
6. Turn on the Onan generator located on the road side of the chassis beneath
the control cabin. Make sure that the power changeover switch inside the
cable reel compartment is set to GEN for generator power.
7. Turn on the ELECTRONICS switch on the curbside battery box. Also, turn on
the HVAC switch if needed.
8. Connect the cabling for establishing communication between the control
cabin and the pump truck units on location. The cable reels are located on the
inside of the cable reel door on the road side of the control cabin. To do this:
a. Use the auxiliary platform mounted on the chassis beside the Onan
generator to gain access to the cable reel compartment door latch.
Unlatch the cable reel compartment door, and lower the door until it
hangs straight down, exposing the mounted cable reels. Pulling down
on the door to open it may require some effort; be very careful when
lowering the door because it has stiff return spring tension that may
cause it to suddenly swing shut.
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Be sure to connect the safety chain from the inside of the cable reel
compartment door to the eyebolt in the middle of the auxiliary platform
frame to prevent the door from swinging back shut when stringing cables
from the reels.

When closing the cable reel compartment door, exercise caution by

carefully raising the door in a controlled manner to prevent it from
suddenly swinging shut and possibly injuring yourself or others.
b. Connect the free cable end of each needed cable reel to corresponding
pump truck units (if wired frac pump control [FPC] is desired), treating
line pressure transducers, backpressure line pressure transducer, and
downstream densitometers to establish communication linkup with the
FracCAT control system.
c. Connect the short end of the cable from each cable reel that is used
to its respective port on the connection box located inside the reel
compartment just above the door.
9. Turn on all computer systems inside the control cabin.

10. Open the radioactive densitometer source shield; keys are inside the cabin.
Note that the source shield is opened only during the job, and must be closed
after finishing the job.
11. Verify that all sensors are operational, and that all devices are working
properly. Check these items in particular:
• mixer gearbox oil pressure

• hydraulic oil pressure
• air pressure, which should increase to about 105 psi
• communication linkup with pump units
• communication with all sensors (pressure, temperature, flowmeter,
densitometer, etc.).
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Note
If one of the pressure display fields on the control screen shows abnormal
pressure (either too high or too low), stop immediately and check the root
cause and correct before restarting. See Section 6 Troubleshooting for more
details.
Note
If the gearbox pressure remains at zero after engine startup, a failure has
occurred in the lube circuit (pump, hose, lube oil level, etc.), which will lead
to very serious consequences when operating the mixer. The pressure
transducer, associated wiring, and/or display calibration could also be at fault.
Verify with a known functioning mechanical analog pressure gauge.
5.2 Mixer and triplex pump prime-up

If startup goes well with all equipment rigged up downstream and upstream, the
mixer and triplex pump prime-up can begin.
This prime-up procedure fills all active plumbing systems with water, including
the mixer and triplex piping, and eliminates air from the plumbing. Refer to
Section in this manual for the plumbing flow diagram of the prime-up operation.
1. Make sure a 2-in prime-up hose is connected between the missile and the
prime-up connection on the SBT-615.
2. Run the engine at LOW IDLE.
3. Open the manual valve M2 of the 2-in prime-up connection.
4. Open the valve(s) from the frac tanks or precision continuous mixer (PCM)
to the SBT-615 to allow the circulation of the pad fluid from the frac tank or
PCM to the C-pump.
5. Engage the C-pump PTO to run slowly at LOW engine IDLE.
6. Open the CPUMP-HEADER valve on the POD touchscreen to begin filling
the header tank. Monitor the fluid level in the header tank until it reaches
the required level.
7. Engage the mixer at low engine speed (be sure the unit transmission is set to
9th gear) and select the RECIRCULATE function to begin priming the mixer.
Increase mixer speed until mixer discharge pressure is between 30 to 50 psi,
and allow the mixer to recirculate for about a minute or so.
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8. Next, select the DOWNHOLE function on the POD touchscreen to begin

priming the first triplex pump. Adjust the mixer speed if necessary to make
sure discharge pressure is between 30 and 50 psi.
9. Allow the mixer to discharge while the first triplex pump being primed
circulates fluid at low speed (no more than 5 bpm maximum) back to the
recirculation line through the 2-in prime-up connection towards the suction
manifold for a few minutes until the suction and discharge flow rates at the
POD stabilize. During prime-up, air will escape from the plumbing out of
the header tank and/or mixer (both are vented to the open atmosphere).
When all air has been removed from the fluid lines, the suction and discharge
flow rates at the POD will become steady, indicating that the triplex pump is
primed. Make sure the mixer discharge pressure is held between 30 and 50
psi while priming the triplex pump.
10. Once the first pump is primed, stop the pump and proceed to prime the next
pump, making sure to run the pump at slow speed (no more than 5 bpm
maximum) for a few minutes; then shut the pump down before proceeding
to the next pump. Prime the remainder of the pumps one at a time as
described in Step 9.
11. When all the pumps have been primed, shut down all the pumps.
12. Close prime-up valve M2 and disconnect the prime-up hose from the 2-in
prime-up connection on the unit.

Potential Loss: Assets, Process
Before putting any of the triplex pumps in gear, make sure the 2-in prime-up
valve is open, and verify the flow rate on the touchscreen.
5.3 Normal job operations
5.3.1 Operation mode recap

Each device in the POD system can be controlled in one of four modes –
MANUAL, AUTO, REMOTE and BACKUP. The operation selected applies to all
additive devices, including the dry add feeders, LAS modules, fiber feeder, and
sand gate. Refer to the earlier section on POD system operation in this manual
for operational details.
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Note
Never perform a water or air calibration at a job location. This should always be
done with special care in the district.
5.3.2 Header tank use during pumping operation

Maintaining recommended header tank level(s) ensures constant suction intake

pressure to the mixer during normal operation on the job; the operator should
regularly check either the control touchscreen display or the fluid level in the
header tank sightglass to make sure the header tank fluid level is adequate
throughout the job.
See Section for more details.
5.3.3 Pumping acid

Pumping acid ahead of slick water fracturing treatments, or in stages during
the fracturing treatment, is a common practice used by many districts. The
SBT-615 can be used to pump acid directly downhole from the unit’s suction
manifold through the C-pump and directly out through the discharge manifold
while bypassing the header tank and POD. An acid transporter or acid tank can
be rigged to the SBT-615 suction manifold using one or more suction hoses as
needed. With the C-pump running, isolate the POD by selecting the Isolate
button on the Main Control screen of the POD touchscreen. Next, close off the
C-pump discharge route to the header tank by selecting CPump-Header Close
to bypass the header tank, and then open the path from the C-pump discharge
directly through the discharge manifold and downhole by selecting CPump-Disch
on the Main Control screen. Bypassing the header tank and the POD in this
manner makes it safer to pump acid with less risk of acid splashing on personnel.

Potential Loss: Assets, Environmental, Personnel
Hazard Category: Human, Machinery equipment hand tools, Toxic
corrosive hazardous substances
Never allow acid to go through the header tank or through the mixer in order to
minimize the danger of acid splashing on personnel.
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5.3.4 Proper POD discharge pressure

Maintaining adequate POD discharge pressure during a job will minimize the
possibility of triplex pump cavitation and adverse consequences on job outcome.
Constantly monitor the POD touchscreen to make sure that mixer discharge
pressure is at least 60 psi during the job. If pressure falls below 60 psi, increase
the mixer speed until the discharge pressure reaches 60 psi.
Note
Mixer discharge pressure will tend to go up when proppant is added and will
peak when the PPA is at its maximum for a given job. This is normal.
5.3.5 Hydraulic system performance limitations

If every hydraulically driven system on the unit were run at the same time (i.e.,
the fiber feeder, both dry add feeders, the two SUP-511 LASs, and the SUP-512
LAS), each system would run up to about 50% in manual setpoint percent mode
due to limitations in available engine power. It is not likely that every hydraulic
system would be required to run simultaneously during the course of a normal
job, but be aware of potential reductions in performance when many systems are
operating at the same time.
5.3.6 POD ingestion rate limitations with sand and

resin-coated sand
The SBT-615 6x4 PodSTREAK with its high-rate gate system is required by
specification to be capable of blending up to about 10,000 lbm/min of 20–40 sand
(22.1 lbm/gal weight density). Actual field test data indicate that the SBT-615 6x4
PodSTREAK unit can routinely deliver 10 PPA of 20–40 sand at 35 bbl/min and
at close to 100% engine load on jobs; this corresponds to a sand rate of slightly
more than 10,000 lbm/min. To attempt a significantly higher rate than 10,000
lbm/min of 20–40 sand is likely to cause the mixer to overflow.
Also, even though the practical working limit is advertised at 10,000 lbm/min for
20–40 sand, the main factor that determines the POD ingestion rate limit is the
material volume rate per unit of time and not the material weight per unit of
time. In other words, the volume rate limit of 20–40 sand with a weight density
of 22.1 lbm/gal at 10,000 lbm/min is:
10,000/22.1 = 452.5 gal/min.
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Furthermore, for resin-coated sand with a weight density of 21.1 lbm/gal, the
blending limit in lbm/min is:
452.5 x 21.1 = 9,547.8 lbm/min (for resin-coated sand).
Therefore, rates that are higher than 9,547.8 lbm/min for resin-coated sand
should not be attempted in order to prevent the mixer from overflowing.
Keep these rate limitations in mind when designing the peak PPA and bbl/min
stage for sand and resin-coated sand on a given job to prevent possible job
disruption and adverse consequences that could arise if the mixer overflows.
The charts in Appendix B show highlighted areas that correspond to gate

positions, bbl/min, and PPA at which the limit of the mixer will be reached for
sand and resin-coated sand and should not be exceeded on a job.
5.3.7 Engine power limitations with high-strength

proppant (HSP)
While the limit at which the POD on the 6x4 PodSTREAK can ingest proppant
is dictated by the volume rate of about 452.5 gal/min of proppant, the case is
different for a high-weight density material such as high-strength proppant (HSP)
because of limits in available engine power. For example, HSP at 452.5 gal/min
with a weight density of 30.8 lbm/gal yields:
452.5 x 30.8 = 13,937.0 lbm/min (for HSP).
However, the proppant weight per unit of time has the biggest impact in reducing
engine power. It is currently unknown what maximum lbm/min of HSP can be
processed by the 6x4 PodSTREAK before the engine power limit is reached, and
therefore 13,937.0 lbm/min of HSP may not be achievable.
To be conservative, a rate of no more than 10,000 lbm/min is recommended

when designing and performing jobs involving HSP and the SBT-615 6x4
PodSTREAK. The charts in Appendix B show highlighted areas that correspond
to gate positions, bbl/min, and PPA for HSP that exceed the recommended limit
of 10,000 lbm/min and should be approached with caution.
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5.4 Emergency manual mode of operation

