Fracturing unit set solutions
Technical Specifications – Standard Solution Configurations
The following tables show our three standard fracturing unit set solutions. Each is available in diesel, electric, or hybrid. For a custom configuration, contact our solutions engineering team.
Solution Overview Table
| Solution Name | Best For | Total HHP | Pump Count | Blender | Manifold | Typical Footprint |
|---|---|---|---|---|---|---|
| FUS‑1000 Solution | Exploration, well testing, acidizing, small jobs | 5,000 – 16,000 | 2 | 3,000 lbs/min | 105 MPa (optional 140) | 15m × 12m |
| FUS‑2000 Solution | Most onshore fracturing, tight gas, conventional oil | 10,000 – 32,000 | 4 | 6,000 lbs/min | 105 / 140 MPa | 25m × 15m |
| FUS‑4000 Solution | Deep shale, HPHT, high sand volume, multi‑well pads | 15,000 – 48,000 | 6 | 2 × 6,000 lbs/min (redundant) | 140 / 175 MPa | 40m × 25m |
FUS‑2000 Solution – Detailed Parameters (Diesel Example)
| Component | Specification |
|---|---|
| Pumps | 4 × QPA2500 quintuplex, diesel drive, 2,500 HP continuous each |
| Blender | 1 × 6,000 lbs/min diesel blender, closed‑loop proppant control (±2% accuracy) |
| Manifold skid | 4″ header, 105 MPa (15,312 PSI) with gate valves and swivel joints |
| Control system | SOFElink Advanced with predictive maintenance and remote access |
| Suction manifold | 6″ low‑pressure header with 4 × 4″ connections |
| Iron package | 150m of 3″ hammer union lines (straight, swivel, and "T” sections) |
| Spare parts kit | Valves, seats, packing, plungers for 500 pump‑hours |
| Digital services | Remote monitoring, job reporting, maintenance alerts |
| Included training | 1 week on‑site for 5 operators + 2 maintenance techs |
| Lead time | 4–5 months (diesel) / 5–6 months (electric) |
FUS‑4000 Electric Solution – Detailed Parameters (Deep Shale)
| Component | Specification |
|---|---|
| Pumps | 6 × SCF8000 electric skids, 8,000 HP continuous each, 175 MPa |
| Blenders | 2 × electric blenders, 6,000 lbs/min each, redundant operation |
| Manifold skid | 5″ dual header, 175 MPa (25,400 PSI), SGH175 series |
| Control system | SOFElink Advanced with full predictive maintenance (valve impact, packing wear, bearing temp) |
| Mobile substation | 6‑35 kV input, 50 MW, with VFD distribution and transformer |
| Suction manifold | 8″ low‑pressure header with 6 × 4″ connections |
| Iron package | 300m of 4″ hammer union lines, 175 MPa rated |
| Spare parts kit | Full set for 1,000 pump‑hours (including valve kits for all 6 pumps) |
| Digital services | Cloud remote monitoring, automated job reporting, maintenance scheduling |
| Included training | 2 weeks on‑site for up to 8 students (operators + maintenance) |
| Lead time | 7–8 months |
Product Types – Fracturing Unit Set Solutions We Offer
We organize our solutions by application complexity and power source.
1. Exploration & Well Testing Solution (FUS‑1000)
Best for: Remote exploration wells, coiled tubing fracturing, acidizing, small‑volume proppant jobs (<200,000 lbs total sand).
What’s included: 2 pumps, 1 small blender, compact manifold, basic SOFElink, 1‑week training. Available in diesel (5,000 HHP) or electric (16,000 HHP). Transportable on two flatbed trucks or in two 40‑ft containers.
Key advantage: Low entry cost, fast mobilization, still API certified.
2. Standard Onshore Fracturing Solution (FUS‑2000)
Best for: Most conventional oil & gas, tight gas, shallow to medium shale, CBM, water wells.
