AFGlobal has successfully completed its field evaluation of the DuraStim pump in the Permian Basin. AFGlobal’s new patented pressure pumping technology offers end users tremendous advantages over traditional fracing technology and those offered by other electric and turbine based systems. The trial, which began last month, followed five years of stringent design and engineering, and significant in-house testing to prove out suitability for actual pressure pumping operations.
Designed by AFGlobal’s pressure pumping technologies group, the DuraStim frac pump at 6,000 HP, offers the equivalent of three times the effective horsepower of a conventional frac unit, while operating at approximately 10% of the cyclic rate. The pump offers many advantages, including more than a 65% reduction in fleet footprint and manpower, while dramatically extending equipment life and reducing maintenance costs. This novel system, when coupled with an electric or turbine drive, is expected to also deliver a significant reduction in fuel consumption and emissions. Initially, AFGlobal will offer the system for sale with an electric direct drive, but expects to provide interested customers a turbine-direct drive system later in 2019, as well as a 3,000 HP diesel system later in 2019 or early 2020. The system will also offer a cloud-enabled control system to optimize the distribution of information and predictive maintenance to improve operational efficiencies.
“In keeping with our history of innovation and new technology development, we are excited to launch this unique pumping system, bringing the first true game-changing technology to the market in more than 3 decades,” commented Curtis Samford, president and CEO at AFGlobal. Samford continued, “The field trial was conducted in the Permian Basin in connection with ProPetro Holding Corp., who has a long-standing relationship with us dating back to our entry into pressure pumping as an OEM in 2012. We greatly appreciate their help in getting the DuraStim pump validated in actual field operations.”
“We believe that the possibility of adding the DuraStim pump technology to our current fleet could help us substantially improve efficiencies and reduce our equipment downtime, which will ultimately benefit our customers with more uptime and better fleet utilization. We are very excited AFGlobal successfully field trials DuraStim pump technology to be participating in the development of the DuraStim technology and look forward to the continued collaboration with AFGlobal,” commented Dale Redman, CEO of ProPetro.
The onshore and offshore application of the DuraStim technology can extend well beyond its pressure pumping application and is envisioned to be applied in other areas that can benefit from continuous flow pumps, including mud pumps, various midstream and downstream applications, and numerous other end uses.
The challenges of executing multi-well pad completions with triplex and quintuplex pumps have come to an end with a fundamental advance in pump technology designed specifically for continuous duty hydraulic fracturing.
AFGlobal’s revolutionary DuraStim® 6,000 HP hydraulic fracturing pump is a far-reaching change in pump design and performance that: — Dramatically lowers the cost of ownership — Greatly improves operational performance — Creates many new safety and environmental advantages
The DuraStim technology redefines the frac pump with a broad set of patents and innovations. The results are game changing from every perspective: — It is a fully automated, electric long stroke (48-in.) pump, featuring low frequency (~20 cycles per minute), and eliminates high cycle rates that quickly destroy the fluid ends of conventional plunger pumps — It provides more than twice the horsepower of a conventional pump unit in the same footprint — Its electric motor prime mover eliminates the burden of Tier 4 diesel emission standards, and greatly reduces noise pollution
A Revolution in Pump Technology
The long stroke, low frequency DuraStim pump is comprised of six individual pump units and fluid ends driven by a constant speed 6,600 VAC motor and four hydraulic rotary pumps. The design is enabled by computerized synchronization, control, and automation that closely orchestrates the pump’s operation and response.
The DuraStim pump is the industry’s first variable displacement frac pump. Its pump rate is determined hydraulically, in contrast with conventional fracturing pumps where engine speed and gear ratio determine rate.
Continuous Duty Solutions
The DuraStim pump is built for the extreme demands of long duration, high pressure hydraulic fracturing. Durability and reliability are keys to performance on the pad, and to a much lower cost of ownership.
Durability – Long stroke, low frequency hydraulic operation saves fluid ends from damaging high cycle rates. Fast ramp up to target rates and “soft” pump rate changes further improve the life of fluid ends. The resulting increase in durability is a step change in achieving longer service life and lower maintenance costs.
Reliability – Continuous duty pumping is reinforced at multiple levels. Field failures are reduced with Cloudenabled predictive maintenance, while built-in diagnostics simplify troubleshooting. The DuraStim system stays on line with six discrete pump units that can be individually disabled while the rest are kept running. Its individual fluid ends are replaced as needed, while quick-change valve cartridges expedite routine maintenance.
Power Solutions
The DuraStim pump’s prime mover is a constant-speed 6,600 VAC electric drive motor. A direct drive turbine motor is under development. Both are enabled and optimized by the pump’s unique hydraulic operation, and yield many benefits for multi-well pad operations.
Eliminate Tier 4 Concerns – The zero emission electric motor eliminates Tier 4 diesel emission requirements, along with the costs, complexity, and uncertainty.
More Horsepower, Same Footprint – With twice the horsepower of a conventional pump unit, the 6,000 HP DuraStim pump occupies the same 3-axle trailer footprint. As a result, the pump: — Reduces size and complexity of the frac spread — Decreases high-pressure iron use, resulting in lower costs, faster set up and breakout, and greater safety — Minimizes total pad size — Simplifies logistics and reduces general site congestion
Full flow rate – Corner horsepower constraints are eliminated by the 6,000 HP, long stroke pump. Instead of a significant drop in flow rate as high treating pressure is reached, The DuraStim pump achieves full flow rates across the pressure range of the fluid ends.
No VFD – The constant-speed prime mover eliminates the cost, size, and complexity of a variable frequency drive to control engine speed.
Environmental Solutions
The DuraStim pump enhances environmental performance in many ways.
Reduced pollution – The 6,600 VAC electric drive motor has zero emissions, and produces much less noise than a conventional diesel-powered spread.
Lower impact – Fewer pumps to do the job reduces pad size and lessens vehicle traffic.
Clean operation – The pump uses environmentally inert hydraulic oil.
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