Frac Support Services

Frac support from start to finish

herever your frac project takes place, the

need for unwavering equipment reliability
remains the same. Thats why Cameron

adopts a holistic view of your frac operation, offering

a total portfolio of frac equipment and services.
We are committed to helping you apply the most
appropriate and effective frac treatment with
minimal downtime through our fleet of innovative
frac trees, manifolds, valves and flowback equipment.
Our services include:
Frac tree and manifold installation and testing
Annulus and casing testing
Valve greasing and maintenance
Hydraulic lubricator testing
Installation of backpressure valves, tree test plugs
and VR plugs
Flowback and well testing
We also believe in giving you options that can have
a positive impact on your CAPEX and OPEX costs.
Our fleet of quality rental equipment can offer an
economical, temporary solution for fast turnaround
situations and greatly helps to reduce well
installation costs.

Frac-Support Rental Equipment

Table of Contents

Frac trees

Frac Support from Start to Finish....................1

Frac manifolds

Frac Support Services.......................................2

Field Services Fleet...........................................4

Frac Valves........................................................5

Frac Trees..........................................................6

Frac Manifolds..................................................8

Frac gate valves

Hydraulic actuators
Torque and test trailers

Frac Isolation Systems

Goat/frac heads

Flowback and Well-Testing Rental Equipment

Plug catchers

Monoline Frac Fluid Delivery Systems.............9

FracServ Valve Integrity Protection Plan....10

Frac Facts.........................................................11

Gate valve choke and plug valve manifolds

Flowback and Well Testing............................12

Emergency shutdown valves (ESD)

Plug Valve Choke Manifolds.......................13

Well test separators

Plug Catchers...............................................13

Hydraulic choke control trailers

Sand Separators..........................................13

Mobile flare units

Hydraulic-Actuated Gate Valve

At Cameron, aftermarket service is paramount.

Choke Manifolds.........................................14

Sand separators

We are prepared to maintain your frac equipment

from the time of installation until it is disassembled

Well Test Separators...................................14

and removed from the project site. To support this

Emergency Shutdown Valves (ESD)...........14

commitment, Cameron has invested in the expansion

Hydraulic Choke Control Trailers................15

of frac-support remanufacturing facilities located in

Grande Prairie, Canada; New Iberia, LA; Minot, ND; and

Flare Systems...............................................15

Corpus Christi and Pearsall, TX.

Cameron is reinventing efficiency in frac equipment, constantly evolving tree

designs to fit operators needs.

Fr ac Suppo rt S ervic e s
Camerons frac equipment is backed by CAMSERV,
Camerons aftermarket services. Camerons service
technicians provide total aftermarket support in the
field or in the shop 24 hours a day, 365 days a year.
Personnel are highly skilled in providing equipment
installation and testing, making field repairs and
performing maintenance on your equipment.

Asset Management
Our asset management system gives you increased
system uptime through integrated support. It is a
comprehensive maintenance and asset management
system specifically designed for equipment and
performance monitoring throughout the life of your
assets. Camerons asset management system offers

Cameron is committed to drive efficiencies throughout

you the ability to manage assets and track spare parts,

your operation by assigning cross-trained personnel

contracts, clients, locations, service tickets and more.

to work on your project location, and by following a

set of defined procedures. The more people present
on your project location the higher the potential is
for HSE issues, unnecessary expenses and logistical
problems. We cross-train personnel to handle both
frac and flowback operations, which allows for a
reduction in required crew members and all costs, NPT
and emissions associated with multiple cranes, testing
units, grease units, and equipment support.

Radio frequency identification (RFID) tagging is at

the core of our asset management initiative. RFID
is used to track Camerons assets, increasing data
integrity and providing accurate asset utilization
information and equipment maintenance history.
This system eliminates the need to locate equipment
serial and parts numbers using hazardous chemicals,
and it reduces the risk of personnel being exposed to
potentially dangerous conditions.

Wellsite Services
Wellhead rental and sales
Frac tree rental and sales
Installation and testing
Annulus and casing testing
Valve greasing and maintenance
Repair, refurbishment and maintenance of all major
frac and wellhead equipment
Installation of BPVs, tree test plugs and VR plugs
Field inspection and general conditioning
Camerons robust frac support services include asset
tracking, journey management and competency
management.
Cameron uses an in-house system to monitor equipment and performance
throughout the life of your assets.

