Heavy duty fracturing unit set

Technical Specifications – Heavy Duty Fracturing Unit Set

The tables below provide key specifications for our two heavy duty unit set variants: electric (48,000 HP) and diesel (15,000 HP). Complete data sheets (horsepower vs. pressure curves, dimensional drawings, material certifications) are available upon request.

FUS‑4000H Heavy Duty Unit Set – Electric Variant (48,000 HP)

Parameter	Specification
Pump model	6 × SCF8000 electric skids
Total continuous horsepower	48,000 HHP (35,800 kW)
Max working pressure	175 MPa (25,400 PSI)
Test pressure	262.5 MPa (38,100 PSI)
Stroke length	10″ (254 mm)
Number of cylinders per pump	7
Fluid end material	Second‑generation high‑strength stainless steel
Fluid end service life (high‑sand shale)	2,000 – 2,500 hours
Blenders	2 × 6,000 lbs/min electric blenders (redundant)
Blender sand accuracy	±2% of setpoint
Manifold	SGH175 series, 5″ dual header, 175 MPa
Control system	SOFElink Advanced with predictive maintenance & remote access
Power source	6‑35 kV grid or mobile substation (50 MW)
Emissions	Zero on‑site
Noise level	22% lower than equivalent diesel spread
Footprint (rigged up)	40m × 25m (typical, depends on pad layout)
Lead time	7–8 months

FUS‑4000H Heavy Duty Unit Set – Diesel Variant (15,000 HP)

Parameter	Specification
Pump model	6 × QPA2500‑HD diesel skids
Total continuous horsepower	15,000 HHP (11,190 kW)
Max working pressure	140 MPa (20,300 PSI) – optional 175 MPa
Stroke length	8″ or 10″ (depending on pump configuration)
Number of cylinders per pump	5 (quintuplex)
Fluid end material	Forged alloy steel (standard) or stainless steel (optional)
Fluid end service life (high‑sand shale)	1,200 – 1,800 hours (with stainless steel option)
Blenders	2 × 6,000 lbs/min diesel blenders (redundant)
Manifold	SGH140 or SGH175 series, 5″ header
Control system	SOFElink Advanced with predictive maintenance
Engine	Dual Caterpillar or MTU per pump (customer choice)
Transmission	Allison oilfield series
Emissions	High (diesel)
Footprint	45m × 30m (larger due to diesel fuel tanks)
Lead time	5–6 months

SCF8000 Pump – Horsepower vs. Pressure (175 MPa Continuous)

Plunger Diameter (custom)	Max Flow @ 10,000 PSI	Max Flow @ 15,000 PSI	Max Flow @ 20,000 PSI	Max Pressure
Custom (per well design)	1.45 m³/min (383 GPM)	0.97 m³/min (256 GPM)	0.73 m³/min (192 GPM)	25,400 PSI

Applications – Where Heavy Duty Unit Sets Are Required

Standard fracturing equipment cannot survive in these environments. Our heavy duty unit set is designed specifically for:

• Ultra‑deep shale gas (3,500–5,000m) – Sichuan Basin, Permian deep benches, similar high‑pressure, high‑sand plays. Requires 140+ MPa treating pressure and continuous 24/7 pumping.

• HPHT conventional wells – Deep gas wells with reservoir pressures exceeding 15,000 PSI. Standard 105 MPa equipment lacks safety margin.

• High‑sand‑volume multi‑stage fracturing – Jobs with 5 million+ pounds of proppant per well. Fluid end life is the limiting factor – our 2,000+ hour design keeps you pumping.

• Arctic winter campaigns -45°C. Diesel equipment must be heated and winterized; electric units (with pre‑heat) also work.

• Continuous‑duty fracturing fleets – Some operators run 24/7 for months. Our pumps are rated for continuous operation, not intermittent duty.

Why Choose SJ Petro for Your Heavy Duty Fracturing Unit Set?

Because when you are pumping at 140 MPa at 4,500m depth, there is no margin for equipment that is "almost” heavy duty.

Your Heavy Duty Requirement	SJ Petro’s Answer
*"We need continuous 140+ MPa pressure. Standard 105 MPa equipment fails.”*	SCF8000 electric pumps rated 175 MPa continuous – 50% safety margin above 140 MPa.
"Our fluid ends only last 800 hours in high‑sand shale. Too much downtime.”	10″ stroke, 7‑cylinder, stainless steel fluid end – 2,000+ hours in field service.
"We have limited pad space. 12 diesel pumps won’t fit.”	6 electric SCF8000 units deliver 48,000 HP in the same footprint as 6 diesel pumps – 48,000 HP vs. 15,000 HP in the same area.
"We need zero emissions on our pad for regulatory compliance.”	Electric variant – zero on‑site emissions, 22% lower noise.
*"We operate in Siberia at -45°C. Standard pumps freeze.”*	Arctic‑rated heavy duty set – heated fluid ends, low‑temp hydraulics, insulated van. Proven in Russia.
*"Our tender requires API 7K/6A certification with full traceability.”*	Full API documentation – material test reports, hydrostatic certs, NDT reports, third‑party witness available.

More reasons to trust SJ Petro heavy duty solutions:

• 40+ years of fracturing equipment engineering – not a new entrant

• Three national manufacturing champion awards – recognized for innovation and quality

• API 7K, API 6A, API Q1 certified – full certification, not marketing claims

• In‑house manufacturing – pumps, fluid ends, blenders, manifolds, controls – all SJ Petro

• Global field support – spare parts in 24 hours, remote diagnostics, on‑site technicians

• Lease and financing options – milestone payments, operating leases, and direct financing available

Frequently Asked Questions (FAQ) – Heavy Duty Fracturing Unit Set

Q1: What is the definition of "heavy duty” for a fracturing unit set?

