Proven Expertise

PREP has completed many development projects over the past 20 years, applying technology and innovation to create unique solutions for our customers. These efforts allow us to continually expand our technical capabilities, and keep ahead of the technology curve. The following examples illustrate the potential for PREP to assist in early adoption of technology for your business:

9-speed Powershift Transmission

During the 1990's, advancements in well stimulation technologies created a market opportunity for a purpose built transmission for driving trailer mounted fracturing pumps. Available transmissions were either under-rated for the power demand, or too heavy to suit the mobile application. PREP was engaged by a major heavy equipment OEM to develop a series of prototype transmissions specifically designed as fracturing pump drives.

Stringent design requirements included a very high power density, increased reliability, lower rebuild costs, and better efficiency than what was available commercially. The resulting prototypes were 9-speed powershift transmissions rated at 2250HP, successfully utilizing and matching standard torque converter and off-highway planetary gearset components. Features include lockup capability, PTO, integral parking brake, oil-cooled wet clutches, and standard SAE engine mounting. PREP also developed sophisticated transmission control software to provide peak performance while providing hardware protection in all operational modes.

Following successful field testing in both hot and cold climates, the IP developed by PREP was purchased and the transmissions are now in full production with one of the top three OEM engine manufacturers.

6000HP Active Heave Compensating Drawworks

As oil exploration activities move farther offshore in the search of new deposits, new technologies are required to drill wells at the extreme depths. Drill ships are starting to use advanced PLC controlled AC powered hoists (drawworks) to "actively" compensate for the heave motion of the ship at sea. This allows precise "weight-on-bit" and "rate of penetration" for the drill pipe that may be over 8 km long, despite the heave and roll motion of the ship at surface. PREP designed and manufactured an Active Heave Compensating drawworks for use in this unique and demanding application. With drill ship day rates above $300,000 per day, critical equipment such as drawworks must meet the highest standard of reliability. Rated to operate continuously with 6000 HP, this system can handle drill string weights of 1000 tons with safety and precision.

Special design requirements include fully redundant systems, with no single point failures acceptable. All aspects of the drawworks design and manufacturing meet the stringent requirements of DNV certification for Offshore Vessels. The PREP designed 3-speed hydraulically clutched transmission delivers a broad performance spectrum and precise control at the cable drum. This product stands alone in the world of offshore drilling, and showcases PREP's ability to deliver in any arena.

All Electric AC Service Rig

In spite of advances in safety and efficiency seen in modern AC drilling rigs using PLC controls, the design of mobile rigs used for well servicing has remained largely unchanged for the past 40 years. In 2004, one of the major oil drilling contractors approached us and we undertook to develop a "next-generation" prototype service rig. Packaging the latest technology for transmissions, electric motors, drawworks, and control systems, we designed and manufactured the world's first heavy-duty electric 5-axle service rig, which was delivered and deployed in 2006.

on board electric power for propulsion and equipment.
advanced lighweight AC drawworks specifically design for mobile application.
fully programmable controls for use in process automation,providing enhanced operator flexibility and control.
fail safe braking methodology to prevent inadvertent equipment related failure.
sophisticated energy storage technologies and applications, providing reliable power for quiet, efficient operations and emergency standby.
cab and platform designs for ease of access, improved.

Outdated mechanical components have been replaced with electric-powered advanced machinery, technologically improved controls and easy-to-use digital instrumentation. Operators can work more efficiently in an environment that is intuitive and comfortable, increasing safety by reducing stress and fatigue.

FDPSO

In the Spring of 2007, PREP was approached by a large drilling contractor to manufacture a 3000 HP Drawworks Package for Murphy West Africa Ltd, a subsidiary of Murphy Oil Corporation, for the conversion and operation of a Floating, Drilling, Production, Storage and Offloading unit (FDPSO).

This vessel will be used for deepwater offshore development near the Republic of Congo coastline. This is the first FDPSO mobile drilling rig in the world. The FDPSO technology is a cost-efficient solution for drilling and producing deepwater fields. The Azurite vessel is being converted and will have a storage capacity of 1.4 million barrels of oil and a process capacity of 60,000 bfpd / 40,000 bopd. The vessel will be spread-moored at a water depth of 1,400 meters.