If the POD control system fails before the beginning of the job, the operator
should make every attempt to locate the failure or reload software, if necessary.
If the failure cannot be corrected before the beginning of the job, then the unit
should not be used for the job until the problem is fixed. If the failure appears
during the job, the operator must perform all operations in MANUAL mode.
In this case, the POD operator may need dedicated help from an assistant to
operate the LAS modules while the POD operator operates the sand gate,
dry add feeders, fiber feeder, and plumbing system valves manually using the
Apitech valves and the backup control console.
If the FracCAT computer system fails, and attempts to fix the problem(s) are
not successful, a conventional FracCAT unit may be needed on location to run
the job. Cable connections between the pump units and the 6x4 PodSTREAK
control cabin must be disconnected and then established between the pump
units and the conventional FracCAT unit.
Note
It is not possible to control the PodSTREAK in Remote mode from an external
FracCAT unit; the external FracCAT unit can only record the data.
The balance of this section details what to do in the event of a POD control
system breakdown, assuming the hydraulic and pneumatic systems still function
properly.
5.4.1 Unit startup in MANUAL mode

Follow as many of the startup procedures as can be successfully performed, as
stated in Section3.1 Power-up procedure.
5.4.2 Manual valve control

The loss of the POD control system requires the use of the backup control
console to manually control the air-actuated valves normally controlled
automatically by the computer. An object such as a pen or pencil can be used to
depress the buttons on the backup control console to perform the required valve
operations. The valve operations controlled from the backup control console
were explained in detail in the plumbing system section earlier in this manual.
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Figure 5-1: Air-actuated valves
5.4.3 Pumping operations

It may be necessary to visually monitor the header tank level during the job
using the header tank sightglass, and to regulate the header tank level using
the manual header tank inlet valve M1, since it is possible that the automatic
header tank regulatory valve may not work properly as a result of POD control
system failure.
5.4.4 Proppant control operation in MANUAL mode

Proppant gate charts in Appendix A Appendix A: Forms and Checklists (p.
A-1) of this manual are used to determine the required gate positions for given
downhole rates and required PPA. The slurry flow rate can be read on the
suction flowmeter display just below the backup control console. Additionally,
use the Apitech gate valve to set the gate position that corresponds to the
required bbl/min and desired PPA for a given job stage.
5.4.5 Operating the LAS in MANUAL mode

Refer to the SUP-51X Operation and Maintenance Manual, InTouch content ID#
3392397, for the specific model(s) used.
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5.4.6 Operating the dry and fiber additive systems in

MANUAL mode
The rates of the dry add and fiber feeder systems can be controlled with
the adjustment knobs on the corresponding Apitech valves. It is likely to be
necessary to know the feed rate per screw turn of each of these systems and to
count screw turns in a given length of time using a watch to manually regulate
feeder speed. For more details, refer to the earlier Section in this manual for dry
add and fiber feeder operation.
5.5 Normal shutdown procedure

To shut down the SBT-615, complete the following steps:
1. Close the sand gate.

2. Stop the LAS modules.
3. Set the mixer to ISOLATE (Figure 3-55).
4. Close the discharge manifold valves.
5. If dry add feeder(s) were used during the job, run the dry add feeder(s) at
moderate speed and fill each feeder hopper full with sand to clean out any
remaining chemicals. After this operation, stop the dry add feeders.
6. If there is any sand left inside the elevated POD hopper (after a job screenout,
for example), use the bypass chute to empty the sand out of the hopper
and into an empty proppant sack or adequately-sized container, or onto the
ground if allowed. Be sure to attach the bypass chute below the sand gate
first before opening the gate to allow sand to flow out of the hopper.
7. Be sure to stow the satellite dish by pressing the STOW button on the dish
control panel.
8. Follow the balance of the wash-up and drainage procedure in Section 5.6
Wash-up and Drainage Procedure.
9. Shut down the POD, FPC, and FracCAT control software on each respective
computer using the normal shutdown procedure of each of the foregoing
softwares.
10. Switch off all computer power.
11. Shut down the Onan electrical generator.
12. Shut off the ELECTRONICS switch located on the curbside battery box
along with any other battery box switches that were used (HVAC, etc.).
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5.6 Wash-up and drainage procedure

One of the most important aspects of the equipment operator’s job begins after
the job is complete—the wash-up, or flushing and drainage, of all fluids from the
unit piping and pumps. Prior to draining the main suction/discharge piping of
the unit, drain all LAS modules, if applicable, using the wash-up and drainage
procedure in the LAS (SUP-51X) Operation and Maintenance Manual, InTouch
content ID# 3392397.
Note
Be sure the mixer, dry add feeders, and fiber feeder contain no sand, chemicals
or solids. If the mixer is not clean, blow-dry the mixer and discharge piping clean
by the following this additional procedure.
1. Close all but one discharge valve on the discharge manifold.

2. Open the 2-in drain cap of the mixer.
3. Set the mixer to full throttle, without engaging the C-pump PTO.
4. Allow the fan action of the mixer to blow through the discharge piping for a
several minutes to clear debris and dry out the piping.
5. Make sure no fluid remains in the header tank and unit piping.
6. Recap the mixer drain pipe when finished.
7. Wash the unit carefully when back at the district wash bay to remove dirt,
debris, and chemical residue from the external surfaces of the truck.
Note
Do not drive the unit with fluid in the header tank or with sand in the hopper.
5.7 Service and maintenance

The operator is responsible for the condition of the SBT-615 and should ensure
that it is serviced at regular intervals. The operator should be observant for any
unusual noises, leaks, or changes in the performance of the unit during operation
that might indicate mechanical problems. Changes in any of these areas should
be reported to the mechanic in charge so that causes can be determined and
repairs made. The Caterpillar Engines Service Manual Guide provides excellent
troubleshooting information, and should be kept with the unit at all times.
Additionally, follow the regular service and maintenance guidelines as outlined
Private
in the STEM form located in Appendix A Appendix A: Forms and Checklists (p.
A-1) of this manual, and in the SBT-615 PodSTREAK Maintenance Manual,
InTouch content ID# 3842981.
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6-i SBT-615 Operations Manual / Troubleshooting 6-i
6 Troubleshooting
6.1 Power, communication, and software troubleshooting __________ 6-1
6.1.1 FracCAT communication problems ____________________________ 6-1
6.1.2 Computer power problems ____________________________________ 6-2
6.1.3 DCU power failure ___________________________________________ 6-2
6.1.4 Touchscreen problems _______________________________________ 6-2
6.1.5 POD control software problems _______________________________ 6-3
6.2 Device troubleshooting ________________________________________ 6-4

6.2.1 Engine failure ________________________________________________ 6-4
6.2.2 Driveline problems ___________________________________________ 6-6
6.2.3 LAS module problems ________________________________________ 6-6
6.2.4 Mixer gate problems _________________________________________ 6-7
6.2.5 Process fluid circuit problems _________________________________ 6-8
6.3 Circuits troubleshooting _______________________________________ 6-8
6.3.1 Hydraulic circuit problems ____________________________________ 6-8
6.3.2 Mixer gearbox lubrication circuit problems _____________________ 6-8
6.4 Electronics troubleshooting ____________________________________ 6-8
6.4.1 Device power problems ______________________________________ 6-8
6.4.2 Densitometer problems _______________________________________ 6-9
6.4.3 Unit plumbing pressure sensor problems _____________________ 6-10
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6-1 SBT-615 Operations Manual / Troubleshooting 6-1
6 Troubleshooting SCD,SBT,615,SBT-615,operations,Troubles hooting
6.1 Power, communication, and software

troubleshooting
6.1.1 FracCAT communication problems

Table 6-1: Absence of Communication Between the Equipment and FracCAT
Problem: Absence of communication between the equipment and FracCAT

General Remedy
• Make sure the required cable connections are clean and properly made before any
equipment is started up.
• Make sure all sensors are working properly.
• Make sure cables are in good working order and without visible damage (broken
conductors, etc.).
• Make sure all devices requiring electrical power are turned on or plugged in.
• Exit and then restart the software.
• Verify that the computer(s) are working properly. Reboot the computers, if necessary.
• Double-check the IP address displayed on the screen.
• Try to stop acquisition for a second, then restart it while monitoring the communication
status. If the connection is established, continue with the job.
• If communication is lost during the job, try the following steps:
1. At the next stage when fluids are not being pumped (e.g., end of DataFRAC or end of
ballout), save the setup file in FracCAT.
2. Stop recording, stop acquisition, and close FracCAT.
3. Reopen the FracCAT program, and reload the setup file.
4. Start acquisition and recording to continue with the job.
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6.1.2 Computer power problems

Table 6-2: Computer(s) Will Not Power On
Problem: Computer(s) will not power on

Remedy
• Make sure the Onan electrical generator is running.

