Before 2010, hydraulic fracturing, commonly known as fracking, was largely unfamiliar to most people in the U.S. and around the world. However, it soon became a widely recognized term, frequently appearing in news coverage as the practice reshaped the energy landscape. When combined with horizontal drilling, fracking had a significant economic impact across numerous industries, including hospitality, equipment manufacturing, and support services.
The Role of Industrial Hoses in Fracking
One of the most notable effects of the fracking boom was its influence on the industrial hose market. Traditionally, industrial hoses were used primarily in sectors such as steel production, agriculture, and the pulp and paper industry. However, the unique requirements of fracking operations necessitated specialized hoses capable of performing under demanding conditions. Industrial hoses became indispensable for a range of applications within the fracking process, from water delivery to drilling operations and high-pressure fluid transfer.
Challenges with Traditional Hoses
Initially, operators attempted to use conventional hoses in fracking operations, but these often proved inadequate due to the high pressures and volumes involved. To address these challenges, hose manufacturers developed specialized products tailored to fracking needs. These innovations included hoses that could withstand higher pressures, handle larger volumes, and operate reliably in rugged environments.
Strong, durable hoses were essential for the various stages of the drilling and fracking processes, which included:
- Water transfer for mixing drilling mud and fracking fluid (comprising water, chemicals, and proppants).
- Pumping drilling mud down the well.
- Cement pumping during well completion.
- High-pressure injection of fracking fluids.
Example: Mandals Superman High Volume Transfer (HVT) Hose
Water Transfer Hoses
Water is a critical component in drilling and fracking, with millions of gallons needed for each well. Because many drilling sites are located in remote areas, transporting water over long distances can be challenging. Long runs of large-diameter hoses, often extending up to 10 miles, are used to transfer water from a source to the site, typically over rough and uneven terrain.
Standard hoses often failed under these conditions due to the large volumes of water and extended use. Manufacturers needed to ensure that the hoses were leak-proof to prevent environmental damage. Initially, domestic supply of such specialized hoses was limited, prompting a scramble to import products from Europe and Asia, where these hoses were more common.
Material Innovations
A major breakthrough came with the shift from polyvinyl chloride (PVC) hoses to PVC/nitrile-blend hoses, which could handle up to 200 psi and provided better durability at a reasonable cost. These hoses, typically 8 inches in diameter and fitted with grooved couplings, became a practical choice for water transfer operations. Later, polyurethane (PU) hoses emerged as an even more durable alternative, capable of handling higher pressures and offering greater abrasion resistance. Although initially more expensive, their price gradually decreased, making them more accessible.
Storage and Safety Considerations
At the fracking site, water is stored in tanks or holding ponds for use in various stages of the operation. Safety is paramount when selecting hoses for these tasks due to the high pressures involved and the range of chemicals used. Hoses must be chosen based on the specific chemicals and pressures required.
Drilling Site Hoses
During drilling, a combination of water, drilling mud, and chemicals is circulated. This mixture places significant demands on hoses, requiring products rated for at least 400 psi to avoid failure. For added safety, hoses used in this process should have crimped ends instead of band clamps and should be inspected regularly for wear and tear.
Drilling Hoses
Once drilling begins, high-pressure hoses are used to pump drilling fluids into the mud pumps and to transport them to the wellhead. These hoses must meet stringent standards, typically those set by the American Petroleum Institute (API), to ensure they can handle the rigors of the operation. Failure of these hoses can halt drilling operations, making proper selection and maintenance crucial.
Cementing Hoses
After drilling is complete and the pipe is installed, cementing hoses are used to pump cement down the well to create the casing. These hoses need to handle high pressures and heavy volumes, and selecting hoses that meet API standards is essential for safe and effective operations.
Frac Hoses
The fracking phase requires specialized hoses that connect tanks and transport the water-chemical-proppant mixture to a blender before pressurizing it for downhole delivery. Frac hoses are built to withstand severe conditions and have protective outer layers to prevent wear. They must be rated for pressures of at least 400 psi to ensure safety and durability. Proper hose routing is important to prevent damage from tight bends, as abrasion is the leading cause of hose failure.
Industry Evolution
The rise of onshore drilling redefined traditional hose applications. Hose manufacturers were challenged to create products that could meet the demands of fracking while remaining cost-effective. Through collaboration with industry contractors, manufacturers developed new hoses that became standard offerings. Even as the market experienced slowdowns, the knowledge and advancements gained during this period laid the foundation for improved hose solutions as operations ramp up again.
The renewed growth in fracking promises to bring further innovation and robust hose solutions to the field, supporting safe and efficient energy extraction.
Don’t forget to ask about Cornell Pumps. Cornell Pumps are widely used in the oil and gas industry, hydraulic fracturing, due to their exceptional uptime, dependability, and efficiency.
