What an innovative production equipment fabrication shop looks like

EnerCorp offers production fabrication for flowback equipment and beyond

Estimated reading time: 6 minutes

Some operators choose off-the-shelf equipment like sand filters and oilfield separators; however, many know that a customized piece of production equipment — that is crafted according to the requirements of your well — yields better performance. 

Customized equipment puts innovation at the forefront, by thinking ahead to potential obstacles and developing solutions to mitigate challenges before they happen. An off-the-shelf piece of oil and gas equipment, on the other hand, doesn’t take into account the intricacies of the well flow, pressure, sand particle size, or other characteristics.   

Finding a production equipment fabricator that has the experience and expertise you need isn’t an easy task. There are several options in our industry, so how do you know which production equipment fabricator to go with? Here are 3 things to consider if you want to work with a production equipment fabricator that puts innovation front and center.

An innovative production equipment fabricator operates their own equipment in the field

What is the relationship between innovation and operating their own equipment in the field? Knowledge.

When a production fabricator has an operations arm that operates the equipment they make in the field, they have the opportunity to actually experience how their equipment performs under different conditions in a variety of geographies. This offers a number of learning opportunities that the fab shop can use to innovate their design and development. A production fabricator that doesn’t operate their own equipment doesn’t have this kind of insight — which is necessary for thinking ahead.

At EnerCorp, we design, engineer, build, sell, rent, and operate our own technology in the field, giving us a full overview of how our equipment performs. With our end-to-end capability, we man the wellsite and monitor our equipment, taking detailed notes on how the equipment behaves under certain conditions and what we can do to optimize its performance. 

Continuous feedback from the field — from our teams, operators, and customers — results in high reliability for anything we build. Having experienced first hand any potential issues that may arise, we design and manufacture equipment using our insights to mitigate challenges, resulting in less downtime in the field. 

An innovative production equipment fabricator has a wide range of expertise 

Look at the portfolio of equipment the production fabricator has experience in. How wide is their range?

Innovative fab shops have the ability to go above and beyond one type of equipment, specializing in a variety of oil and gas equipment that operators require in the field, from cyclones to sand filters to production equipment beyond flowback. 

At EnerCorp, our production equipment fabrication shop designs, engineers and builds the entire industry-leading Sahara family of dual sand cyclones:

• Sahara Advanced Sand Cyclone: No two wells are alike, which is why our engineers innovated this cyclonic sand separator. We customize each Sahara based on the characteristics of the well, such as the range of flow rates for oil, water, and gas; varying wellhead pressures; various solids and sand particle sizes; and expected sand volumes.
• High-Capacity Sahara Sand Cyclone: On some high-producing wells with longer laterals of over 15,000 feet, one Sahara isn’t enough. However, instead of using multiple sand cyclones and increasing equipment footprint, labor costs, HSE exposure, and maintenance touchpoints, we developed the High-Capacity Sahara Sand Cyclone. Based on the original Sahara, it has double the power and double the capacity.
• Sahara Facility Cyclone: Sand management is a priority for many operators beyond flowback. That’s why our fab shop developed the Sahara Facility Cyclone specifically for the steady state phase. It offers sand management services for production facilities that are connected to 20, 30, 40, or more wells at a time, because sand production rarely ends completely after flowback. With it, operators can ensure virtually no sand particles make it through to the production facility.
• eFlowback: Arguably the most innovative of the Sahara family of products is eFlowback, an industry-leading sand separation technology that combines automation, measurement systems, and cloud-based software. The ecosystem includes a Sahara Advanced Sand Cyclone, automated choke manifold, automated blowdown unit, sand quantification unit, tank level monitoring system, automated control unit, and cloud-based software. With it, operators can control their job sites remotely. 

An innovative production equipment fabricator offers a range of customizations

The level of customization production equipment fabricators offer varies greatly. Some are only able to customize certain small aspects of their equipment while others — like EnerCorp — are able to offer completely bespoke production equipment based on the customer’s requirements.

Being innovative doesn’t mean following a predefined path, it means having the ability to fully understand what the customer needs and the expertise to make it come to life — while considering how to optimize performance at every step.

For example, at EnerCorp, customization is at the heart of our fabrication process. We have a research and development team that consists of engineers who are focused on continuous improvement. After we design equipment, we run simulations on the designs to ensure they meet performance standards. Our production equipment engineers use a multivariate approach on all new oilfield equipment designs using computational fluid dynamics (CFD), developing highly effective sand management solutions for the flowback, early production, and steady state phases. 

We not only design and manufacture new equipment, but also repair and alter existing equipment. We use a unique temper bead weld procedure to repair older pressure vessels and certify them for use, saving customers time, money, and resources, with our innovative approach.