Eliminating unnecessary idling in East Texas

An E&P operator’s initial goal on an East Texas pad was to eliminate unnecessary engine idling of frac equipment on site.  A secondary goal soon emerged as well.  The pad was strewn with excess rental equipment (generators, compressors, boost pumps, etc.), taking up a lot of room. What if most of this rental equipment could be eliminated also?

This early field test of MGB’s PowerCELL® system eliminated excess idling and frac site equipment and reduced fuel use and emissions generated by frac equipment.  The trial’s successful outcome led to the adoption of PowerCELL technology as a permanent part of this frac fleet.

Solution

  1. Deployment of a single PowerCell® to the field provided a centralized power source and control system for the frac equipment.
  2. Daisy Chain rig up to 19 frac pumps, allowed efficient power distribution and control across multiple units.
  3. By supplying air to all major systems of the frac equipment, the PoweCELL unit eliminated the need for multiple compressors on location.
  4. Installation of hydraulic Bulkhead connections on the frac pump provided secure and reliable hydraulic connections for optimal performance.
  5. Replacement of open-center solenoid valves with closed-center solenoid valves (24V), improving control over hydraulic flow and reducing energy waste.
  6. Standardize tractor quick disconnects to match PowerCell® quick disconnects, facilitated seamless and efficient connection between the PowerCell® and other equipment.
  7. Hooking up hydraulics to Blender and Hydration Unit to start engines, enabled easy engine startups and smooth operation.

By deploying a PowerCELL unit, the operator was able to eliminate 10 hours per day of engine idle time, reducing fuel costs, minimizing equipment wear and tear, optimizing pad space utilization, and eliminating the need for rental compressors and generators. Ultimately, the PowerCELL solution improved operational efficiency and reduced maintenance costs.

The PowerCell® advanced power system eliminate 10 hours per day of engine idle time, reducing fuel costs, minimizing equipment wear and tear, optimizing pad space utilization, and eliminating the need for rental compressors and generators.

By deploying a PowerCELL unit, the operator was able to eliminate 10 hours per day of engine idle time, reducing fuel costs, minimizing equipment wear and tear, optimizing pad space utilization, and eliminating the need for rental compressors and generators.

Reduced Idle Time Results in Substantial Savings

The customer’s decision to address unnecessary engine idling yielded significant financial benefits.

The PowerCELL solution resulted in substantial savings for the customer. Significant financial benefits were achieved by eliminating 10 hours per day of engine idling time. Over the course of a month with 26 operating days, the customer experienced the following savings:

  • Reduced diesel fuel usage by approximately 3,500 gallons per day, resulting in a total savings of around 91,000 gallons of diesel fuel. The cost of $2.96 per gallon translated to savings of $269,360 per month.

  • The solution also led to a reduction of approximately 160 hours per day in frac engine runtime. This amounted to a total reduction of around 4,200 engine hours per month. With an estimated cost of $50 per hour, the customer saved $210,000 in engine maintenance and usage costs.

  • By eliminating the need for rental air compressors and generators, the customer avoided expenses associated with 104 rental unit days. An approximate rental cost of $225 per day resulted in savings of $23,400 per month.

In total, the savings achieved on the pad amounted to an impressive $502,760. These savings were primarily attributed to reduced fuel consumption, decreased engine runtime, and the elimination of rental equipment expenses.

The customer’s decision to address unnecessary engine idling and optimize their operations yielded significant financial benefits, achieving savings of $502,760 for one month.