• Make sure the power selector switch located inside the control cabin cable reel
compartment is set to GEN for generator power.
• Turn on the computers by using the power button on the front of the computer case.
• Use a voltmeter to measure the AC voltage in the AC outlets inside the control cabin. It
should read approximately 110 volts AC.
• Use a voltmeter to measure the DC voltage on the input terminals of the inverter. It should
read approximately 13 volts DC. If no power is read, the power relay is not operating.
• Make sure that all computers are plugged in and that all power cables are securely
connected.
• Use the diagnostic LEDs on the inverter to help troubleshoot. Refer to the SBT-615
PodSTREAK Vendor Maintenance Manual and Tripp-Lite Vendor Manual for information on
use of the diagnostic LEDs on the inverter.
6.1.3 DCU power failure

Refer to the SBT-615 Maintenance Manual, InTouch content ID# 3842981, for
more information.
6.1.4 Touchscreen problems

Table 6-3: Touchscreens Will Not Power Up
Problem: Touchscreens will not power up

Possible Cause Remedy
Make sure the Onan electrical generator is on and running.
Power Source Also make sure that the power selector switch located inside
the control cabin cable reel compartment is set to GEN.
Check the touchscreen cables (e.g., power cable, serial cable,
Cable Connection
and SVGA cable) to make sure they are properly connected.
In cold weather or a cold environment, the touchscreen
Too cold. Heaters are warming display may appear faint or have an unusual color tinge to it
up the electronics inside the (sometimes pink or yellowish green). Wait until the electronics
touchscreen. warm up. If necessary, speed up the process by increasing
the control cabin temperature to at least 60 degF.
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6.1.5 POD control software problems

Table 6-4: POD Control Software Problems
Problem: Poor POD control performance

• Verify that only the high-rate gate is selected as the

Density Control/Proppant standard gate.
Concentration issues including: • Check the status of the Densitometer Calibration from the
Advanced Diagnostics screen. If necessary, perform new
• Large discrepancy Air and Water calibrations along with a Zero on Pad.
between proppant
concentration from • Verify that the proper control mode is selected
densitometer and gate (Densitometer or Gate Position) from the Backups
position screen.
• Erratic density control • Verify that the suction flowmeter is working properly.
• Proppant concentration • Check to make sure that there is nothing physically

irregularities interfering with the movement of the gate.
• Verify that the proper Proppant Type is selected from
the Calibration screen.
• Verify that the proper screw factors are entered on the

Calibration screen.
Dry add and/or PropNET • Verify that when operated manually, the tachometer
control is not working properly. signal is displayed on the touchscreen.
• Verify that all DCUs are ONLINE from the Diagnostics
screen.
• Verify that the hydraulic system is working correctly.
• Make sure that the air pressure system is functioning

The software will not actuate properly and supplying enough pressure to the valves.
any of the valves because the
air pressure is less than 60 psi • If there is enough pressure, but the Air Pressure sensor is
malfunctioning, the air pressure checking can be disabled
from the Advanced Calibration screen.
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Problem: Poor POD control performance
When entering setpoints for • Verify that all DCUs are ONLINE from the Diagnostics
one or more additives, nothing screen.
happens.
• Verify that the hydraulic system is working properly.
• Go to the Advanced Diagnostics screen and check the

status of the various network components (including the
ECM server).
Problems communicating with
FracCAT • Check all physical connections between the PodSTREAK
computer, switch, router, and FracCAT computer.
• Verify that both the switch and router are powered ON.
• If necessary, power cycle both the switch and router.
6.2 Device troubleshooting
6.2.1 Engine failure

Refer to Caterpillar engine troubleshooting and maintenance in the SBT-615
Maintenance Manual, InTouch content ID# 3842981.
Table 6-5: Engine Will Not Start, Or Runs With Low Output Power
Problem: Engine will not start, or runs with low output power
Check the following:
• Engine battery switch should be switched ON.
Electrical Power Supply • Engine battery voltage output should be at least 12 V.

• Battery cables. Clean the terminals of the battery if
corrosion is visible.
• Other cable connections (fuel injectors, etc.).
Check the fuel level. If there is no smoke while cranking the
engine, check the following:
• Fuel line may be pinched, cut, or collapsed.

Fuel Supply
• There may be a loose fuel line connection.
• A valve may be bad.
• Fuel filter may be collapsed or dirty.
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Problem: Engine will not start, or runs with low output power
Dirty Air Filter Check and clean/replace air filter.
The engine can be turned over from the POD touchscreen but
Ignition key is turned off will not start if the ignition key is turned off. Make sure the
ignition key is switched ON.
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6.2.2 Driveline problems

Abnormal vibration, noise and heat can indicate driveshaft misalignment and
inadequate lubrication. Make sure that the driveshaft is properly aligned, and
that all U-joints and support bearings are lubricated properly and regularly as
defined in the SBT-615 Maintenance Manual.
Table 6-6: Mixer Gearbox Not Working Correctly
Problem: Mixer gearbox not working correctly

• Check that hoses are connected properly.

• Check the lube pump on top of the gearbox.
Overheating due to lube oil • Check the circuit for leaks or disconnects; check the level
circulation failure on the lube tank.
• Look for leaks, and verify the type of oil used (refer to the
SBT-615 Maintenance Manual for the correct oil required).
• Check for clogs in the lines and remove them if present.
• Verify whether or not contaminants have entered the

gearbox by checking the lube oil.
• Inspect the lube oil filter for blockage or collapse.
• Change the lube oil, and clean the components if needed.
• Check the gear lash for excessive clearance, indicating
Mechanical problem wear in the gears (refer to the SBT-615 Maintenance
Manual for details).
• Check bearings for excessive noise, axial/radial play,
and/or temperature.
• Use an infrared gun to check the temperature. (Bearing
temperature should not exceed 200 degF during normal
operation.)
6.2.3 LAS module problems

Refer to the LAS (SUP-51X) Operation and Maintenance Manual in InTouch,
content ID# 3392397, for troubleshooting assistance.
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6.2.4 Mixer gate problems

Table 6-7: The Gate Does Not Move Correctly
Problem: The gate does not move correctly or does not move to the correct
gate position % setpoint on the POD touchscreen
Gate hydraulic circuit failure Check the hydraulic lines for leaks, improper connections, etc.
• Verify that the contact area between the gate and the
rollers is clean, and that no proppant or other object
Mechanical jamming restricts the movement of the gate.
• Verify that all fasteners holding the gate assembly and the
cylinder are correctly fitted and secure.
Calibrate gate using Calibrate Gate function in the Calibration
Gate not calibrated
Control screen as described in the manual.
Verify that the high-rate gate is selected in the Advanced
Incorrect gate type selected in
function on the Calibration Control screen and that Gate Type
POD touchscreen
is Standard.
• Check circuit breakers to see if any have been tripped.

• Use a multimeter to measure the input and output
voltages of the 12 to 24 volt DC/DC converter.
• Disconnect the cable, and verify 24 volts input on the
Position sensor rod electrical appropriate pins of the pressure transducer cable (refer
problems to the Rota Engineering gate position sensor literature in
the SBT-615 6X4 Vendor Maintenance Manual, InTouch
content ID# 3882299, for exact cable pinout).
• Tripped circuit breaker
for 12 to +24 volt DC/DC • Reconnect the cable to the transducer, and use a
converter multimeter connected in series with the circuit to
determine whether a 4 to 20 mA return signal can be
• Defective 12 to 24 volt
detected from the sensor. If no return signal is measured,
DC/DC power supply
the detector is defective.
• Short in transducer cable
• If a return signal is measured, check the solids DCU
• Defective sensor board for the incoming signal on the channel used by the
pressure transducer. If a signal is present, the solids DCU
• Defective solids DCU
board may be defective and cannot process the signal.
board
• Verify that LEDs on the solids DCU board are illuminated;
the absence of illuminated LEDs on the solids DCU board
may indicate that no power is going to the board.
• Verify that the solids DCU board is correctly jumpered;
refer to the solids DCU board Part #100136231 drawing
in the SBT-615 Maintenance Manual for jumper details.
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6.2.5 Process fluid circuit problems

For valve leaks (manual or air-actuated), refer to the valve leak test section in
theSBT-615 PodSTREAK Maintenance Manual for assistance in identifying
which valve is leaking.
6.3 Circuits troubleshooting

Refer to electrical system circuit diagrams in the SBT-615 PodSTREAK
Maintenance Manual in InTouch, content ID# 3842981, for more information.
6.3.1 Hydraulic circuit problems

Refer to hydraulic system circuit diagrams in the SBT-615 PodSTREAK
Maintenance Manual in InTouch, content ID# 3842981, for more information.
6.3.2 Mixer gearbox lubrication circuit problems

Refer to mixer gearbox lubrication system diagrams in the SBT-615 PodSTREAK
Maintenance Manual in InTouch, content ID# 3842981, for additional information.
6.4 Electronics troubleshooting
6.4.1 Device power problems

Table 6-8: No Power for an Electrical Device
Problem: No power for an electrical device

• Battery disconnect Check switches and circuit breakers in the control cabin
switches not in the ON sensor box DCU cabinet and in the Rose Box mounted inside
position the curb side battery box to make sure they are set properly.
• Tripped circuit breakers
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6.4.2 Densitometer problems

Table 6-9: No Densitometer Signal
Problem: No densitometer signal

• Make sure the shutter is open and secure in the ON

position.
• Using a voltmeter, measure the input and output of the 12
to +/-15 volt DC/DC converter.
• Disconnect the cable, and measure +/-15 volts on the
• Radioactive shutter closed appropriate pins of the densitometer cable.
• Tripped circuit breaker for • Reconnect the cable to the densitometer, and measure
12 to +/-15 volt DC/DC the return signal for a voltage between 0–10 volts. If no
converter return signal is measured, the detector is defective.
• Defective 12 to +/-15 volt • If a return signal is measured, check the solids DCU
DC/DC power supply board in the control cabin for the incoming voltage on the
proper channel.
• Short in densitometer
cable • If the voltage signal can be measured off the solids DCU
board with a voltmeter, the solids DCU board may be
• Defective sensor
defective and not able to process the signal correctly.
• Defective solids DCU
• Verify that the LEDs on the solids DCU board are
board
illuminated and receiving power; the absence of
illuminated LEDs on the solids DCU board may indicate
that no power is going to the board.
• Verify that jumpering of the solids DCU board is correct;
Refer to the Texas Nuclear Densitometer section of the SBT-615 PodSTREAK

Vendor Maintenance Manual, InTouch content ID# 3882239, for exact cable
pinouts.
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Table 6-10: No Flowmeter Signal
Problem: No flowmeter signal

• Check to see if any circuit breaker has tripped.

