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Frac Water Transfer Project

THE CHALLENGE

Instead of placing semi-permanent freshwater tanks onsite, many fracking companies are moving to a “frac on the fly” approach that involves a portable buffer tank. Often, these tanks need to be placed a long way from the pump (especially on multi-well pads).

Our client required an automated solution to monitor and control water levels (ensuring the buffer tank didn’t overflow or run dry). They wanted it to be wireless since exposed cables can get easily damaged on the well site. One more request: it also had to be portable and easy to mobilize/demobilize!

Following the initial installation, the client determined they wanted to add real-time high and low-level alarms to the system. This would reduce the risk of costly environmental cleanups if the tank overflowed while ensuring water was always on hand when required.

THE SOLUTION

Jadler went to work devising a portable plug-and-play solution that would be quick and easy to deploy. And be oilfield-tough!

A Dwyer Submersible Pressure Sensor was selected to control freshwater volume and a Flowline Ultrasonic Sensor was selected for produced water. A 4-20 mA wireless receiver provided reliable communication between the control panel and pump. It was designed to securely transmit over a 2 km range, allowing for flexible tank placement. The panel was battery-powered, with an external plug receptacle for easy charging.

Jadler built everything into a sturdy, waterproof pelican case for maximum protection and portability. All components were rated to -40°C.

Initially, our solution was specified to provide a basic alert through a blind signal transmitted into the SCADA system. To upgrade to real-time level alarm functionality, we installed a Walchem Intuition 6 controller and local transmitter. This local I/O controller transmits a signal that will trigger an audible and/or visual alarm via a compact receiver to notify the operator. It provided a 2 km range, could be placed in a shack or vehicle, and included a free web-based monitoring platform to allow remote viewing and setup.

This new system will help reduce human error to protect the site while ensuring greater operational efficiency. And by eliminating the need for SCADA, we were able to save the client some money and simplify the setup.