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FRACair Compressor Manual

Air Flow Adjustment Valves

FRACair BLOWER SELECTION AND INSTALLATION

Blower selection depends on: the pressure and cfm required; power available; water pressure heads; and whether continuous or short term air pulsing is required; the number of frac tanks you are aerating or mixing; and the treatment application selected. Air needs to be controlled to deliver the proper amount of air for mixing/aeration.  

The blower should be located as close as possible to the frac tank(s) i.e. no farther than 50 ft.  Attach a 2” hose or piping to the air injection point.  The hose or piping should be supported every 5 ft and is supplied by the customer.

Two-Stage Regenerative Blowers

The smallest 5.5 to 6.1 Hp two-stage regenerative three phase blowers can provide 85 cfm to 100+ cfm (depending on the manufacturer selected or available) at 140” of water and can provide enough air for one or two frac tanks that require approximately 40 cfm each.  They run cooler and quieter than rotary lobe blowers. 8 Hp 3 phase blowers can provide 130 cfm @ 140” or water.  Other larger blowers are also available. Discharge temperatures can be less than 100oF under certain operating conditions. A 10 Hp blower can deliver 125 to 175 cfm at 160” of water and 100” of water respectively.

Rotary Lobe Blowers

Rotary lobe blowers are belt driven by a motor. The smallest application uses a 42 URAI Roots Blower. These blowers require inlet and discharge silencers, an enclosure, and generally generate 110+ dBA at the blower and < 85 dBA 30 ft away.  Air should be supplied through a 2” outlet to match FRACair’s magnetic aeration system. They run hotter than two-stage regenerative blowers with discharge temperature exceeding 200oF in many cases.  This usually requires heat dissipation a specified distance from the blower.

Single phase 5 Hp blowers 60 Hz, 230V, 1740 rpm, 20.5 amps can provide 135 cfm @ 5.2 psi and generally produce enough air to mix or aerate three (3) 20,000 gal frac tanks.  Three phase blowers of different sizes are also available.

Tow Behind Compressors

Diesel powered tow behind compressors may produce 140 psi air at 185+ cfm.  Air can be supplied through a conventional 3/4” air line that is converted to a 2” air supply mount at the frac tank.  Pressure has to be reduced by a two stage pressure regulator with a bypass valve between the two regulators. Since the run time is dependent on available fuel, these compressors are usually used for intermittent short term pulsed air.

Plant Air

When plant air is used it needs to be determined if enough air is available to  supply FRACair systems without reducing plant air requirements. Tees can be cut into air lines with pressure reduced by a two stage pressure regulator with a bypass valve between the two regulators.  Air needs to be balanced between tanks if multiple frac tanks are aerated.

FRACair BLOWER INSTALLATION

The blower can be ordered with or without a starter and mounting platform.  If shipped without either, mount the blower on a platform with vibration suppressors between the blower base and platform.  Select a starter that works with the blower.  Have a licensed electrician make all connections.  

Instructions for blower electrical connections will be provided with the blower. Unpack the blower pallet and assemble the air inlet chamber and silencer and mount the blower and starter on the platform.  Verify the rotation of the blower is in the pressure delivery mode.

The air discharge piping should be mounted so that the pressure relief valve and bypass valve are pointed downward to avoid rainwater infiltration.  Support the discharge metal piping every 2 ft.  Tighten all pipe and air inlet mount parts. The pressure relief valve is generally set at 5 psi.

FRACair Blower Startup

Connect air supply hose or piping to the blower and air inlet mount. Before starting blower install the FRACair magnetic aeration system in the frac tank.

FRACair PREPARATION FOR INSTALLATION

Remove the red 2” EPDM Truck hose from the pallet and lay it outside and parallel to the frac tank with the air supply Trunk hose connection close to the top manhole bridge air supply connection.  Make sure that the magnets are placed facing up.  Use the brush provided to remove any metal objects and debris attached to the magnets. DO NOT DROP OR HIT MAGNETS AGAINST HARD SURFACES.

Tighten any loose magnet connections to the ½” stainless pipe clamps. Note that these connections are only tight enough to secure to pipes but may still rotate around pipes. Turn the crosses over and attach the disc diffusers to the ¾” bell connectors on the diffuser crosses. Be careful not to cross thread poly membrane diffusers to the cross fittings.  Start poly threads by reverse turning until the clockwise connection is smooth.  Finger tighten only.  Do not tighten with a wrench.

Before inserting into the tank, turn the crosses upside down and align diffuser connections on crosses so they will be perpendicular to the bottom of the tank. Check to see that all stainless cross connections are tight.  Clean any metal objects and debris from the contact face of the magnets with the brush provided.