Journey Management

Service Competency Management

Cameron fulfills client journey management

Cameron utilizes a global network of highly skilled

requirements and strives toward our own goal of

service technicians to address your needs. Our

safety excellence. Journey management is required

personnel provide expert installation, testing, repair

by every Cameron employee for each service job

and maintenance support for your equipment.

conducted. Camerons employees complete a jobsite

Camerons field service personnel are trained to bring

review checklist before each job is executed. These

reviews include some of the following tasks: PPE
preparation, review of customer jobsite requirements,
mapping of jobsite location, review and preparation
for weather conditions, and properly outfitting the
work vehicle with tools, supplies and equipment.
GPS devices on our service vehicles allow us to
examine driving behaviors, track use of the vehicles
and estimate travel time to and from field locations,
optimizing operating efficiencies.

Use of RFID tagging results in valuable

asset information, including equipment
maintenance history.

professionalism, knowledge, skills, safe work practices,

and efficiencies to your project. Having invested in
a 15,000-sq-ft facility and a fully functional shop,
Cameron requires service technicians to attend a
comprehensive basic wellhead field-service training
program and targeted advanced training. This helps
to ensure technicians remain up-to-date on equipment
procedures. In addition, tracking and recording of
their experience and proficiency is ongoing.

A trainee extracts a backpressure valve with a

manual lubricator.

Camerons field service technicians undergo continuous training

throughout their career to ensure competency at the operators
location.

F i e ld S e rvic e s F l e e t
Camerons field services fleet maintains an average
of more than 1000 frac jobs per year in the US and
Canada. Our test, torque and grease units trucks
and trailers have a maximum test pressure of 5000,
7000, 10,000 or 15,000 psi.

Trucks for Test, Torque and Grease Utility

Cameron has a large fleet of 348-Peterbilt trucks with
sleeper cabs and 25-ft flatbeds. Each truck carries the
same equipment package within a smaller length of
Trucks are equipped to perform skid-mounted pressure tests for wellheads,
valves, BOPs and casing.

vehicle. In addition, the trucks are:

Equipped to deliver, lift and place up to 10,000 lb
Equipped to perform skid-mounted pressure tests
up to 10,000 lb
Equipped to perform skid-mounted pressure tests
up to 15,000 psi for wellheads, valves, BOPs and
casing
Equipped to hydraulically torque all flange sizes
Skid-mounted for valve grease operations up to
15,000 psi
Equipped with mechanical casing cutters in all sizes
through 13-3/8 in

Trailers are fitted to perform integrated field testing, power torque and
high-pressure greasing from a single platform.

Equipped with a self-contained rotary-screw air

compressor

Trailers for Test, Torque and Grease Utility

Camerons trailers are fitted to perform integrated
field testing, power torque and high-pressure
greasing from a single platform. Each trailer is
equipped to carry and pump methanol, glycol and
water. Operational and safety upgrades include:
Pump capabilities of 30 gal/min and 15,000-psi
working pressure
Increased fluid capacity (700 gal)
Fluid containment/catch pans
Camerons service fleet includes both trucks and trailers for test, torque and
grease applications.

Runaway shutdown safeties and pusher fans

Modular deck components

F r ac Va lv es
For more than a century, Cameron has been developing valves

Frac service is severe. Gate valves

are exposed to nearly continuous
service, flowing and controlling
abrasive fluids for long periods
of time.

specifically for the oil and gas industry, while earning a reputation for
quality and reliability.
Frac service is just about as harsh as it gets. With the introduction of zip
fracing, gate valves assembled into frac trees and manifolds are exposed
to nearly continuous service, flowing and controlling high-pressure,
high-volume, abrasive frac fluid for days, and even weeks, on end.
Given the erosive, corrosive and sometimes sour nature of typical frac
and flowback fluids, Camerons FLS-Frac, FLS-R-Frac, and FLS-DA2-Frac
gate valves are designed with standard features:
Trimmed for maximum corrosion and erosion protection
CRA inlay in seat pockets and ring grooves for added protection

FLS-R-Frac Gate Valve

Manual valve for highpressure, large-bore
applications

Allows reduced breakopen and running

torque

Features flow direction

versatility and increased
service life

Zero-chamfer flowbores are utilized in order to mitigate turbulence

that is known to exaggerate erosion
Two grease fitting ports are utilized for flushing and greasing the
valve body cavity
As a result of these unique features designed into Camerons frac
valves, and of the care given to them when they return from
the field for cleaning, disassembly, inspection, reassembly and testing
for the next project, they have grown a reputation for enhanced
reliability.

