View of ECAMS console from cabin

ECAMS Multi-unit Frac Control System

Industry-leading, multi-unit control system for hydraulic fracturing and cementing operations

  • Description Description
Description

ECAMS™ is a distributed, multi-unit control system for hydraulic fracturing operations that connects the data van, frac pumpers, blenders, hydration unit, and chemical additive units. The system allows for centralized data access, utilizes HMI touchscreen controls for ease of operator function, facilitates manual or fully automated control, is rugged, customizable, and easily serviceable worldwide. ECAMS provides service companies with  unparalleled confidence to control their fracturing fleet with precision and meet the most stringent safety and job-quality demands in the well servicing industry.

 

The ECAMS system design and configuration facilitates local and remote operation. All external panels and enclosures are built on a rugged platform that meets minimum standard Nema 4X. Our systems have been installed and operated in all weather environments around the world.

 

The fast data processing exhibits typical sensor sampling rates of 33 to 100 Hz or 10 to 30 ms based on the scan time of the PLC. High serviceability is of paramount importance and is integral to the hardware design, utilizing standardized hardware that is available worldwide.

 

The software architecture is field proven, and the stack is fully customizable. New ECAMS features can be added and/or adapted to meet customer-specific process needs.

ECAMS Fleet Control Features

Data van

  • Centralized data access – All process and setup data available in the data van for monitoring and/or logging purposes on Siemens HMIs, PC screens, or configured servers
  • Auto pump control – Total of 32 pumps can be controlled together in auto or manual mode
    • Software presently supports two separate auto groups to achieve a target rate and can be modified to handle four or more groups

Frac pumper

  • Manual and automatic modes
  • Auto mode – Pump by rate, automatic control of engine RPM, and transmission gear for optimal torque and engine performance
  • Overpressure shutdown – Pumper will go to engine idle and neutral upon an overpressure event; overpressure trip point can be set by the operator
  • Automatic pressure test – Automatically ramp up output pressure for on-site leak testing
  • Totalization - Fluid output, engine hours, and fuel consumption
  • Setup for multiple discharge pump configurations – fluid end geometry and rod loading
  • Full remote control from ECAMS data van

Blender

  • Manual and automatic modes
  • Auto modes – Suction, discharge, augers, and chemicals
  • Suction control – Pressure or tub level
  • Discharge control – Rate, pressure, or concentration (density)
  • Auger control – RPM, mass flow, and density
  • Automatic density control – Densitometer, clean versus dirty
  • Liquid and dry additive auto concentration control
  • Slipstream functionality
  • Job and stage setup with operator-defined proppant library
  • Remote parameters are available in ECAMS data van

Chem additive

  • Manual and automatic modes
  • Up to 10 liquid additive delivery systems for multiple chemical injections
  • Auto concentration based on flow rate from an external source such as a blender or hydration unit
  • Job and stage setup with operator-defined chemical library
  • Remote parameters are available in ECAMS data van

Hydration

  • Manual and automatic modes
  • Auto concentration based on flow rate information from an external source such as a blender
  • Remote parameters are available in ECAMS data van

Cementer

  • Manual and automatic modes
  • Auto density via mix water valve and bulk cementer gate valve based on on-board Coriolis meter
  • Overpressure shutdown – pumper will go to engine idle and neutral upon an overpressure event; overpressure trip point can be set by the operator
  • Downhole totalizer

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