American Oil and Gas Reporter - August 2019 - 103

SpecialReport: Hydraulic Fracturing Technology

Trends Push Frac Pump Technology
By Zachery Kokel
HOUSTON-While hydraulic fracturing
has been around for more than 100 years,
the most remarkable transformation has
occurred in the fracturing field over the
past 15 years. The evolution of job site
frac operations and the speed of engineering
innovations to match is helping oil and
gas producers accelerate their production
capacities while simultaneously solving
the greatest challenges in the field. Interestingly, today's challenges are shaping
trends that could alter the frac site dramatically within another five years.
When modern-day hydraulic fracturing
began its upswing in the early 2000s, the
frac site operated much different than today. Field operations and equipment were
based on intermittent use. It was common
for fleet operators to run frac equipment
fewer than 10 hours a day. Heavy-duty,
durable equipment was not needed for
such light use.
Today, however, frac equipment is
running on a near continuous-duty basis,
with pumping operations averaging 1620 hours a day. This change to roundthe-clock completion operations on multiwell pads with longer laterals, more
stages, higher pressure requirements, and
greater proppant and fluid consumption
per well is placing increasingly rigorous
demands on equipment. Horsepowerhours per well have increased 200% in
recent years. These factors, combined
with operating in increasingly complex
environments, are pushing conventional
frac fleets to their limits with longer
pumping hours and less frequent service
intervals to increase daily stages.
The increased operational intensity
requires much more rugged and durable
equipment engineered to stand up to the
long hours and harsh environments that
can quickly wear down conventional materials and components. Consequently,
the two most crucial factors for fleet operators' success in the field are efficiency
and the number of pumping hours. These
elements make or break the bottom line
for fleet owners, and also have a direct
impact on the bottom line for their oil
and gas company customers.
Distinct Challenge
Fleet operators compete on efficiency,
and efficiency is tied directly to equipment

maintenance. This poses a distinct challenge: operators need to pump more
hours than ever before, yet stopping
equipment to perform maintenance reduces the number of pumping hours.
The need for maintenance also creates
another challenge: a dwindling workforce
that is overwhelmed with maintaining a
multitude of different types of equipment.
It is incredibly challenging for frac site
personnel today to know proper maintenance procedures for all equipment in
use, and in some cases, to properly perform routine maintenance. Improper
maintenance costs money in the field. It
can be the difference between a frac
pump-a crucial piece of equipment in
any hydraulic fracturing operation-being
down for only a few hours or being in a
shop for several weeks.
Pumps must be designed to deliver
improved performance and reliability
under the 24/7 operating conditions and
extended exposure to high-rate, abrasive,
proppant-laden fluids. Operators are putting
time on pumps much faster in today's
fracturing climate. Additionally, pumps

are being sent to workshops less and less,
even though they have accumulated more
run time. The solution to this challenge is
engineered equipment that has longerlasting components that are more forgiving
and easier to maintain in the field.
The latest generation of high-performance quintuplex frac pump technology
is an example of how today's equipment
is solving the increasing efficiency and
maintenance challenges. The newest
pump design addresses all causes for
typical power end and fluid ends to
expire from service. Engineered as a
drop-in replacement for existing frac
pumps, the new design offers a high rod
load rating (238,000 pounds), resulting
in performance at maximum rod load at
16-20 hour duty cycles with less unscheduled downtime.
An integrated skid reduces vibration
across the frame to decrease stress on
the welds, increasing longevity. A unibody
nose plate and solid steel rigid frame
design drastically reduce cracking by
employing fewer welds, of which 80
percent may be robotically welded for

The latest generation of high-performance quintuplex frac pumps is engineered for increased operational efficiency and durability while reducing maintenance challenges
and unscheduled downtime in today's demanding near-continuous duty applications.

AUGUST 2019 103

American Oil and Gas Reporter - August 2019

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