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Saving $ 250,000 on fuel consumption Russian Federation

More than 20 hydraulic fracturing fleets were equipped with Galileosky tracking devices for the largest oilfield service companie in Russia. As a result, enormous savings were achieved – during month and a half, fuel costs decreased by 250,000 dollars. 

The fleet management provider Modern technologies, LLC implement a lot of high end solutions in various spheres and specializes in complicated projects, when their competitors decide not to take such a challenge. Company's experts are convinced that there is nothing impossible and the most important is to choose and to use correctly the suitable equipment. Thus, wide functions of the units were implemented in 280 hydraulic fracturing machines that work under severe conditions of the far North. Data from pumping equipment, mixers, and remote control stations was processed by Galileosky trackers. The project was based on the Wialon software.

About the project

During prolonged work on one well, its oil recovery decreases rapidly and drilling a new well is impractical. In such cases, hydraulic fracturing technology is used to extend the working life of the well. A fleet of machines with complex pumping, heating, chemical and computing equipment is sent to the oil field. A chemical mixture is pumped into the well under high pressure and breaks the rock from the inside, providing an easier oil flow. One hydraulic fracturing fleet consists of 20-25 vehicles, and some of them have 2000 hp engines with huge fuel consumption. Before the to integration, the hydraulic fracturing company put up with facts of draining tons of fuel, and measured the cubic volume of the mixture according to standard rate, receiving less in payment.

Alexey Beifus, Technical Director at Modern Technologies, LLC:

 - At peak power, pumping unit engines consume more than 500 liters per hour, and fuel consumption is faster than draining it through an opening in the fuel tank.

Challenges

  • Monitor fuel consumption in different operating modes
  • Receive and process pressure data and quantity of mixture pumped into the well
  • Minimize fuel consumption on heating and mixing equipment

Solution

Specialists opted for Galileosky 5.0 units. The hydraulic fracturing fleet operates in the extreme North, where mobile connection is very poor, so the tracking devices with two SIM cards and external aerials were needed. The amount of inputs also played crucial role, as for complex monitoring of one item of equipment you need to connect many onboard sensors.

Alexey Beifus, Technical Director at Modern Technologies, LLC:

- During the installation, we faced with the fact that we used all inputs on the unit, but unconnected sensors still remained. As a result, we solved the problem with the help of operational amplifiers and a voltage divider. In other words, we get two signals into one analog input.

Results

With the help of Galileosky units, integrator company implemented fuel consumption control of the pump unit at different speeds. A month and a half after equipping all the client's hydraulic fracturing fleets, fuel savings reached 250,000 dollars. Moreover, volume of mixed, heated and fed into the well mixture was considered more correctly as it is important for people who receive piecework wages.

Maxim Revyakin, Head of Regional Development at Galileosky:

- Sometimes we are surprised at how integrators use our trackers. They do not limit themselves only with transport monitoring but undertake monitoring projects of complex industrial equipment.

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