A: In our context, "heavy duty” means:

• Continuous power rating (not peak) of 8,000 HP per pump or 48,000 HP per set

• Pressure rating of 175 MPa (25,400 PSI) continuous – not intermittent

• Fluid end service life of 2,000+ hours in high‑sand shale service

• Redundant systems (dual blenders, dual‑header manifold) for zero single points of failure

• Continuous 24/7 operation without derating
  Standard fracturing equipment does not meet these criteria.

Q2: What is the advantage of 10‑inch stroke over 8‑inch stroke?

A: For the same flow rate, a 10‑inch stroke pump completes 20–25% fewer cycles per barrel than an 8‑inch stroke pump. Fluid end life is determined by fatigue cycles – fewer cycles means longer life. This is why our heavy duty fluid ends achieve 2,000+ hours, while standard pumps often fail at 800–1,200 hours.

Q3: Can I use the electric heavy duty set without a grid connection?

A: Yes. We supply a mobile substation as part of the unit set. The substation takes medium‑voltage input (6–35 kV) from a generator or transmission line and distributes power to the pumps and blenders. Many of our electric heavy duty sets operate in remote areas with diesel or gas turbine generators – still lower emissions and fuel cost than direct diesel pumps, but not zero emissions.

Q4: How long does it take to rig up a 6‑pump heavy duty set?

A: For an electric set (6 skids + 2 blenders + manifold + mobile substation + data van):

• First setup on a new pad: 5–7 days (includes substation connection and testing)

• Move between wells on the same pad (skidding): 8–12 hours

• Move to a different pad (disassemble, transport, reassemble): 3–4 days

For a diesel set (6 skids + 2 blenders + manifold + fuel tanks): similar times, but fuel tank setup adds 1–2 days.

Q5: What is the expected maintenance schedule for a heavy duty unit set?

A: Based on field data from Sichuan Basin:

Component	Inspection Frequency	Replacement Interval (high‑sand shale)
Valve & seat sets	Daily visual + weekly impact monitoring	300–500 hours
Packing	Daily visual	200–400 hours
Plungers	Weekly gauge	600–1,000 hours
Complete fluid end overhaul	NDT at 1,000 hours	2,000–2,500 hours
Power end bearings	Oil analysis every 500 hours	15,000 hours

SOFElink predictive maintenance provides real‑time alerts, so you do not need to guess.

Q6: Can I get a heavy duty unit set with a different number of pumps (e.g., 4 pumps instead of 6)?

A: Yes. We can build heavy duty sets with 2, 4, or 6 pumps. However, the 6‑pump set offers the best power density (48,000 HP in the smallest footprint). For lower horsepower requirements, consider our standard FUS‑2000 set (4 pumps, 10,000 HP diesel or 32,000 HP electric) – also heavy duty capable.

Q7: What documentation do you provide for international heavy duty tenders?

A: Full tender package including:

• API 7K data sheets for pumps

• API 6A data sheets for manifold

• Material test reports (EN 10204 3.1) with full traceability

• Hydrostatic test certificates (1.5× MWP)

• NDT reports (MT, PT, UT) with inspector certifications

• Dimensional inspection reports

• As‑built drawings

• Compliance matrix

• Third‑party witness test reports (if ordered)

We have supplied heavy duty documentation for NOC tenders in the Middle East, Russia, and Southeast Asia.

Q8: Do you offer a warranty on the 2,000+ hour fluid end life claim?

A: The fluid end is warranted against manufacturing defects for 12 months (or 18 months from shipment). The 2,000+ hour life is a field‑proven performance estimate based on specific operating conditions (sand concentration ≤10 ppg, pressure ≤140 MPa, continuous duty). We do not warranty a fixed number of hours because actual life depends on your specific sand, pressure, and fluid chemistry. We provide a life prediction worksheet with each set, and our SOFElink system tracks wear in real time.

Q9: Can I see a heavy duty unit set in operation before purchasing?

A: Yes. We welcome customer visits to our active field sites in Sichuan Basin, where heavy duty electric sets are currently operating at 140 MPa, 24/7, on commercial shale gas wells. You can see the equipment performing, talk to operating crews, and review maintenance logs. Contact our solutions team to schedule a site visit.

Q10: What is the total cost of ownership difference between electric and diesel heavy duty sets?

A: For a 48,000 HP spread running 5,000+ pumping hours per year:

Cost Factor	Electric (48,000 HP)	Diesel (15,000 HP)
Upfront cost (approx.)	$5.5M – $7.5M	$3.5M – $5.0M
Fuel cost per hour (full load)	~$200 – $300 (grid) or ~$400 (generator)	~$2,500 – $3,500
Maintenance cost per hour	~$50 – $80	~$150 – $250
Fluid end rebuild cost (per 2,000 hrs)	~$30,000 (per pump)	~$20,000 (per pump)
5‑year TCO (10,000 hrs/year)	Lower by 25–35%	Higher

Electric has higher upfront cost but much lower operating cost. For continuous heavy duty operation, electric pays back in 12–24 months.

Q11: Do you offer refurbished heavy duty unit sets?

A: Occasionally. As operators upgrade from first‑generation heavy duty sets to newer configurations, some become available. Refurbished sets include new fluid ends, power end bearings, fresh paint, full load testing, and a 6‑month warranty. Price is typically 50–60% of new. Contact us for current inventory.