Downtime Hours Saved
Split stream operations are when a frac spread runs clean fluid through a set number of pumps and dirty fluid (fluid with proppant and other dense materials) through the rest of the pumps.
Clean pumps typically run harder and are more likely to cavitate because the fluid is less dense.
There are several inherent challenges related to monitoring split stream.
Typically, pressure is set on the blender and is not adjusted regardless of rig-up design and pump needs.
Increasing boost pressure by 20 PSI, we see a 10% Reduction in fluid end damage and see a 15 PSI overall increase in minimum peak pressure and 15 PSI decrease in dP.
Frac fleets were noticing an increased amount of cavitation on fleets with a Blender and Ground Pig configuration. The ground Pig is a manifold that helps distribute pressurized fluid from the blender to the pumps. We decided to have the optimization team do an in-depth analysis of the ground Pig and found that utilizing the ports that are directly across from an inlet port should be used to best feed the pumps on location.
There are several inherent challenges related to monitoring pressure and flow.
Typically, this problem is solved by increasing boost pressure at the blender and a small prayer that it stops pumps from cavitating.
By utilizing the information that the optimization team has provided us we are able to recommend specific ports that should be used on the ground pig and the number and size of hoses that should be used. This optimizes the way the pumps are being fed and allows them to get the best pressure down the line.
High-Pressure Iron is one of the leading causes of downtime in Hydraulic Fracturing Operations. A frac spread is riddled with dangerous blind resonance conditions since each pump and spread configuration has its own unique resonance frequency. Resonance is a system's natural frequency and causes catastrophic failures when excited.
There are several inherent challenges related to monitoring high-pressure iron.
Real-time monitoring of frac iron coupled with pump rate integration enables the operator to…
The KCF team noticed several pumps showing signs of a lubrication issue on the Fluid Ends. Upon digging into why so many pumps were showing the same issue we discovered that the oil tote that was being used to fill all the pumps was contaminated.
There are several inherent challenges related to monitoring Fluid Ends.
Without KCF monitoring this problem goes unnoticed until there are failures or until someone notices the tote is contaminated.
By monitoring the pumps this oil goes in we can see if or when there is a lubrication issue within these pumps.
I am excited to drive continuous improvement in partnership with you, find new efficiencies, take on complex challenges, and decrease downtime across the upstream oil & gas space while making your team's work life safer and productive. Please contact me to discuss your unique asset challenges!