Most frac rigs operate at idle 40 to 60 percent of the time. That’s a lot of nonproductive hours, and they’re not free. The costs of excessive idling add up quickly when it comes to fuel consumption and maintenance. New technology that reduces idle hours - like Caterpillar’s Engine Idle Reduction System (EIRS) - can save a fleet of 16 units anywhere from $320,000 to $600,000 annually. In fact, it’s priced to pay for itself in about a year. Here are four reasons to consider putting it to work for your operation:

1. Cut your fuel bill

Shutting down the engine between pumping stages can reduce your fuel burn significantly. Say you use EIRS to decrease idle time by 60 percent for a 16-unit frac rig fleet. Over the course of a year, that can cut fuel consumption by 8.5 percent — accounting for about one-half to two-thirds of your overall savings.

2. Spend less on PM

The other one-third to one-half of your savings comes from maintenance. By shutting down the engine when it’s not in use, your power train accumulates fewer hours. That translates directly to less time and money spent on preventive maintenance. Plus, reducing the frequency at which your operators have to stop to change oil and filters or perform other common tasks frees up their time for more productive work.

3. Improve safety

Traditionally, starting the deck engine of a frac rig is a process orchestrated between an operator in the data van and onsite mechanics next to the rigs who power up the hydraulic starters. EIRS introduces remote electric start, taking the mechanic out of the operation zone and saving valuable start-up time. You can also use EIRS’ digital outputs to custom-design lights and alarms that let your operators know exactly what the unit is doing and when it’s safe to approach. It all makes for an easier, safer starting sequence.

4. Reduce emissions

An idling engine is still generating emissions. With EIRS, you can eliminate idle-time emissions and reduce the overall carbon footprint of your fleets.

It’s easy to start taking advantage of engine idle reduction.

EIRS is a simple hardware technology available factory-installed on new Cat® 3512C and 3512E engines, or it can be retrofit on your existing engines. Your Cat dealer can help facilitate and expedite the integration.