• Using a voltmeter, measure the input and output of the 12
to 24 volt DC/DC converter.
• Measure the return signal from the flow tube (between 4

• Tripped circuit breaker and 20 mA). If no return signal is measured, the detector
for 12 to +24 volt DC/DC may be defective.
converter
• If a return signal is measured, check the solids DCU
• Defective 12 to 24 volt board for the incoming signal on the channel used for the
DC/DC power supply flowmeter. If the signal is detected, then the solids DCU
• Short in flowmeter cables board may be defective and cannot process the signal
correctly.
• Defective sensor
• Verify that LEDs on the solids DCU board are illuminated
• Defective solids DCU and receiving power; absence of illuminated LEDs on the
board solids DCU board may indicate that no power is going
to the board.
• Verify that jumpering of the solids DCU board is correct;
For more information, refer to the Johnson Yokogawa Flowmeter manual in

the SBT-615 PodSTREAK Vendor Maintenance Manual, InTouch content ID#
3882239.
6.4.3 Unit plumbing pressure sensor problems

For problems involving signal loss from any of the pressure sensors of the
suction manifold, discharge manifold, and C-pump, refer to the SBT-615
Electronics Operation Manual for troubleshooting information.
Private
A-i SBT-615 Operations Manual / Forms and checklists A-i
A Forms and checklists

A.1 Driver’s trip report DS98-2-A ___________________________________ A-2
A.2 STEMs forms ___________________________________________________ A-4
Private
Well Services WSD\Hau Pham\InTouch content ID 3842979\1.1\Release Date:18-May-2010\EDMS UID: 1653786795\Produced: 19-May-2010 15:13:21 A-ii SBT-615 Operations Manual / Forms and checklists A-ii
Intentionally Blank
Private
A-1 SBT-615 Operations Manual / Forms and checklists A-1
A Forms and checklists Multipurpose Float,pumper

SCD,MPF,MPF-331,MPF-341,maintenance,
The forms shown here are only samples. A full-size printable package of forms
is available in InTouchSupport, content ID# 3842981, together with the full
SBT-615 Maintenance Manual.
Private
A.1 Driver’s trip report DS98-2-A

DRIVER'S TRIP REPORT
DATE DISTRICT TRUCK NO. TRAILER NO. SERVICE RECEIPT NO.
OPERATOR SERVICE SUPERVISOR WELL NAME OR JOB NAME JOB SCHEDULED AM
DATE TIME PM
DIRECTIONS ROUTE TO WELL OR PLANT SITE LEAVE DISTRICT AM
DATE TIME PM
ARRIVE DISTRICT AM
DATE TIME PM
JOB LOCATION MILES FROM TOWN STATE
ADDRESS
SPEEDOMETER OR HUBOMETER AND FUEL RECORD HOURMETER

HOME STATE STATE NO.1 NAME STATE NO. 2 NAME STATE NO.3 PRIME OR AUX. OR
NAME NAME FRONT REAR
ARRIVE LEAVE GOING LEAVE RETURN LEAVE LEAVE RETURN LEAVE AFTER AFTER
DISTRICT
LEAVE DISTRICT ENTER GOING ENTER RETURN ENTER ENTER RETURN ENTER BEFORE BEFORE
TOTAL MILES MILES GOING MILES RETURN MILES MILES RETURN MILES HOURS HOURS
TRUCK AUX. TRUCK AUX. TRUCK AUX. TRUCK AUX. PUMP STROKE
TRUCK AUX. TRUCK AUX. TRUCK AUX. TRUCK AUX. PRIME AUX.
AFTER AFTER
BEFORE BEFORE
CHECK INDICATES "OK" D.O.T. PRE-TRIP x MEANS "NEEDS ATTENTION"

OIL/FUEL/COOLANT BRAKE SYSTEMS/4 POINT WINDOWS/MIRRORS DENSITOMETER LOCK
FIRE EXTINGUISHER STEERING LIGHTING SYSTEMS BLINDS/CAPS/DOMES
LUGS/CLAMPS/TIRES WINDSHIELD WIPERS HORN LOAD SECURED
COUPLING DEVICES INSTRUMENTATION PLACARDING Signature:
D.O.T. POST-TRIP AUXILIARY POST-TRIP

ALL FLUID LEVELS STEERING ALL FLUID LEVELS CENTRIFUGAL PUMPS
ALL BELTS BRAKE SYSTEMS ALL BELTS HIGH PRES. PUMPS
BATTERIES/CABLES CLUTCH OPERATION AIR FILTER INDICATOR BULK SYSTEMS
TRANSMISSION WINDSHIELD WIPERS ENG./TRANS./PTO DISPLACEMENT TANK
FIRE EXTINGUISHER INSTRUMENTATION BATTERIES/CABLES SAFETY SYSTEMS
TIRES/LUGS/CLAMPS HORN EXHAUST SYSTEMS DOME LIDS
DRIVETRAIN/DIFF. WINDOWS/MIRRORS INSTRUMENTATION TANK TEST DATE
SUSPENSION LIGHTING SYSTEMS CLUTCH OPERATION PLACARDING
LICENSE PLATE EXHAUST SYSTEM HYDRAULIC SYSTEMS BLINDS/CAPS
DRAIN AIR TANKS REQUIRED PAPERS DRAIN AIR TANKS RADIATION PAPERS
MUD FLAPS SEAT/SEAT BELTS MIXING SYSTEMS DENSITOMETER LOCK
COUPLING DEVICES SAFETY EQUIPMENT CHEM. ADD SYSTEM ITEMS IN RED/BOLD ITALIC
CHOCK BLOCKS INSPECTION STICKER SUCT./DISC. PIPING ARE THE RESPONSIBILITY OF LAST
AIR FILTER INDICATOR LAST OPERATING PERSON
SIGNATURE: SIGNATURE:
DATE COMPLETED MECHANIC'S INITIALS DESCRIPTION OF DEFECT
SAFETY DEFECTS REPAIRED
MECHANIC SIGNATURE: DATE:
NEXT DRIVER REVIEW SIGNATURE: DATE:
DISTRIBUTION: WHITE-DIVISION, YELLOW-DISTRICT UNIT FILES, PINK-NEXT DRIVER
Private
Well Services WSD\Hau Pham\InTouch content ID 3842979\1.1\Release Date:18-May-2010\EDMS UID: 1653786795\Produced: 19-May-2010 15:13:21 A-3
Private
SBT-615 Operations Manual / Forms and checklists

A-3
A.2 STEMs forms

Private
Private

A-5
Private

A-6
B-i SBT-615 Operations Manual / High-rate hopper gate position charts for various B-i
proppants
B High-rate hopper gate position charts for

various proppants
B.1 20–40 sand, SGU = 2.65, size factor = 1.0 _______________________ B-2
B.2 30–60 or 40–70 sand, SGU = 2.65, size factor = 1.17 ____________ B-4
B.3 20–40 resin-coated sand, SGU = 2.53, size factor = 1.0 __________ B-6
B.4 30–60 or 40–70 resin-coated sand, SGU = 2.53, size factor = 1.17 B-8
B.5 16–30 high-strength proppant, SGU = 3.55, size factor = 0.9 __ B-10
B.6 20–40 high-strength proppant, SGU = 3.55, size factor = 1.0 __ B-12
B.7 30–60 or 40–70 high-strength proppant, SGU = 3.55, size factor =
1.17 __________________________________________________________ B-14
Private
B-ii SBT-615 Operations Manual / High-rate hopper gate position charts for various B-ii
proppants
Intentionally Blank
Private
B-1 SBT-615 Operations Manual / High-rate hopper gate position charts for various B-1
proppants
B High-rate hopper gate position charts

for various proppants b
SCD,SBT,615,SBT-615,operations,proppant,gate,charts,appendix
Note
The following tables show highlighted areas that correspond to gate positions,
bbl/min, and PPA at which the limits of the mixer and/or available engine power
are likely to be reached for certain proppants. Exercise caution when performing
jobs with the SBT-615 6x4 PodSTREAK that enter within the highlighted areas
on these charts.
Private
proppants
B.1 20–40 sand, SGU = 2.65, size factor = 1.0