Erosion Study
Given the inherent severity of frac service and the high cost of failure,

FLS-Frac Gate Valve

Full-bore, throughconduit valve for severe
applications

Bi-directional design for

flow direction versatility
and increased service
life

Positive metal-to-metal
sealing

Cameron has anticipated the necessity for all possible failure modes to
be identified and eliminated in the design, manufacture, installation
and maintenance cycles of the equipment, and has undertaken preemptive activities to attain a deep understanding of the way in which
critical components perform in this harsh environment. We then use
that knowledge to provide the quality and reliability that is demanded.
Two of these pre-emptive activities were an erosion study of critical
components to locate and quantify high-pressure slurry damage and
a fatigue analysis to evaluate the effects of overpressuring, erosion
and inadequate flange bolting.
The first study was conducted to investigate relative erosion rates of a
5-1/8 gate valve and a 7-1/16 gate valve when exposed to identical
fluid flow conditions and properties, simulating worst-case frac stage

FLS-DA2-Frac Gate Valve

Combination of
Camerons FLS gate
valve with double
acting hydraulic
actuator

Offers reliable control

throughout entire valve
stroke

Remains in position
should hydraulic power
failure occur

components at 7500 psi.

F r ac Trees
Just as selecting the most appropriate frac treatment is

In a conventional stacked-valve design, advantages can

critical to your operation, selecting the best frac tree is

be seen in the inherent flexibility of the configuration.

paramount. Cameron offers access to technology and

By incorporating the master and swab valves and wing

new innovations that have the potential to be game

outlets into a solid body, the number of potential

changers. Leveraging our reputation for industry

leak-path connections, as well as the tree height and

leadership and technically sound products, we actively

weight, are reduced. The height and weight available

resolve the unique challenges of shale oil and gas

with compact designs offer safety advantages, such as

development and offer frac tree design options that

ease of handling during installation and elimination of

conform to your wellsite needs.

the need to work at heights.

Camerons Frac Trees

Another innovation, the composite block frac tree,

Camerons solutions have evolved with industry needs,

houses the master and swab valves, as well as the

creating four generations of frac trees, as shown

below. We have evolved our frac tree designs to
include composite frac tree systems as an alternative
to conventional systems.

horizontal wing outlets, into a single block body,

creating a significantly shorter assembly. The reduced
tree height reduces the bending stress transferred
from the goat head to the tree and wellhead
connections below.

5-1/8 15M

5-1/8 15M
220

190

182

5-1/8 15M
2-1/16 15M

5-1/8 15M

2-1/16 15M

5-1/8 15M

5-1/8 15M

5-1/8 15M

5-1/8 15M

5-1/8 15M

5-1/8 15M

Conventional Frac Tree

6

Composite Frac Tree

Compact Frac-Tree Design

Taking the compact concept further, Cameron has
introduced an innovative horizontal design, the F-T90TM,
which offers an ultra-compact footprint and reduced
height, and also enhances the integrity of overall frac
operations. This tree is built to reduce bending stress
at the tree connection and can be operated with
pneumatic, hydraulic or electric actuation.
The F-T90 horizontal tree represents more than 50%
reduction in size and about 25% in weight from our
first conventional frac tree. It is short, stable, and easily
anchored an ideal configuration for frac-tree service.
The 90-degree goat head is located at the end of the
horizontal section, resulting in the distance across
which the bending loads act being less than half of
that of a conventional stacked-valve frac tree.

Frac Tree Technological Evolution and Innovation

5-1/8 15M
182
5-1/8 15M
5-1/8 15M

2-1/16 15M

Camerons F-T90 tree leverages proven FLS-R gate valve design,

incorporating metal-to-metal sealing.

