Case Study: Reducing the Costs of Fuel and Engine Rebuilds

Fuel efficiency stands at the core of operational cost-effectiveness and environmental responsibility. Recognizing this, the study aimed to quantify the fuel consumption of a 2500 BHP frac pump engine during idle periods and under the strain of external loads amidst fluctuating ambient temperatures.

Solution

The methodology involved the strategic installation of fuel flow meters on a test engine, which was then rigorously analyzed on a dynamometer over an extended period. This allowed the capture of accurate fuel consumption data under varied conditions, providing a comprehensive understanding of the engine’s performance.

The analysis revealed critical insights into the fuel consumption patterns of frac pump engines:

  • Baseline Idle Consumption: The engine’s fuel consumption at idle was determined to be an average of 10.3 gallons per hour.

  • Under Load: With the engagement of external cooling systems, fuel consumption escalated to about 15 gallons per hour.

  • Additional Considerations: The study also highlighted that aging engines and supplementary systems could push fuel consumption to exceed 20 gallons per hour.

Significant savings can be achieved through decreased fuel consumption and engine maintenance by minimizing engine idling. The MGB PowerCELL technology platform was proven in a separate study to reduce idle times by up to 85% in a typical frac operation without requiring extra capital investment. This leads to considerable cost savings while also reducing the environmental footprint.

These findings highlight a significant opportunity for operational improvement. By focusing on reducing idle times and managing operational loads more efficiently, there is a potential to achieve substantial cost savings and minimize environmental impact.