PCM Tally-JET Rev.

A Page 1

Tally-JET

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PCM
Tally-JET is designed as a wellsite guide notebook intended
to capture STEM maintenance notes and key reminders
for the fracturing operation. Used in conjunction with the
Pocket-JET Manual, the Tally-JET can be a useful tool in
achieving the operational goal –No Pumps Down!
 Page 2 PCM Tally-JET Rev. A

Spotting and Placement

• Spot equipment so that equipment position and hose routing are

optimized.
–– Discharge manifold aligned with blender.
–– Suction manifold aligned with fluid source.
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• Trailer landing legs must be down

during operation and before filling tanks
one or two. Confirm the position and
operation of all four legs when spotting
or preparing to mobilize the PCM

Preparing for Operation

• Be aware of equipment rig up requirements for both normal and

contingency operations and ensure hose selection is appropriate.
–– Discharge hoses from the PCM are in effect suction hoses for the
blender.
–– Do not use discharge hoses in any suction condition.

Unit Type Suction Suction Discharge

(BPM) (4-in.) (8-in.) (4-in. hose)

POD Blender 4 20 10
(No C-Pump or Header Tank)

S&S Blender 8 35 10
(With C-Pump and Header Tank)

Transfer Pump 8 35 10
PCM Tally-JET Rev. A Page 3

• Check that fluid drains on C-pumps are closed before attempting

prime-up and operation
• Visually inspect hoses for erosion or corrosion that may weaken the
end fittings or result in leaks.
• Do not use hoses with damaged clamps, or cuts and abrasions that
expose wire or reinforcing fabric.
• Ensure all hose end connections are cleaned with wire brush and
lightly lubricated.
• Confirm O-ring seals are in place and in good condition.
• Ensure a positive shutoff valve between each suction hose and the
fluid source.
• Reduce and optimize the hose length to minimize the risk of cavitation.
• Use only approved liquid additive hoses and optimize hose length and
number of connections to reduce risk of spill or leakage.
• Check, and if necessary, flush hoses
and pipe work clear of debris or

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solidified chemical before
assembling the
system.
• When connecting
to the high-
pressure prime up
line, do not install
additional valves at
the PCM.
• Ensure the air system pressure is at
least 100psi before attempting to
operate the unit.
• Drain moisture from the air reservoirs
before operation. When the unit is not
in use, open drains to reduce moisture
build up.
 Page 4 PCM Tally-JET Rev. A

Operational Checks

• Ensure an adequate fluid level before

running the compartment mixers. The
mixers provide energy to the fluid for
improved hydration.
• Confirm all DCU’s are confirmed as “ONLINE” on the diagnostics
screen before operation.
–– “ONLINE” indicates communication is good.
–– “OFFLINE” indicates communication has been lost.
–– “---“ indicates communication has not been established.
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• Confirm that both ERAD modules are turned on during operation. The
dry guar tachometer No. 2 sensor (guar screw rpm) is only available if
the right hand side ERAD is turned on.
• When using the dry guar totalizer, do not modify the calibration factor
during the operation. Wait until the end of the job/stage to make
changes.
PCM Tally-JET Rev. A Page 5

• Periodically compare the dry guar

tachometers (1 and 2) for compatible
readings. Tachometer No. 1 is default for
control, tachometer No. 2 can be used as
backup. Do NOT select Tachometer 2 as
backup if reading is zero.
• Left-hand ERAD module displays
Suction Flowrate on top and Discharge
Flowrate on bottom. ERAD module on
the right displays guar screw speed
from secondary speed sensor.
• When unit is not in use, especially during winter time, ensure to open
drains on C1, C2, C4 (if equipped), and LAS 1 hose to Compartment 1.
• Verify that air safety valve is in normal
position for operation. Place valve in
venting position while performing any

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checks or maintenance in this area.
• Ensure that the educator pressure is at
least 30psi before attempting to run guar.
• Ensure that the engine is at idle before loading or unloading the hydraulic
pumps.
• When operating units with additional
C-pump (C4), attempt a manual re-generation
on the tractor engine to reduce the risk of
interrupting the operation.

ENGINE DPF
STATUS INDICATORS ON HIGHWAY AT WELL SITE
LIGHT LIGHT

DPF LIGHT OFF NO ACTION NO ACTION

MANUAL
AT NEXT STOP,
DPF LIGHT ON REGNERATE BEFORE
MANUAL REGENERATE
NEXT STAGE

PULL OFF ROAD, REGENERATE AS

DPF LIGHT BLINKING
MANUAL REGENERATE SOON AS POSSIBLE

DPF LIGHT BLINKING STOP IMMEDIATELY, PREPARE FOR

+ ENGINE LIGHT ON MANUAL REGENERATE ENGINE SHUTDOWN
 Page 6 PCM Tally-JET Rev. A

PCM R-Checks

For the sake of consistency can we

review the R-checks to make sure
they are “R-checks” and not main-
tenenace/STEM items (e.g., greas-
ing equipment??)