2-1/16 15M
5-1/8 15M

101
4-1/16 15M

5-1/8 15M
5-1/8 15M

5-1/8 15M

Composite Frac Tree

5-1/8 15M

F-T90 Horizontal Frac Tree

7

F r ac MANI F O L Ds
From the first treatment to the last, Cameron strives to
enable operators to improve well economics through
almost continuous utilization of the frac crew and
equipment. The various generations of Camerons
frac manifolds represent our commitment to constant
improvement. Modular frac manifolds are designed,
constructed and installed to accommodate as many
wells as required, in essentially any configuration. The
primary variables are frac-pumping service capacity,
nominal size of the frac lines, nominal bore size of the
frac tree, and wellbore characteristics.
Camerons manifolds can be equipped with a safety
ladder and platform to provide safe access to the
valves. Also, hydraulic actuation of the valves enables
remote operation, reducing the risk of injury.

Design Features and Benefits

Erosion Study
A study was conducted to evaluate the selection
of specific critical components of a known frac
delivery system on the basis of previous experience
and engineering judgment. Input parameters for
the study included such elements as equipment
geometry, materials of construction, flow rate and
fluid characteristics. A computational fluid dynamics
(CFD) model was constructed and used to simulate
the path of the sand particles and thereby the erosion
characteristics of the manifold and valve equipment.
These erosion studies offered an in-depth
understanding of the erosive effects of common frac
slurry on critical elements of manifolds and gate
valves.
Cameron also commissioned an analysis of the

Enhances safety of operations

fatigue life of frac manifold components using finite

Increases number of fracs performed per day

element modeling. The analysis examined all of the

Provides ease of operation

essential components of frac manifold assemblies

spacer spool, inlet tee, outlet cross, model FLS-R gate

Decreases number of rigup/rigdown cycles

valve and flange bolting. Results of the assessments

Decreases pumping downtime

revealed interesting and pertinent insight into frac

Reduces multiple frac lines

manifold design and maintenance.

The completion of the erosion and fatigue life studies,
in addition to feedback from years of experience,
have provided Cameron with a uniquely complete and
quantitative understanding of the anticipated fatigue
life of the frac manifold data that now are used in
the design of frac and gate valve equipment and in
developing the maintenance procedures that help
extend the life of equipment and provide reliable
field performance.

A frac manifold is an arrangement of flow fittings and valves installed

downstream of the frac pump output header and upstream of each frac
tree served by it.

Mo n olin e F r ac F luid D e liv e ry S yst e m (F F D S )

An example of Camerons constant improvement in

In developing the Monoline, Cameron used a variety

manifold designs is the second generation Frac Fluid

of design methods, including finite element analysis

Delivery System (FFDS), a solid monoline solution that

(FEA) and CFD to perform erosion studies on the

adheres to API standards and uses controlled bolted

system, in order to determine critical stresses and

connections that promote a higher level of system

erosion rates. Field trials that included a frac and

integrity and safety. Camerons latest innovation the

inspection program were undertaken to observe

Monoline presents a safer, faster, cleaner solution

and analyze performance in actual frac conditions to

than the industrys traditional frac iron method in

optimize life cycle.

which the link from the outlet of the frac manifold to

Monoline FFDS Design Features and Benefits

TM

the inlet of the frac tree is made awkward due to the

inherent misalignment between the manifold and the

Cost effective compared to traditional frac iron

tree in the vertical and horizontal planes.

Assembled quickly, reducing OPEX and NPT

The Monoline FFDS concept is fairly simple. A series of

Significantly de-clutters the work environment

5 high-pressure pipe segments are joined together

Uses industry standard flanges; no sledge hammers

with 90-degree elbows and swivel flanges. This

are involved

configuration allows for the full three degrees of

freedom movement needed to accommodate vertical
and horizontal misalignment between the frac tree
and the frac manifold.

Our latest innovation, the Monoline FFDS, presents a safer, faster, cleaner
solution than the frac iron method.

Field service technicians assemble the Monoline FFDS.

