Frac Pump Maintenance

There are two sides to every story. On one hand are the frac pumps that customers find on websites, in brochures, and at trade shows. These new pumps are pristine, freshly-painted monuments to advances in engineering technology.

However, an often-ignored reality is seen by district managers and maintenance mechanics, who see examples of the damage and abuse that frac pumps take on a daily basis.

These damaged pumps and fluid ends that inspired this article. To ensure the safest possible working conditions for operators in the field, pumps must continue to perform better. Improved performance and reliability are also key factors influencing the bottom line.

Engineering teams across the industry have been hard at work designing pumps that can withstand the conditions imposed by unconventional plays. Now, the industry’s maintenance programs must rise to meet the challenge.

Structuring a Maintenance Program

Having the appropriate tools, resources, and training is the foundation of any good maintenance program. As a start, maintenance managers will need to ensure that operators and mechanics have the correct tools to perform maintenance. This may seem relatively straightforward, until the number of different pump models and brands on the market is considered. Many oilfield service companies will mix and match pumps and fluid ends, further complicating the issue.

In addition to tools, field personnel should also be provided with the right resources and information to properly maintain their pumps. Many of the most successful maintenance programs create booklets that detail important guidelines for pump maintenance. As an example, an effective guide might include:

• A service manual
• A parts list
• Torque and clearance specifications
• A guide to replacing expendable parts
• A guide to removing and reattaching the fluid end
• Any technical bulletins from the manufacturer
• A pump maintenance schedule

As a reminder, this guide should include information covering each power end and fluid end that the operator may encounter on the job because specifications for each brand and model may differ.

If questions remain on how to develop such a booklet, the pump manufacturer will likely be able to help. Finally, it is also a good idea to take field conditions into account. Laminating the pages in any instructional manual will ensure that it remains useful in the dirt and grime of the oil patch.