2 0-40 SAND SGU = 2.65 SIZE FACTOR = 1.0
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 6 8 10 11 12 13 13 14 15 15 16 16 16 17 17 17 18 18 18 18
2 8 11 13 15 16 17 19 19 20 21 22 22 23 23 24 24 25 25 25 26
3 10 14 16 18 20 21 22 24 25 25 26 27 28 28 29 29 30 30 31 31
4 11 15 18 21 23 24 26 27 28 29 30 31 32 33 33 34 35 35 36 36
5 13 17 21 23 25 27 29 30 32 33 34 35 36 36 37 38 38 39 40 40
6 14 19 22 25 28 30 32 33 34 36 37 38 39 40 41 41 42 43 43 44
7 15 20 24 27 30 32 34 36 37 39 40 41 42 43 44 45 45 46 47 47
8 16 22 26 29 32 34 36 38 40 41 42 44 45 46 47 48 48 49 50 51
9 17 23 27 31 34 36 38 40 42 44 45 46 47 49 50 51 51 52 53 54
10 18 24 29 32 36 38 40 42 44 46 47 49 50 51 52 53 54 55 56 57
11 18 25 30 34 37 40 42 45 46 48 50 51 52 54 55 56 57 58 58 59
12 19 26 31 35 39 42 44 46 48 50 52 53 55 56 57 58 59 60 61 62
13 20 27 33 37 40 43 46 48 50 52 54 56 57 58 59 61 62 63 64 64
14 21 28 34 38 42 45 48 50 52 54 56 58 59 60 62 63 64 65 66 67
15 21 29 35 40 43 47 49 52 54 56 58 60 61 63 64 65 66 67 68 69
16 22 30 36 41 45 48 51 54 56 58 60 62 63 65 66 67 68 69 70 71
17 23 31 37 42 46 50 53 55 58 60 62 63 65 66 68 69 70 71 73 74
18 23 32 38 43 47 51 54 57 59 61 63 65 67 68 70 71 72 74 75 76
19 24 33 39 44 49 52 55 58 61 63 65 67 69 70 72 73 74 76 77 78
20 25 34 40 46 50 54 57 60 62 65 67 69 70 72 74 75 76 77 79 80
21 25 35 41 47 51 55 58 61 64 66 68 70 72 74 75 77 78 79 81 82
22 26 35 42 48 52 56 60 63 65 68 70 72 74 76 77 79 80 81 82 84
23 26 36 43 49 53 57 61 64 67 69 72 74 75 77 79 80 82 83 84 85
24 27 37 44 50 55 59 62 65 68 71 73 75 77 79 81 82 83 85 86 87
BPM 25 27 38 45 51 56 60 64 67 70 72 75 77 79 80 82 84 85 87 88 89
26 28 38 46 52 57 61 65 68 71 74 76 78 80 82 84 85 87 88 90 91
27 28 39 47 53 58 62 66 69 72 75 77 80 82 84 85 87 88 90 91 92
28 29 40 48 54 59 63 67 71 74 76 79 81 83 85 87 89 90 92 93 94
29 29 40 48 55 60 64 68 72 75 78 80 83 85 87 88 90 92 93 95 96
30 30 41 49 56 61 66 70 73 76 79 82 84 86 88 90 92 93 95 96 97
31 30 42 50 57 62 67 71 74 77 80 83 85 88 90 91 93 95 96 98 99
32 31 42 51 57 63 68 72 75 79 82 84 87 89 91 93 95 96 98 99
33 31 43 52 58 64 69 73 77 80 83 86 88 90 92 94 96 98 99
34 32 44 52 59 65 70 74 78 81 84 87 89 92 94 96 98 99
35 32 44 53 60 66 71 75 79 82 85 88 91 93 95 97 99
36 33 45 54 61 67 72 76 80 83 87 89 92 94 96 98 100
37 33 46 55 62 68 73 77 81 85 88 91 93 96 98 100
38 34 46 55 63 69 74 78 82 86 89 92 94 97 99
39 34 47 56 63 69 75 79 83 87 90 93 96 98 100
40 34 47 57 64 70 76 80 84 88 91 94 97 99
41 35 48 57 65 71 77 81 85 89 92 95 98 100
42 35 49 58 66 72 77 82 86 90 93 96 99
43 36 49 59 66 73 78 83 87 91 94 98 100
44 36 50 59 67 74 79 84 88 92 96 99
45 36 50 60 68 75 80 85 89 93 97 100
46 37 51 61 69 75 81 86 90 94 98
47 37 51 61 69 76 82 87 91 95 99
48 38 52 62 70 77 83 88 92 96 100
49 38 52 63 71 78 84 89 93 97
50 38 53 63 72 79 84 90 94 98
Figure B-1: 20–40 sand, SGU = 2.65, size factor = 1.0
Private
proppants
CAUTION: The recommended maximum delivery rate for sand is 10,000

lbm/min. Avoid performing jobs within the highlighted area if possible.
Private
proppants
B.2 30–60 or 40–70 sand, SGU = 2.65, size factor

= 1.17
3 0-60 OR 40-70 SAND SGU = 2.65 SIZE FACTOR = 1.17
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 4 6 7 8 9 10 11 12 12 13 13 14 14 14 15 15 15 16 16 16
2 6 9 11 13 14 15 16 17 18 19 20 20 21 21 22 22 23 23 23 24
3 8 11 14 16 18 19 20 22 23 24 24 25 26 27 27 28 28 29 29 30
4 9 13 16 19 21 22 24 25 26 28 29 29 30 31 32 32 33 34 34 35
5 10 15 18 21 23 25 27 29 30 31 32 33 34 35 36 36 37 38 38 39
6 11 17 20 23 26 28 30 31 33 34 35 37 38 39 39 40 41 42 42 43
7 13 18 22 25 28 30 32 34 36 37 39 40 41 42 43 44 44 45 46 46
8 14 20 24 27 30 33 35 37 38 40 41 43 44 45 46 47 48 48 49 50
9 14 21 25 29 32 35 37 39 41 43 44 45 47 48 49 50 51 51 52 53
10 15 22 27 31 34 37 39 41 43 45 46 48 49 50 52 53 53 54 55 56
11 16 23 28 32 36 39 41 43 45 47 49 50 52 53 54 55 56 57 58 59
12 17 24 30 34 38 41 43 45 48 49 51 53 54 55 57 58 59 60 61 62
13 18 26 31 35 39 42 45 47 50 52 53 55 56 58 59 60 61 62 63 64
14 19 27 32 37 41 44 47 49 52 54 55 57 59 60 61 63 64 65 66 67
15 19 28 34 38 42 46 49 51 53 56 57 59 61 62 64 65 66 67 68 69
16 20 29 35 40 44 47 50 53 55 57 59 61 63 64 66 67 68 69 70 71
17 21 29 36 41 45 49 52 55 57 59 61 63 65 66 68 69 70 72 73 74
18 21 30 37 42 46 50 53 56 59 61 63 65 67 68 70 71 73 74 75 76
19 22 31 38 43 48 52 55 58 60 63 65 67 69 70 72 73 75 76 77 78
20 23 32 39 45 49 53 56 59 62 65 67 69 71 72 74 75 77 78 79 80
21 23 33 40 46 50 54 58 61 64 66 68 70 72 74 76 77 79 80 81 82
22 24 34 41 47 52 56 59 62 65 68 70 72 74 76 78 79 80 82 83 84
23 24 35 42 48 53 57 61 64 67 69 72 74 76 78 79 81 82 84 85 86
24 25 35 43 49 54 58 62 65 68 71 73 75 78 79 81 83 84 86 87 88
BPM 25 26 36 44 50 55 60 63 67 70 72 75 77 79 81 83 84 86 87 89 90
26 26 37 45 51 56 61 65 68 71 74 76 79 81 83 84 86 88 89 91 92
27 27 38 46 52 57 62 66 69 73 75 78 80 82 84 86 88 89 91 92 94
28 27 38 47 53 59 63 67 71 74 77 79 82 84 86 88 90 91 93 94 95
29 28 39 48 54 60 64 68 72 75 78 81 83 85 87 89 91 93 94 96 97
30 28 40 48 55 61 65 70 73 77 80 82 85 87 89 91 93 94 96 97 99
31 29 41 49 56 62 67 71 75 78 81 84 86 88 91 92 94 96 98 99 100
32 29 41 50 57 63 68 72 76 79 82 85 88 90 92 94 96 98 99
33 30 42 51 58 64 69 73 77 80 84 86 89 91 93 95 97 99
34 30 43 52 59 65 70 74 78 82 85 88 90 93 95 97 99
35 31 43 52 60 66 71 75 79 83 86 89 92 94 96 98 100
36 31 44 53 61 67 72 76 81 84 87 90 93 95 98 100
37 32 45 54 61 68 73 78 82 85 89 92 94 97 99
38 32 45 55 62 69 74 79 83 86 90 93 96 98 100
39 32 46 55 63 69 75 80 84 88 91 94 97 99
40 33 46 56 64 70 76 81 85 89 92 95 98
41 33 47 57 65 71 77 82 86 90 93 97 99
42 34 48 58 66 72 78 83 87 91 95 98 100
43 34 48 58 66 73 79 84 88 92 96 99
44 35 49 59 67 74 80 85 89 93 97 100
45 35 49 60 68 75 81 86 90 94 98
46 35 50 60 69 76 82 87 91 95 99
47 36 51 61 70 77 83 88 92 96 100
48 36 51 62 70 77 83 89 93 97
49 37 52 62 71 78 84 90 94 99
50 37 52 63 72 79 85 91 95 100
Figure B-2: 30–60 or 40–70 sand, SGU = 2.65, size factor = 1.17
Private
proppants
CAUTION: The recommended maximum delivery rate for sand is 10,000

