North American pressure pumping operators using a new dynamic gas blending (DGB) system reduced diesel consumption by approximately 100 million gallons in 2023 alone, according to Caterpillar Oil and Gas. This outcome, quantified via telemetry, signals that pressure pumping operators significantly lowered fuel costs by leveraging the DGB solution. The system, known as the Cat®Tier 4 DGB, was introduced in 2019 to optimize dual fuel blending and help operators reduce fuel consumption and costs. The company later began tracking performance data for the system. The 2023 data was obtained from connected assets in North America and spanned all operating conditions. The data showed an average diesel displacement rate of 60 percent for the fleet over the year, with a common peak displacement average of 85 percent. With the U.S. Energy Information Administration listing the average annual price of diesel during 2023 at $4.21/gallon, operators’ overall savings on diesel costs with Tier 4 DGB system totaled hundreds of millions of dollars for the year.
“As oil and gas companies continuously seek ways to reduce fuel consumption and costs while meeting energy demands, this data demonstrates that our Tier 4 DGB system plays an important part in achieving those goals,” said Derek Kamp, Caterpillar Oil and Gas vice president and general manager. “This success in the field underscores our commitment to innovation and empowering pressure pumping operators to improve operational efficiency.”
The Tier 4 DGB system offers advanced diagnostics that help mitigate costly disruptions and meets U.S. EPA Tier 4 Final standards. As the rate of diesel displacement can vary depending upon site conditions, those who are interested can calculate their fuel savings with the DGB Fuel Cost Estimator.
