The further development of unconventional shale oil and gas production has growing demands for operation pressure and rate. The increasing depth of wells creates higher pressure and rate requirements. In a large-scale frac operation when more continuous working hours are required, higher requirement for the frac equipment, especially for the frac pumps is needed. In view of this situation, Jereh engineers, based on pump performance - parameters and configuration, have developed the 5000BHP super-power quintuplex plunger pump that can operate continuously under heavy load with less maintenance frequency to better serve the large-scale frac operation and improve the operation efficiency and economy.

Figure 1: Fracturing units operating in Sichuan, China shot by Jereh Group

 With 4,500HP maximum output power, 11” stroke and 270,000lbf maximum rod load, the JR5,000QPN plunger pump delivers high rate and efficiency. Suppose a conventional frac job is carried out at 100bbl/min (16m3/min) rate and 10,000psi (70MPa) working pressure in which case at least twenty 2,500HP frac units will be needed. However, only eleven 5,000HP pumps can satisfy the job, reducing the unit quantity by over 40%. Also, at the same stroke rate, a 5,000HP pump can enable twice the rate of a 2,500HP pump and allow lower rod load to extend the parts life.

Figure 2: Table 1.1 2,500Hp frac unit and 5,000HP frac unit comparison.

The Jereh 5,000QPN electric frac unit is equipped with a high reduction ratio planetary gearbox suitable for electric drive which realizes infinitely variable speeds for accurate pressure and rate control. Compared with the diesel driven frac unit with an engine and transmission, the electric frac unit is more cost effective and allows the overall unit to be more compact and lighter to guarantee stable operation. The weight of an electric frac skid is equivalent to a conventional 2,500HP frac truck but the output power is doubled which offers higher power density.

Figure 3: Electric frac pumper, shot by Jereh Group

At present, JR5,000QPN electric frac units have been widely used in many job site in China with average continuous working time of over 20 hours per day. Some have worked for over 4,000 hours stably with no abnormality, which proves that the super-power plunger pump can be a better solution for high pressure and high rate frac jobs to increase efficiency and create more value for customers.