lbm/min. Avoid performing jobs within the highlighted area if possible.
Private
proppants
B.3 20–40 resin-coated sand, SGU = 2.53, size

factor = 1.0
2 0-40 RESIN-COATED SAND SGU = 2.53 SIZE FACTOR = 1.0
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 5 7 9 10 11 12 13 13 14 14 15 15 16 16 16 17 17 17 17 18
2 8 10 13 14 16 17 18 19 20 20 21 22 22 23 23 24 24 24 25 25
3 9 13 15 17 19 21 22 23 24 25 26 26 27 28 28 29 29 30 30 31
4 11 15 18 20 22 24 25 27 28 29 30 31 31 32 33 33 34 34 35 35
5 12 17 20 23 25 27 28 30 31 32 33 34 35 36 37 37 38 39 39 40
6 13 18 22 25 27 29 31 33 34 35 36 37 38 39 40 41 42 42 43 43
7 14 20 24 27 29 32 34 35 37 38 39 40 42 42 43 44 45 46 46 47
8 15 21 25 29 31 34 36 38 39 41 42 43 44 45 46 47 48 49 50 50
9 16 22 27 30 33 36 38 40 42 43 45 46 47 48 49 50 51 52 53 53
10 17 24 28 32 35 38 40 42 44 46 47 48 50 51 52 53 54 55 55 56
11 18 25 30 34 37 40 42 44 46 48 49 51 52 53 54 55 56 57 58 59
12 19 26 31 35 39 41 44 46 48 50 52 53 54 56 57 58 59 60 61 62
13 19 27 32 37 40 43 46 48 50 52 54 55 57 58 59 60 61 62 63 64
14 20 28 34 38 42 45 48 50 52 54 56 57 59 60 61 63 64 65 66 66
15 21 29 35 39 43 46 49 52 54 56 58 59 61 62 64 65 66 67 68 69
16 22 30 36 41 45 48 51 53 56 58 60 61 63 64 66 67 68 69 70 71
17 22 31 37 42 46 49 52 55 57 60 61 63 65 66 68 69 70 71 72 73
18 23 32 38 43 47 51 54 57 59 61 63 65 67 68 70 71 72 73 74 75
19 23 33 39 44 49 52 55 58 61 63 65 67 69 70 72 73 74 75 76 77
20 24 33 40 45 50 54 57 60 62 65 67 69 70 72 73 75 76 77 78 79
21 25 34 41 47 51 55 58 61 64 66 68 70 72 74 75 77 78 79 80 81
22 25 35 42 48 52 56 60 63 65 68 70 72 74 75 77 78 80 81 82 83
23 26 36 43 49 53 57 61 64 67 69 71 74 75 77 79 80 82 83 84 85
24 26 37 44 50 55 59 62 65 68 71 73 75 77 79 80 82 83 85 86 87
BPM 25 27 37 45 51 56 60 64 67 70 72 75 77 79 80 82 84 85 86 88 89
26 28 38 46 52 57 61 65 68 71 74 76 78 80 82 84 85 87 88 89 91
27 28 39 47 53 58 62 66 69 72 75 77 80 82 84 85 87 88 90 91 92
28 29 40 47 54 59 63 67 71 74 76 79 81 83 85 87 89 90 91 93 94
29 29 40 48 55 60 65 68 72 75 78 80 83 85 87 88 90 92 93 94 96
30 30 41 49 56 61 66 70 73 76 79 82 84 86 88 90 92 93 95 96 97
31 30 42 50 57 62 67 71 74 78 80 83 85 88 90 91 93 95 96 98 99
32 31 42 51 57 63 68 72 76 79 82 84 87 89 91 93 95 96 98 99
33 31 43 52 58 64 69 73 77 80 83 86 88 90 92 94 96 98 99
34 31 44 52 59 65 70 74 78 81 84 87 89 92 94 96 98 99
35 32 44 53 60 66 71 75 79 82 85 88 91 93 95 97 99
36 32 45 54 61 67 72 76 80 84 87 89 92 94 97 99 100
37 33 46 55 62 68 73 77 81 85 88 91 93 96 98 100
38 33 46 55 63 69 74 78 82 86 89 92 95 97 99
39 34 47 56 63 70 75 79 83 87 90 93 96 98
40 34 47 57 64 70 76 80 84 88 91 94 97 100
41 35 48 58 65 71 77 81 86 89 93 96 98
42 35 49 58 66 72 78 82 87 90 94 97 99
43 35 49 59 67 73 79 83 88 91 95 98 100
44 36 50 60 67 74 80 84 89 92 96 99
45 36 50 60 68 75 80 85 90 93 97 100
46 37 51 61 69 76 81 86 91 95 98
47 37 51 62 70 76 82 87 92 96 99
48 37 52 62 70 77 83 88 93 97 100
49 38 52 63 71 78 84 89 94 98
50 38 53 64 72 79 85 90 94 99
Figure B-3: 20–40 resin-coated sand, SGU = 2.53, size factor = 1.0
Private
proppants
CAUTION: The recommended maximum delivery rate for resin-coated sand is

9,500 lbm/min. Avoid performing jobs within the highlighted area if possible.
Private
proppants
B.4 30–60 or 40–70 resin-coated sand, SGU =

2.53, size factor = 1.17
30-60 OR 40-70 RESIN-COATED SAND SGU = 2.53 SIZE FACTOR = 1.17
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 8 10 11 12 13 14 15 16 16 17 17 18 18 18 19 19 19 20 20 20
2 10 13 15 17 18 19 20 21 22 23 23 24 25 25 26 26 26 27 27 28
3 12 15 18 20 22 23 24 26 27 27 28 29 30 30 31 32 32 33 33 33
4 13 17 20 23 25 26 28 29 30 31 32 33 34 35 35 36 37 37 38 38
5 14 19 22 25 27 29 31 32 34 35 36 37 38 39 39 40 41 41 42 43
6 15 21 24 27 30 32 34 35 37 38 39 40 41 42 43 44 45 45 46 46
7 17 22 26 29 32 34 36 38 40 41 42 43 44 45 46 47 48 49 49 50
8 18 24 28 31 34 37 39 41 42 44 45 46 47 48 49 50 51 52 53 53
9 19 25 29 33 36 39 41 43 45 46 48 49 50 51 52 53 54 55 56 56
10 19 26 31 35 38 41 43 45 47 49 50 52 53 54 55 56 57 58 59 59
11 20 27 32 36 40 43 45 47 49 51 53 54 55 57 58 59 60 61 61 62
12 21 28 34 38 41 44 47 49 51 53 55 56 58 59 60 61 62 63 64 65
13 22 30 35 39 43 46 49 51 53 55 57 59 60 61 63 64 65 66 67 67
14 23 31 36 41 45 48 51 53 55 57 59 61 62 64 65 66 67 68 69 70
15 23 32 37 42 46 49 52 55 57 59 61 63 64 66 67 68 69 70 71 72
16 24 33 39 44 48 51 54 57 59 61 63 65 66 68 69 70 72 73 74 75
17 25 33 40 45 49 52 56 58 61 63 65 67 68 70 71 73 74 75 76 77
18 25 34 41 46 50 54 57 60 62 65 67 69 70 72 73 75 76 77 78 79
19 26 35 42 47 52 55 59 61 64 66 68 70 72 74 75 77 78 79 80 81
20 27 36 43 48 53 57 60 63 66 68 70 72 74 76 77 79 80 81 82 83
21 27 37 44 50 54 58 62 65 67 70 72 74 76 77 79 80 82 83 84 85
22 28 38 45 51 55 59 63 66 69 71 74 76 77 79 81 82 84 85 86 87
23 28 39 46 52 57 61 64 67 70 73 75 77 79 81 83 84 85 87 88 89
24 29 39 47 53 58 62 66 69 72 74 77 79 81 83 84 86 87 89 90 91
BPM 25 30 40 48 54 59 63 67 70 73 76 78 80 82 84 86 88 89 90 92 93
26 30 41 49 55 60 64 68 72 75 77 80 82 84 86 88 89 91 92 93 95
27 31 42 50 56 61 66 70 73 76 79 81 84 86 88 89 91 92 94 95 96
28 31 42 51 57 62 67 71 74 77 80 83 85 87 89 91 93 94 96 97 98
29 32 43 51 58 63 68 72 76 79 82 84 86 89 91 92 94 96 97 99 100
30 32 44 52 59 64 69 73 77 80 83 86 88 90 92 94 96 97 99 100
31 33 45 53 60 65 70 74 78 81 84 87 89 92 94 96 97 99 100
32 33 45 54 61 66 71 76 79 83 86 88 91 93 95 97 99
33 34 46 55 62 67 72 77 80 84 87 90 92 94 97 99 100
34 34 47 56 63 68 73 78 82 85 88 91 94 96 98 100
35 35 47 56 63 69 75 79 83 86 89 92 95 97 99
36 35 48 57 64 70 76 80 84 87 91 94 96 99
37 36 49 58 65 71 77 81 85 89 92 95 97 100
38 36 49 59 66 72 78 82 86 90 93 96 99
39 37 50 59 67 73 79 83 87 91 94 97 100
40 37 50 60 68 74 80 84 88 92 95 99
41 37 51 61 69 75 80 85 89 93 97 100
42 38 52 62 69 76 81 86 91 94 98
43 38 52 62 70 77 82 87 92 95 99
44 39 53 63 71 78 83 88 93 97 100
45 39 53 64 72 78 84 89 94 98
46 39 54 64 73 79 85 90 95 99
47 40 54 65 73 80 86 91 96 100
48 40 55 66 74 81 87 92 97
49 41 56 66 75 82 88 93 98
50 41 56 67 76 83 89 94 99
Figure B-4: 30–60 or 40–70 resin-coated sand, SGU = 2.53, size factor = 1.17
Private
proppants
CAUTION: The recommended maximum delivery rate for resin-coated sand is