F r acSe rv Valve I nt eg r ity P r ot e cti on P l a n

A common maintenance practice for other suppliers

The result of Camerons stringent procedures is

of gate valves for hydraulic frac service is to perform a

reliability that minimizes downtime and extra expense

simple flush and test between frac jobs. This minimal

from your bottom line. Our valve success rate is

service practice provides no disassembly, no removal of

99.95%. Estimates available to us indicate that the

trapped sand/debris and very little in terms of quality

failure rate of non-Cameron frac valves ranges from a

control only a hydrostatic pressure test.

minimum of 10% to more than 30%.

Given the severity of the hydraulic fracturing

In the absence of FracServ, the potential exists

environment, and the impact to equipment,

of having to cease frac operations through a frac

Camerons design and quality engineers have compiled

manifold in order to service or replace a component,

recommended procedures for maintenance of our

which can be expensive. As an example, the time lost

frac equipment. These FracServ

to have a new valve brought to the well site, set a

TM

procedures establish

a sequence of activities and inspections designed

plug and replace the faulty valve is about the time it

to ensure that any degradation of frac equipment

takes to complete a frac stage. In essence, then, the

is identified and corrected before the equipment is

cost to replace a frac valve is about the same as the

reassigned to another frac project. Adherence to these

substantial cost of a frac stage.

service procedures yields Camerons frac valves in

as new condition for each frac project.

Equipment is offloaded and checked for NORM.

The customer and well name are documented
and part number and serial number are verified.

Dedicated cells are set up to follow defined

QA for frac valves. The technician begins
disassembly.

Trained inspectors qualify or disqualify

components per FracServ procedures.

The valve is reassembled with qualified parts.

The valve is tested.

Painted valves are tagged with a test tag

verifying repair is complete.

10

Fr a c Fa cts

Left unchecked,

frequently fluctuating
pressure coupled
with corrosive and
erosive service can
damage the structural
integrity of a
valves body.

Without intervention,

the extreme nature of
frac service can cause
pitting and other frac
valve seal surface
damage over time.

Sand, acid and many other


erosive and corrosive
elements of a frac job reduce
the life of a valves gate and
seat, if left untreated.

L acking proper attention,

the high-pressure variations
and chemical make-up of
fluids used during a frac job
can reduce the lifespan of
elastomers and other soft
goods in a frac valve.

S
 and and other
particulate debris left
unmonitored can affect
the performance of
grease fittings over time.

If ignored, the dynamic

environment typical of a
frac job can significantly
fatigue damage bolting.

11

F LOWBACK AN D W E L L T E S T IN G
8

Horizontal and vertical 2-, 3- and 4-phase 500-,

720-, 740-, 1440- and 2000-psi well-test separators
Hydraulic and pneumatic Emergency Shutdown
Valves (ESD)
Indirect line heaters

3
4

Flare stacks

4
2

Frac tanks with gas busters

Hydraulic choke and control valves

7

Cameron customizes flowback and well-testing

equipment and services to meet your individual needs
in every geographical area in which your company
participates. Cameron tailors equipment and services
to your target basin, offering a selection of basin
packages that reflect unique temperature and pressure
needs and the nature of liquid content per operators
basin requirements. Our flowback and well-testing
equipment portfolio includes equipment operability
and flexibility to meet a vast array of operating
requirements and conditions. The portfolio is comprised
of only Camerons technology, which means premium
equipment is used on your projects. Cameron follows
a set of standard equipment maintenance procedures,
and our equipment undergoes constant inspection to
offer reliable performance.
Camerons CAMSERV field service personnel are
among the most experienced in the industry as a result
of continuous training. Our service competency is a
requirement that extends beyond basic training to
include continuous certification throughout technicians
careers. Our flowback and well-testing equipment
includes:
10,000 and 15,000-psi upstream equipment
Single- and double-barrel plug catchers
V
 ertical and spherical 5800-, 10,000- and 15,000-psi
sand separators
Hydraulic actuated and manual gate choke manifolds