What’s included: 4 pumps, 1 full‑size blender (6,000 lbs/min), 4″ manifold, SOFElink Advanced, 1‑week training, comprehensive iron package. Diesel version for remote locations; electric version for grid‑connected pads.
Key advantage: The industry workhorse – balances capacity, cost, and mobility.
3. Deep Shale & HPHT Solution (FUS‑4000)
Best for: Deep shale (3,500–5,000m), HPHT wells (140+ MPa), large‑scale multi‑well pads, 24/7 continuous duty.
What’s included: 6 electric pumps (SCF8000), 2 redundant blenders, 5″ 175 MPa manifold, mobile substation, SOFElink with predictive maintenance, 2‑week training, premium iron package. Footprint optimized for tight pads.
Key advantage: Highest power density (48,000 HP), zero emissions, lowest cost per stage at high utilization.
4. Hybrid Transition Solution (Custom)
Best for: Operators moving from diesel to electric, or pads with partial grid access.
Example configuration: 2 electric SCF8000 + 2 diesel QPA2500 on the same manifold skid, with dual control system and mobile substation for the electric units. Same physical footprint as a standard set. You can later replace the diesel pumps with more electric units.
Key advantage: No stranded assets – your diesel pumps stay in use while you gain electric experience.
5. Arctic‑Rated Solution (For -45°C)
Best for: Siberia, Northern Canada, Alaska, any location where standard equipment fails in extreme cold.
Modifications: Heated fluid ends (electric heat tracing), low‑temperature hydraulic fluids (-55°C pour point), engine block heaters and battery warmers, insulated control van, heated air intake for pneumatics. Proven in Russia’s Orenburg field.
Key advantage: Reliable cold starts and continuous operation at -45°C.
6. Desert‑Rated Solution (For 50°C+)
Best for: Middle East, North Africa, arid basins.
Modifications: Oversized cooling systems (radiators and heat exchangers), sand‑sealed electrical enclosures, dust filtration on air intakes, corrosion‑resistant coatings, reinforced chassis for rough terrain.
Applications – Where Our Solutions Deliver Proven Results
Our fracturing unit set solutions are field‑proven across the globe:
| Region / Basin | Solution Used | Key Outcome |
|---|---|---|
| Sichuan Basin (deep shale, China) | FUS‑4000 electric | 48,000 HP spread, 140 MPa continuous, 2,000+ hour fluid end life, zero emissions |
| Ordos Basin (tight gas, China) | FUS‑2000 diesel | 20,000 HP spread, 105 MPa, 6,000+ stages pumped |
| Permian Basin‑style (USA) | XJ350 & QPA2500 sets | Hundreds of workover and fracturing jobs, American flag derricks |
| Siberia (Russia) | FUS‑2000 arctic diesel | -45°C operation, three rigs delivered to Orenburg Drilling Company |
| Middle East (UAE, KSA) | FUS‑2000 desert diesel | 50°C+ ambient, sand‑sealed components, years of reliable service |
| Southeast Asia (Indonesia, Malaysia) | FUS‑1000 small sets | Remote jungle locations, helicopter‑transportable modules |
Why Choose SJ Petro for Your Fracturing Unit Set Solution?
Because a solution is only valuable if it works in your specific wells, with your specific crew, on your specific timeline.
| Your Challenge | SJ Petro’s Solution |
|---|---|
| "I don’t know exactly how much horsepower I need for my well.” | We analyze your well data and recommend the optimal set size – no overselling. |
| "I have limited pad space. A full spread won’t fit.” | Our electric SCF8000 units pack 8,000 HP into a 40‑ft container footprint – 67% smaller than equivalent diesel. |
| "My crew has never operated electric fracturing equipment.” | We include 1–2 weeks of on‑site training with every solution. Our digital controls are intuitive. |
| "I operate in a remote area. Parts and support are hard to get.” | 24‑hour emergency parts shipping. Remote diagnostics via video. Field technicians available. |
| "I need a solution that can grow as my business grows.” | Unit sets are modular. Buy one set today, add identical sets later – they work together seamlessly. |
| "I need API certification for a tender.” | Full API 7K/6A documentation provided. Third‑party witness testing available. |
More reasons to trust SJ Petro fracturing unit set solutions:
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40+ years of fracturing equipment integration – not a new entrant
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Three national manufacturing champion awards – recognized quality
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API 7K, 6A, Q1 certified – full certification
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In‑house manufacturing – pumps, blenders, manifolds, controls – all SJ Petro
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Global track record – solutions in USA, Russia, Middle East, Asia, Africa
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Flexible commercial terms – new, refurbished, lease, or milestone payments
Frequently Asked Questions (FAQ) – Fracturing Unit Set Solutions
Q1: What is the difference between a "fracturing unit set” and a "fracturing spread”?