9,500 lbm/min. Avoid performing jobs within the highlighted area if possible.
Private
proppants
B.5 16–30 high-strength proppant, SGU = 3.55,

size factor = 0.9
16-30 HIGH-STRENGTH PROPPANT SGU = 3.55 SIZE FACTOR = 0.9
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 6 8 9 10 11 12 12 13 14 14 15 15 15 16 16 16 17 17 17 18
2 8 10 12 14 15 16 17 18 19 19 20 21 21 22 22 23 23 24 24 24
3 9 12 15 17 18 19 21 22 23 24 24 25 26 26 27 28 28 29 29 30
4 10 14 17 19 21 22 24 25 26 27 28 29 30 30 31 32 32 33 33 34
5 12 16 19 21 23 25 26 28 29 30 31 32 33 34 35 35 36 37 37 38
6 13 17 20 23 25 27 29 30 32 33 34 35 36 37 38 39 39 40 41 41
7 13 18 22 25 27 29 31 33 34 35 37 38 39 40 41 42 42 43 44 45
8 14 19 23 26 29 31 33 35 36 38 39 40 41 42 43 44 45 46 47 48
9 15 21 25 28 30 33 35 37 38 40 41 43 44 45 46 47 48 49 50 50
10 16 22 26 29 32 35 37 39 40 42 44 45 46 47 48 49 50 51 52 53
11 17 23 27 31 34 36 38 41 42 44 46 47 48 50 51 52 53 54 55 56
12 17 24 28 32 35 38 40 42 44 46 48 49 50 52 53 54 55 56 57 58
13 18 24 29 33 36 39 42 44 46 48 49 51 52 54 55 56 57 58 59 60
14 19 25 30 34 38 41 43 46 48 50 51 53 54 56 57 58 59 61 62 62
15 19 26 31 35 39 42 45 47 49 51 53 55 56 58 59 60 62 63 64 65
16 20 27 32 37 40 43 46 49 51 53 55 56 58 60 61 62 63 65 66 67
17 20 28 33 38 41 45 48 50 52 54 56 58 60 61 63 64 65 67 68 69
18 21 29 34 39 43 46 49 51 54 56 58 60 62 63 65 66 67 68 70 71
19 21 29 35 40 44 47 50 53 55 58 60 61 63 65 66 68 69 70 72 73
20 22 30 36 41 45 48 51 54 57 59 61 63 65 66 68 69 71 72 73 74
21 22 31 37 42 46 50 53 56 58 60 63 65 66 68 70 71 73 74 75 76
22 23 31 38 43 47 51 54 57 59 62 64 66 68 70 71 73 74 76 77 78
23 23 32 38 44 48 52 55 58 61 63 65 68 69 71 73 74 76 77 79 80
24 24 33 39 45 49 53 56 59 62 65 67 69 71 73 74 76 77 79 80 81
BPM 25 24 33 40 45 50 54 57 60 63 66 68 70 72 74 76 78 79 80 82 83
26 25 34 41 46 51 55 58 62 65 67 70 72 74 76 77 79 81 82 83 85
27 25 35 42 47 52 56 60 63 66 68 71 73 75 77 79 81 82 84 85 86
28 26 35 42 48 53 57 61 64 67 70 72 74 76 78 80 82 84 85 87 88
29 26 36 43 49 54 58 62 65 68 71 73 76 78 80 82 83 85 87 88 89
30 27 37 44 50 55 59 63 66 69 72 75 77 79 81 83 85 87 88 90 91
31 27 37 45 50 56 60 64 67 70 73 76 78 80 82 84 86 88 90 91 92
32 27 38 45 51 56 61 65 68 71 74 77 79 82 84 86 88 89 91 92 94
33 28 38 46 52 57 62 66 69 73 75 78 81 83 85 87 89 91 92 94 95
34 28 39 47 53 58 63 67 70 74 77 79 82 84 86 88 90 92 94 95 97
35 29 39 47 54 59 64 68 71 75 78 80 83 85 88 90 92 93 95 97 98
36 29 40 48 54 60 64 69 72 76 79 82 84 87 89 91 93 95 96 98 100
37 29 40 49 55 61 65 70 73 77 80 83 85 88 90 92 94 96 98 99
38 30 41 49 56 61 66 70 74 78 81 84 86 89 91 93 95 97 99
39 30 41 50 56 62 67 71 75 79 82 85 88 90 92 95 97 98 100
40 30 42 50 57 63 68 72 76 80 83 86 89 91 94 96 98 100
41 31 42 51 58 64 69 73 77 81 84 87 90 92 95 97 99
42 31 43 52 59 64 70 74 78 82 85 88 91 93 96 98 100
43 32 43 52 59 65 70 75 79 83 86 89 92 95 97 99
44 32 44 53 60 66 71 76 80 84 87 90 93 96 98 100
45 32 44 53 61 67 72 77 81 85 88 91 94 97 99
46 33 45 54 61 67 73 77 82 85 89 92 95 98 100
47 33 45 55 62 68 73 78 82 86 90 93 96 99
48 33 46 55 63 69 74 79 83 87 91 94 97 100
49 34 46 56 63 70 75 80 84 88 92 95 98
50 34 47 56 64 70 76 81 85 89 93 96 99
Figure B-5: 16–30 high-strength proppant, SGU = 3.55, size factor = 0.9
Private
proppants
CAUTION: The recommended maximum delivery rate for HSP is 10,000 lbm/min.
Avoid performing jobs within the highlighted area if possible.
Private
proppants
B.6 20–40 high-strength proppant, SGU = 3.55,

size factor = 1.0
20-40 HIGH-STRENGTH PROPPANT SGU = 3.55 SIZE FACTOR = 1.0
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 4 6 8 9 10 11 11 12 12 13 13 14 14 15 15 15 16 16 16 16
2 6 9 11 13 14 15 16 17 18 18 19 20 20 21 21 22 22 23 23 23
3 8 11 14 15 17 18 20 21 22 23 23 24 25 26 26 27 27 28 28 29
4 9 13 16 18 20 21 23 24 25 26 27 28 29 30 30 31 32 32 33 33
5 10 14 18 20 22 24 25 27 28 29 30 31 32 33 34 35 35 36 37 37
6 11 16 19 22 24 26 28 29 31 32 33 34 35 36 37 38 39 39 40 41
7 12 17 21 24 26 28 30 32 33 35 36 37 38 39 40 41 42 43 43 44
8 13 18 22 25 28 30 32 34 36 37 39 40 41 42 43 44 45 46 46 47
9 14 20 24 27 30 32 34 36 38 39 41 42 43 45 46 47 48 48 49 50
10 15 21 25 28 31 34 36 38 40 42 43 44 46 47 48 49 50 51 52 53
11 15 22 26 30 33 36 38 40 42 44 45 47 48 49 50 52 53 54 55 55
12 16 23 27 31 34 37 40 42 44 46 47 49 50 52 53 54 55 56 57 58
13 17 24 28 32 36 39 41 44 46 47 49 51 52 54 55 56 57 58 59 60
14 17 24 30 34 37 40 43 45 47 49 51 53 54 56 57 58 59 60 62 63
15 18 25 31 35 38 42 44 47 49 51 53 55 56 58 59 60 61 63 64 65
16 19 26 32 36 40 43 46 48 51 53 55 56 58 60 61 62 64 65 66 67
17 19 27 33 37 41 44 47 50 52 54 56 58 60 61 63 64 65 67 68 69
18 20 28 34 38 42 46 49 51 54 56 58 60 62 63 65 66 67 69 70 71
19 20 28 34 39 43 47 50 53 55 57 60 61 63 65 66 68 69 71 72 73
20 21 29 35 40 44 48 51 54 57 59 61 63 65 67 68 70 71 72 74 75
21 21 30 36 41 46 49 52 55 58 60 63 65 66 68 70 71 73 74 75 77
22 22 31 37 42 47 50 54 57 59 62 64 66 68 70 72 73 75 76 77 78
23 22 31 38 43 48 52 55 58 61 63 66 68 70 71 73 75 76 78 79 80
24 23 32 39 44 49 53 56 59 62 65 67 69 71 73 75 76 78 79 81 82
BPM 25 23 33 40 45 50 54 57 60 63 66 68 71 73 74 76 78 79 81 82 84
26 24 33 40 46 51 55 58 62 65 67 70 72 74 76 78 79 81 83 84 85
27 24 34 41 47 52 56 60 63 66 69 71 73 75 77 79 81 83 84 86 87
28 25 35 42 48 53 57 61 64 67 70 72 75 77 79 81 82 84 86 87 89
29 25 35 43 49 54 58 62 65 68 71 74 76 78 80 82 84 86 87 89 90
30 26 36 43 49 54 59 63 66 69 72 75 77 80 82 84 85 87 89 90 92
31 26 36 44 50 55 60 64 67 71 73 76 79 81 83 85 87 89 90 92 93
32 27 37 45 51 56 61 65 68 72 75 77 80 82 84 86 88 90 92 93 95
33 27 38 45 52 57 62 66 69 73 76 79 81 83 86 88 90 91 93 95 96
34 27 38 46 53 58 63 67 71 74 77 80 82 85 87 89 91 93 94 96 98
35 28 39 47 53 59 64 68 72 75 78 81 84 86 88 90 92 94 96 97 99
36 28 39 48 54 60 65 69 73 76 79 82 85 87 89 92 94 95 97 99 100
37 29 40 48 55 61 65 70 74 77 80 83 86 88 91 93 95 97 99 100
38 29 40 49 56 61 66 71 75 78 81 84 87 90 92 94 96 98 100
39 29 41 49 56 62 67 72 76 79 82 85 88 91 93 95 97 99
40 30 41 50 57 63 68 73 77 80 83 87 89 92 94 97 99
41 30 42 51 58 64 69 73 77 81 85 88 90 93 95 98 100
42 30 43 51 58 65 70 74 78 82 86 89 92 94 97 99
43 31 43 52 59 65 71 75 79 83 87 90 93 95 98 100
44 31 44 53 60 66 71 76 80 84 88 91 94 96 99
45 32 44 53 61 67 72 77 81 85 89 92 95 97 100
46 32 45 54 61 68 73 78 82 86 90 93 96 99
47 32 45 54 62 68 74 79 83 87 91 94 97 100
48 33 45 55 63 69 75 79 84 88 91 95 98
49 33 46 55 63 70 75 80 85 89 92 96 99
50 33 46 56 64 70 76 81 86 90 93 97 100
Figure B-6: 20–40 high-strength proppant, SGU = 3.55, size factor = 1.0
Private
proppants
Private
proppants
B.7 30–60 or 40–70 high-strength proppant, SGU

