Gas-Powered Mechanical Drive Fuels Industry-Wide Benefits

 

Today’s completions operations are increasingly challenging, requiring a power system to deliver high performance and dependable reliability without added complexity. Additionally, the desire to power sites with 100% gas continues to grow as such endeavors further the oil and gas industry’s objective to lower greenhouse gas (GHG) emissions and reduce total fuel costs.

As Caterpillar looks to the next 100 years, solutions that support oilfield companies’ sustainability goals while helping decrease OpEx and CapEx are a priority. With project bids increasingly specifying 100% natural gas use and diesel displacement requirements, the Caterpillar Gas Mechanical System (GMS), a natural gas-integrated power solution, is a timely option to help exploration and production (E&P) and oilfield service companies reduce GHG emissions while driving greater cost savings through on-site efficiencies.

This natural gas-powered mechanical drive system empowers oilfield companies to optimize completions in crucial ways.

Greater Power Density

The, purpose-built 100% gas-powered system joins the next generation 3600 hp Cat® G3520 engine and the new TH55G-E90 transmission into one integrated system and offers a noticeable increase in pressure pumping output. Its scalable design requires fewer trailers on-site, increases the power density per trailer, and decreases fuel consumption, compared to alternative frac operation methods. Whereas a traditional trailer powered by Tier 4 dual-fuel engines typically produces four barrels per minute, a GMS trailer is field-proven to more than double that output rate to produce up to 13 barrels per minute while pumping over 20 hours per day.

The GMS also minimizes the amount of horsepower needed on-site. As a result, fuel consumption and costs can be reduced which decreases overall operating costs.

Streamlined System and Site Operations

Next-generation frac systems often require significant learning curves, as crews adapt to substantial changes to the overall pad layout. Rooted in a simplistic and familiar design, the GMS eliminates the need for crews to manage medium voltage components and electrical wires. This supports greater site safety and streamlined maintenance protocols.

Compared to alternative next-generation configurations, the GMS delivers more power per trailer, which ultimately reduces the footprint on the pad by up to 50% compared to an eFleet or traditional Tier 4 dual-fuel engine fleet. This helps lower CapEx by reducing the number of trailers needed on-site.

The GMS’ streamlined layout creates additional benefits for crews operating in a 24/7 oilfield. It not only minimizes potential site hazards but also helps minimize crew member training time and cost, ultimately enhancing safety. Additionally, the GMS easily pairs with any SPM™ frac pump to deliver a comprehensive, optimized sitewide solution that embraces existing pressure pumping assets.

100% Natural Gas-Powered Operations

The GMS combats rising fuel costs and supports E&Ps’ sustainability objectives by relying on natural gas for fuel, delivering higher site efficiency and important flexibility as the system operates on field gas without compromising high-horsepower performance or uptime. The GMS’ highly efficient combustion technology further boosts cost savings while delivering the lowest GHG emissions compared to other next-generation technologies.

The GMS represents a new era in completions that emphasizes configuration simplicity and flexibility. Incredibly rugged and able to withstand harsh field, the system promotes ease of use and greater operational efficiency with lower capital requirements and a smaller footprint at a system level. Compared to next-generation options, the cost savings and GHG emissions reductions the GMS delivers make it especially compelling in today’s competitive oilfield environment.

 

Building a New Reality for Completions

The Simplest Fully Integrated System for 100% Gas-Powered Operations is in the works

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