Frac Service Companies - Pump Monitoring
Below is a case study that shows EXC’s ability to develop an effective predictive analytics and data analysis solution for optimizing pump operation.
Problem and Project Goal
Many oilfield service companies face serious challenges when operating frac pumps. Frac pumps are prone to failure, whether it be through operating error or conditions in the field. EXC is working to develop a predictive model for frac pumps that will minimize these errors, thus reducing down-time and increasing pump life-time.
EXC Solution
In order to build such a predictive model, it is necessary to first collect the data. This requires some installation of sensor equipment and data loggers. Most service or fracturing companies should already have sufficient data collection equipment already in place.
Once data is collected, it can be analyzed through statistical and artificial intelligence methods. These methods will automatically produce a predictive model that understands what pump and field conditions (e.g., flow rate, RPMs, surface pressure, etc.) will lead to pump failure. The model can provide suggestions to the operator on how to adjust pumping so that optimal performance is achieved (i.e., maximum flow with the least risk of failure).
The model is capable of providing quick suggestions if failure conditions manifest quickly. Pump operation can be adjusted within minutes or seconds ahead of probable failure.
ROI Benefit
In most cases, the client should see a pump’s average life expectancy to increase anywhere between 10 to 50 days of pump-time. When used across an entire fleet of frac pumps, EXC’s predictive solution can save a service company millions of dollars each year.