Dry Guar System

1. Unusual noise or vibration
2. Product leaks or fluid leaks
3. Fluid level in blower
4. Eductor drain valve closed
5. Electrical connection with tractor
6. Proximity switch condition and guards installed
7. Intrometer at front closed to ensure agitators turn
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8. Safety pins pulled and secured

9. Verify safety valve for knife gate is open
10. Verify camera is working and clean

Road Side
1. Valves have handles and are functioning
2. Close all drains (C1, C2, and all ADDS)
3. Battery box cover installed
4. Driveline cover installed
5. Battery controls on (12, 24, 24 Volt)

Ladder and Operators Control Panel

1. Handrails secured
2. Grating in place
3. Control panel clean

Road Side LAS Pumps (1 and 3)

1. Sight glass clean and secure
2. Tanks labelled with proper chemical
3. 206 connection or Victaulic
PCM Tally-JET Rev. A Page 7

4. Waukesha pumps greased

5. Ball valves working
6. CMHPG valve to compartment 1 closed
7. Ladder secured

Rear Engine
1. Unusual noise or vibration
2. Fluid leak
3. Fluid level
4. Air filter indicators
5. Turbo charger signs of overheating
6. Emergency kill system
7. Fuel filler caps
8. DPF status
9. Hydraulic filter indicators (4)
10. Hydraulic hose condition

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Curb Side LAS Pumps (2 and 4)
1. Sight glass clean and secure
2. Tanks labeled with proper chemical
3. 206 connection or Victaulic
4. Waukesha pumps greased
5. Ball valves working

Curb Side
1. Check V20 is open
2. Check V17 is open
3. Check bleeds on all c-pumps
4. Grease all C2 pump zirts
5. Verify KCL pump is cleaned and functional
6. Fuel tank full
7. Fuel tank lid and vent functioning

Guar System Curb Side

1. Guar bin inspection door closed
2. Fire extinguisher is charged
3. Lube oil tank full
PCM Tally-JET Rev. A
Page 8

PCM Schematic
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PCM Tally-JET Rev. A Page 9

Wellsite Tips and Tricks

Efficient operation of the PCM is critical to the fracturing operation and

potential issues should be identified and resolved early to avoid jeopardiz-
ing the operation.

Issues that can typically be resolved at the wellsite

• Ensure Stem 1 checks are properly completed

• Repair or replace leaking butterfly valves
• Tighten or repair hydraulic and pneumatic connections that show
evidence of leaks
• Close and secure junction box covers
• Keep the LAS system clean and repair or tag faulty components.
• Ensure work lights are operational
• Keep the operating area free from obstructions or trash

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Issues for which help may be needed

• Yellow tag and identify on Stem 1 report any issues that are not
repairable on location
• Clean and reconnect, repair, and/or replace leaking process hoses.
• Yellow tag hoses or fittings that should be repaired or replaced
• Replace or tag pressure switches, sensors or gauges that are not
operating properly

PCM hydraulic systems

1. Mixing systems
2. Additive systems
3. C-Pump 1
4. C-Pump 2
1 2

3 4
 Page 10 PCM Tally-JET Rev. A

Normal Operation Overview

Optimize waste and fluid disposal from the PCM following the operation
by following shut-down sequence.
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Shutdown Process Stage I

When it is determined that sufficient fracturing gel has been prepared to
complete the job, the Stage I shutdown is initiated.

1. The water supply from the fracturing tanks is closed.

2. The fluid from compartments 1 and 2 is pumped to compartments 3 and
4 by pump C1.
3. The mixers in compartments 2, 3, and 4 are turned off.
PCM Tally-JET Rev. A Page 11

Shutdown Process Stage II

Stage II begins when compartments 1 and 2 are empty.

1. The gate between compartments 1 and 4 is opened and the fluid

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pumped to compartment 5 by the C1 pump.
2. When the fluid is pumped to compartment 5 the mixer is turned off. The
remaining fluid is pumped from compartments 5 to 6 by the C2 pump.
3. When compartment 5 is empty, the C2 pump is turned off.

Shutdown Process Stage III

Stage III is used when the job requires more fluid than the PCM has on
board for fracturing water breakdown.

1. Compartment 1 is bypassed and the fracturing fluid is pumped from

the fracturing tanks into Compartment 5 by the C1 pump.
2. During Stage III, the control valves are operated in sequence from left to
right. However, the controls must first be in Stage II settings before being
moved to Stage III positions.
 Page 12 PCM Tally-JET Rev. A

LAS 1 LAS 2 LAS 3 LAS 4

SBF214 Flowmeter type Micro Motion Micro Motion Micro Motion Micro Motion
Waukesha Model 18 18 18 18
Rate Range 1-15 gpm 1-15 gpm 1-15 gpm 1-15 gpm
SBF215 Flowmeter type Micro Motion Micro Motion Micro Motion Micro Motion
Pre 2009 Waukesha Model 18 18 18 18
Rate Range 0.25-15 gpm 0.25-15 gpm 0.25-15 gpm 0.25-15 gpm
SBF215 Flowmeter type Yokogawa Yokogawa Micro Motion Micro Motion
2009 to Waukesha Model 6 18 6 18
Present
Rate Range 0.1-6 gpm 0.25-15 gpm 0.1-6 gpm 0.25-15 gpm
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Idle Operating
Range Min. Range Max.
Caterpillar C12-13
Oil Pressure(psi) 25-40 35 50-70
Engine

Coolant Temp.(°F) 190-200 210

Fuel Pressure (psi) 58-116 60 85-90 116
Voltage 24-28v 23.5 24-28v
Air Pressure(psi) 90-120 70 90-110
Charge pressure at idle, cold(psi) 275 – 325 250 275 – 325 325
Hydraulics

Charge pressure at idle, warm(psi) 225 – 300 250 275-350 350

Additive main pressure(psi) 1450-1550 1450-1550
Mixer main pressure(psi) 2950-3050 2950-3050
C-1, C-2 main pressure(psi) 400 – 4600 4700
Hydraulics must be in “Load” position.