= 3.55, size factor = 1.17
30-60 OR 40-70 HIGH-STRENGTH SGU = 3.55 SIZE FACTOR = 1.17
PROPPANT
PPA
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
1 5 7 8 9 10 11 11 12 13 13 14 14 14 15 15 15 16 16 16 17
2 7 9 11 13 14 15 16 17 18 18 19 20 20 21 21 22 22 23 23 23
3 8 11 14 15 17 18 20 21 22 23 23 24 25 25 26 27 27 28 28 29
4 9 13 16 18 20 21 23 24 25 26 27 28 29 29 30 31 31 32 33 33
5 10 15 18 20 22 24 25 27 28 29 30 31 32 33 34 34 35 36 36 37
6 11 16 19 22 24 26 28 29 31 32 33 34 35 36 37 38 38 39 40 40
7 12 17 21 24 26 28 30 32 33 34 36 37 38 39 40 41 42 42 43 44
8 13 18 22 25 28 30 32 34 35 37 38 39 41 42 43 44 44 45 46 47
9 14 20 24 27 30 32 34 36 38 39 40 42 43 44 45 46 47 48 49 50
10 15 21 25 28 31 34 36 38 40 41 43 44 45 47 48 49 50 51 51 52
11 16 22 26 30 33 35 38 40 41 43 45 46 48 49 50 51 52 53 54 55
12 16 23 27 31 34 37 39 41 43 45 47 48 50 51 52 53 54 55 56 57
13 17 23 28 32 35 38 41 43 45 47 49 50 52 53 54 55 57 58 59 60
14 17 24 29 33 37 40 42 45 47 49 50 52 54 55 56 58 59 60 61 62
15 18 25 30 35 38 41 44 46 48 50 52 54 56 57 58 60 61 62 63 64
16 19 26 31 36 39 42 45 48 50 52 54 56 57 59 60 62 63 64 65 66
17 19 27 32 37 41 44 47 49 52 54 56 57 59 61 62 63 65 66 67 68
18 20 28 33 38 42 45 48 51 53 55 57 59 61 62 64 65 67 68 69 70
19 20 28 34 39 43 46 49 52 55 57 59 61 62 64 66 67 68 70 71 72
20 21 29 35 40 44 48 51 53 56 58 60 62 64 66 67 69 70 71 73 74
21 21 30 36 41 45 49 52 55 57 60 62 64 66 67 69 70 72 73 74 76
22 22 30 37 42 46 50 53 56 59 61 63 65 67 69 71 72 74 75 76 77
23 22 31 38 43 47 51 54 57 60 62 65 67 69 71 72 74 75 77 78 79
24 23 32 38 44 48 52 55 59 61 64 66 68 70 72 74 75 77 78 80 81
BPM 25 23 32 39 45 49 53 57 60 63 65 67 70 72 74 75 77 78 80 81 82
26 24 33 40 45 50 54 58 61 64 66 69 71 73 75 77 78 80 81 83 84
27 24 34 41 46 51 55 59 62 65 68 70 72 74 76 78 80 81 83 84 86
28 25 34 41 47 52 56 60 63 66 69 71 74 76 78 80 81 83 85 86 87
29 25 35 42 48 53 57 61 64 67 70 73 75 77 79 81 83 84 86 87 89
30 26 36 43 49 54 58 62 65 69 71 74 76 78 81 82 84 86 87 89 90
31 26 36 44 50 55 59 63 66 70 72 75 78 80 82 84 86 87 89 90 92
32 26 37 44 50 56 60 64 68 71 74 76 79 81 83 85 87 89 90 92 93
33 27 37 45 51 56 61 65 69 72 75 77 80 82 84 86 88 90 92 93 95
34 27 38 46 52 57 62 66 70 73 76 79 81 84 86 88 90 91 93 95 96
35 28 38 46 53 58 63 67 71 74 77 80 82 85 87 89 91 93 94 96 98
36 28 39 47 54 59 64 68 72 75 78 81 84 86 88 90 92 94 96 97 99
37 28 40 48 54 60 65 69 73 76 79 82 85 87 89 92 94 95 97 99 100
38 29 40 48 55 61 65 70 74 77 80 83 86 88 91 93 95 97 98 100
39 29 41 49 56 61 66 71 75 78 81 84 87 89 92 94 96 98 100
40 30 41 50 56 62 67 72 76 79 82 85 88 91 93 95 97 99
41 30 42 50 57 63 68 72 76 80 83 86 89 92 94 96 98 100
42 30 42 51 58 64 69 73 77 81 84 87 90 93 95 98 100
43 31 43 51 58 64 70 74 78 82 85 88 91 94 96 99
44 31 43 52 59 65 70 75 79 83 86 89 92 95 98 100
45 31 44 53 60 66 71 76 80 84 87 90 93 96 99
46 32 44 53 60 67 72 77 81 85 88 91 94 97 100
47 32 45 54 61 67 73 78 82 86 89 92 95 98
48 32 45 54 62 68 74 78 83 87 90 93 96 99
49 33 45 55 62 69 74 79 84 88 91 94 97 100
50 33 46 55 63 70 75 80 84 88 92 95 98
Figure B-7: 30–60 or 40–70 high-strength proppant, SGU = 3.55, size factor = 1.17
Private
proppants
Private

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Stimulation Blender Truck

SBT-615 Operations Manual

Private SCD,SBT,615,SB T-615,operations,blending,pro ppant,Prop NET

Copyright © 2010 Schlumberger, Unpublished Work. All rights reserved.

Copyright © 2010 Schlumberger, Unpublished Work. All rights reserved.

electronic or mechanical, in whole or in part, without the express written

Trademarks & Service marks

Schlumberger, the Schlumberger logotype, and other words or symbols used

A complete list of Schlumberger marks may be viewed at the Schlumberger

Author: Hau Pham

Reviewer: Hau Pham

Approver: Juurong Hsieh

1.0 18-Aug-2005 Original issue date. Author:

1 Introduction ____________________________________________________ 1-1

2 QHSE __________________________________________________________ 2-1

3 Unit operations _________________________________________________ 3-1

4 Job preparation ________________________________________________ 4-1

5 Job execution __________________________________________________ 5-1

6 Troubleshooting ________________________________________________ 6-1

6.3 Circuits troubleshooting ______________________________________ 6-8

A Forms and checklists __________________________________________ A-1

1-1 PodSTREAK roadside view ________________________________________ 1-3

3-2 Dashboard PTO switch locations ___________________________________ 3-2

3-41 Gate response test screen ________________________________________ 3-60

3-50 Close-up view of the backup console switches______________________ 3-75

3-89 Liquid Add Tachometer Calibration screen_________________________ 3-130

1-1 General Specifications _____________________________________________ 1-4

3-5 Mixer Controls____________________________________________________ 3-22

1.1 Application overview

An integrated deck-mounted control cabin with FracCAT software provides the

A 10-bbl capacity header tank, working in conjunction with an 8x6 direct-driven

The unit comes standard with the following:

• one Fiber feeder

the unit) and miscellaneous fittings.

Optional configurations available include:

• winterized unit version for cold climate operation

1.2 General equipment overview and unit layout

• 10 bbl-capacity header tank/hydraulic fluid tank assembly integrated within a

Figure 1-1: PodSTREAK roadside view

Figure 1-2: PodSTREAK curbside view

Figure 1-3: PodSTREAK underside view

Truck Chassis Peterbilt 357 heavy version

Tires – Front (2) Bridgestone M-844F

* Weights are without hoses, connections, chemicals, and/or miscellaneous

** The performance envelope is extrapolated based on test data using 20–40

Figure 1-4: SBT-615 PodSTREAK performance envelope

1.4 Scope of this manual

2.5 Transportation _________________________________________________ 2-4

described in Well Services Field Safety Handbook, InTouch content ID#

2.1 Safety standards and PPE

You should also be familiar with the following:

• Well Services Safety Standard 30: Pumping Combustible and Flammable

2.2 Personnel safety

It is important to remember the dangers of heat generated by this unit. The

Potential Severity: Serious

Do not climb on the engine while it is in operation.

2.3 Equipment safety

• Driver’s Trip Report DS-598-2-A

2.3.1 Pre-trip safety inspections

• Schlumberger 15-point checklist, as applicable for the unit. This is part of

• Review deficiencies recorded on the unit from the previous job.

In addition, check the following items on the unit:

• water coolant level