A: A fracturing unit set is a pre‑engineered, standardized building block – typically 2, 4, or 6 pumps with integrated blender and manifold, designed to be combined. A fracturing spread is the total assembly of unit sets on a pad (e.g., two FUS‑2000 sets to make a 20,000 HP spread). Our solutions approach means we help you select the right number and type of sets for your well program.
Q2: Do you offer solutions for operators who want to lease rather than buy?
A: Yes. We offer operating leases, direct financing, and milestone payment plans. You can lease a complete unit set solution for a specific project (e.g., 6 months) with an option to purchase at the end. Contact our solutions team for a lease proposal.
Q3: Can you help me design the layout of my pad to fit a unit set solution?
A: Absolutely. Our solutions engineering team provides a complete pad layout drawing showing the position of each component, connection points, crane access, and safety clearances. We have done this for pads as small as 20m × 15m.
Q4: What is included in the "training” part of the solution?
A: Standard training includes:
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Classroom sessions – equipment overview, safety, control system operation
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Hands‑on field training – rig‑up, pressure testing, running a stage, shutdown procedures
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Maintenance training – packing replacement, valve/seat change, plunger inspection, basic troubleshooting
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Documentation – digital manuals, video tutorials, checklists
We tailor the training duration (1–2 weeks) to the complexity of the solution and the experience level of your crew.
Q5: How does the predictive maintenance feature work? Do I need to be connected to the internet?
A: Predictive maintenance uses sensors on each pump (valve impact, packing leakage, bearing temperature, cylinder loading). The system learns normal operating patterns and alerts you when a parameter exceeds a threshold. You can run in offline mode (alerts shown on the data van screen) or connect to the cloud for remote monitoring and automatic maintenance scheduling. Internet connection is not required for the system to protect your equipment – but remote monitoring is an option.
Q6: What is the typical lead time for a custom solution?
A: Standard solutions (FUS‑1000/2000/4000 with standard options): lead time as shown in the specifications table. Custom solutions (e.g., hybrid, arctic, desert, custom pump count): add 2–4 months for engineering and documentation. Expedite options may be available – contact us for current production slots.
Q7: Can I get a refurbished unit set solution to reduce upfront cost?
A: Yes. We occasionally have trade‑in sets from customers upgrading to electric. Refurbished solutions are disassembled, inspected, fitted with new wear parts (valves, seats, packing, plungers), repainted, load tested, and come with a 6‑month warranty. Price is typically 40–60% of new. Contact us for current inventory.
Q8: Do you provide on‑site commissioning for international locations?
A: Yes. We have commissioned fracturing unit set solutions in the United States, Russia, Kazakhstan, UAE, Saudi Arabia, Indonesia, Malaysia, Nigeria, and across South America. Our technicians travel with the equipment, oversee installation, and stay until the first stage is successfully pumped. Travel expenses are quoted separately.
Q9: What is the warranty on a complete fracturing unit set solution?
A: 12 months after commissioning or 18 months after shipment – whichever occurs first. The warranty covers all SJ Petro components (pumps, blender, manifold, iron, control system). Wear parts (valves, seats, packing, plungers) are not covered but are included in the spare parts kit. Extended warranty (up to 5 years) is available for an additional fee.
