Evolution Well Services: Improves operational efficiency with ifm moneo enabling predictive maintenance
With a focus on sustainability, operational efficiency, safety, and innovation, Evolution Well Services has earned long-term partnerships and record-breaking results in the pressure pumping industry. They needed a partner that could deliver a solution to support their goal of increasing access to more pump data. The results have improved efficiency and safety onsite.
Benefits
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Improved Operational efficiency |
Increased worker safety |
Seamless interoperability |
| Continuous, real-time monitoring of pumps provides enough data to schedule maintenance and develop predictive models. The transition from reactive to predictive maintenance increased machine uptime to improve operational efficiency. | The remote monitoring capabilities of ifm solutions ensure electric fracturing pump data is accessible in real-time from safer locations. Increase safety by enabling workers to diagnose and troubleshoot maintenance issues from afar. | Due to ifm products supporting multiple protocol options, the solution transferred data seamlessly into the existing process controls and data collection systems. This ensures all data is centralized and integrated into existing workflows. |
Results
“Achieving an initial accuracy rate of 85%, we are confident that with further refinements and continued collaboration between the Data Technology and Operations teams, we can exceed 95% accuracy in predicting consumable and component failures” says Nick Fornicola, Director of Data Technology.
This accuracy rate was achieved immediately after system implementation, without any refinement to the vibration objects or parameters. This led to a more efficient maintenance schedule, ultimately returning time to the broader operation.
Project Goal
Evolution Well Services wanted a vibration monitoring solution that would reduce pump trailer maintenance time and increase consumable life. The company wanted to increase data sources to further implement data science, machine learning, and artificial intelligence techniques to move beyond prescriptive maintenance to truly predictive maintenance.
The Challenge
In the pressure pumping industry, pump trailer maintenance accounts for a sizable portion of repair and maintenance costs. Even marginal increases in consumable life results in large operational impacts. With a culture that emphasizes digital transformation and innovation, Evolution Well Services realized they needed more data than just historical pressure and temperature to build predictive models that would accurately and preemptively identify machine failures.
The ifm Solution
While they determined vibration data was an important value to collect, finding the best vibration solution for an application requires evaluating options with a few key considerations in mind. Evolution Well Services already had robust process control and data collection infrastructure in place, so any potential solution had to integrate into the existing systems. After evaluating multiple providers and solutions, Evolution decided to move forward with ifm for a variety of important reasons.
Quick proof-of-concept
From the beginning, the hardware and software components of the ifm pump monitoring solution simplified implementation of a proof-of-concept project. The benefits of continuous real-time monitoring quickly proved valuable, and the technologies scaled easily to facilitate a larger installation.
Simplified data collection
Accommodating a wide variety of communication protocols, ifm solutions prioritize flexibility and interoperability. This allowed a seamless integration with the existing infrastructure and accelerated their ability to leverage internal expertise to make more data-driven decisions. The ifm moneo Cloud software platform offered a simplified remote monitoring solution that also streamlined control and configuration of the entire system. This eliminated the need for personnel to be onsite during system setup or troubleshooting, reducing the overall administrative burden of managing multiple devices.
Robust vibration sensors
ifm vibration sensors increased the quality and quantity of vibration data collected, and the robust sensor design easily withstood the extreme conditions of industrial applications. The affordability of ifm products paired with their industry-leading expertise and customer support significantly reduced the total cost of the project while also providing high-quality systems and components.
Aerial views of the hydraulic fracturing pumps onsite.
Conclusion
As an industry leader, Evolution Well Services always looks for and evaluates innovative technologies to improve access to machine data. Increasing the quality and quantity of their data continually improves their machine learning models that optimize operations. By partnering with ifm for hardware and software solutions, Evolution Well Services measured significant improvements in the accuracy of their predictive models. The improvements helped optimize maintenance schedules of critical equipment to reduce costs and increase uptime. With a commitment to innovation and continuous optimization, Evolution Well Services is setting new standards in the industry.
