CanadaEnergy and utilities2021 – ongoingCalfrac Well Services
Machine-learning predictive maintenance across hydraulic fracturing fleets
Calfrac Well Services reported a 6x return from KCF Technologies' predictive maintenance across its 10 US fleets
Problem
Fracturing pumps fail in the field, and unplanned maintenance and non-productive time are costly. Calfrac wanted to avoid catastrophic component failures.
Approach
Calfrac started with KCF Technologies' Machine Health Platform on one fleet in 2021. It then extended the platform to all 10 of its US fleets. KCF reported that the largest gains came from pump optimization and from combining RPM, pressure and gear data in its diagnostics software. New field staff also took KCF training during onboarding.
Results
Takeaway
Calfrac scaled from one fleet to the full US operation. The savings figure is a vendor estimate for one year.
Categories
- Size
- Large enterprise
- Industry
- Energy and utilities
- Business function
- Production and quality
- Innovation type
- Process innovation
- AI technology
- Predictive analytics and ML
- Adoption
- Vendor solution
- Evidence
- Vendor case study
Sources
Source summaries
KCF describes Calfrac's move from one fleet in 2021 to all 10 US fleets on its Machine Health Platform. It gives a 6x return and an estimated $10.5M in savings for 2022. It also lists the main sources of the gains and notes a planned 2023 rollout of a real-time alerting application.
Full details are in the original sources.