12

Trained and experienced flowback and well-test

technicians
Technician office and sleeping trailers
Before flowback of the high-pressure frac water can
begin, its necessary for the coiled tubing operator to
drill out or mill out the composite zone plugs, which
will allow the well fluids to flow back to the surface.
High-pressure frac water flowing from the frac stack
or production tree is pressure and volume controlled
by the choke manifold according to predetermined
customer requirements and is diverted to water storage
tanks for treatment or disposal. Once water, oil and
natural gas are present, well testing can begin.
During the well-testing phase, the wellstream continues
to be pressure and volume controlled by the choke
manifold according to customer requirements, and is
directed into the test separator where the oil, water
and natural gas are separated. The liquids are accurately
measured and discharged to an existing gas sales
pipeline through a metering station or flared if a gas
pipeline isnt available. During well testing, pressures,
temperatures, specific gravities, liquid volumes and
flow rates are measured and documented at regular
intervals. This information is available to the customer
in real-time transfer with Camerons electronic data
acquisition equipment (Scanner and microEFMTM) and
Fekete well testing and rates transient analysis software.
The Fekete analysis report enables a comprehensive
understanding of reservoirs, completion efficiency and
optimization potential.

1 Plug Valve Choke Manifolds

1.
Manual quarter-turn plug valve choke manifolds are
used to control downstream pressure and volume
control during flowback and well testing.
U
 p to 15,000-psi working pressure standard-service
plug valves
1
 0,000-psi working pressure NACE (sour service)
plug valves
D
 esigned to provide pressure isolation and control
redundancy
Manual bypass configured in assembly
Offers operator-friendly quarter-turn manual actuation
Easy to repair and maintain

2.
2 Plug Catchers
Plug catchers support well cleanup by filtering isolation
plug remnants and fragments of casing, cement and loose
rock in the area of the perforations. Our design features:
S ingle barrel with bypass or dual barrel (allows for
continuous filtration during blow-down activities)
E
 liminates potential equipment damage or blockage
by removing large solid debris immediately after the
frac stack
1
 0,000- to 15,000-psi working pressure
S weet or sour service
P
 lug valve- or gate valve-based design
A
 vailable with hydraulically controlled dump

3 Sand Separators
3.
Sand separators are designed to remove sand and other
solids from flowback process fluid. Our designs feature:
Centrifugal force to spin solids out of the wellstream
Single or dual systems
Vertical or spherical designs
Can withstand full wellhead pressures
Automatic dumping

13

4 Hydraulic-Actuated Gate-Valve
4.
Choke Manifolds
These unique valves are designed for remote control
of downstream pressure and volume control during
flowback and well testing. A choke control trailer and
hydraulic choke control trailer are used in conjunction
with this equipment.
Up to 15,000-psi working pressure
CAMERON gate valves and chokes
2
 -9/16 or 3-1/16 dual-choke manifold
with bypass
S kid-mounted leveling jacks provided as standard

5 Well Test Separators

5.
High and/or low working-pressure vessels are used to
separate oil, water, gas and sometimes solids (sand) into
individual streams for more accurate measurement and
discharge control.
Rated for 500- to 2000-psi working pressure
Available in skid-mounted or trailer-integrated designs
NACE compliant equipment available
2-, 3- or 4-phase separator test units
Horizontally or vertically skid mounted
Currently available in several sizes

6 Emergency Shutdown Valves (ESD)

6.
ESD valves are used to isolate pressure and flow from a
particular source during an emergency situation.
Integrated into the design of the well-testing
equipment
Can be moved to any location upstream of testing units

14

7 Hydraulic Choke Control Trailers

7.
These trailers are portable office trailers rigged up
to control valve and choke position/operation, data
acquisition, and monitoring of the entire jobsite.
Four-station hydraulic power unit
Air pumps
ESD safety system can be tied to controls
Can provide remote data capturing and transmissions
Provides control and monitoring of hydraulic actuated
valves and chokes
Provides temperature and pressure monitoring
Integrated with the electronic flow meter (EFM) on the
test separator
Skid-mounted hydraulic high-pressure units (HPUs) with
lifting frames for spill containment and fast-acting
remote actuation

8 Flare Systems
8.
Flare systems are used to burn or incinerate natural gas
and natural gas vapors.
D
 imensions: 3, 4 or 6 diameter stacks with multiple
heights
Use is based upon customers export strategy
Equipped with an auto-ignition system
Can be easily relocated between sites

15

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more than 35 locations. Each facility offers Camerons

expertise and commitment to provide innovative solutions,
quality and reliable equipment, and competent service.

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16

N U N AV U T

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17

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