Maintenance in Vaca Muerta: how to reduce downtime of pumps, compressors and motors with the right parts

Operations in Vaca Muerta impose extreme conditions on rotating equipment. Fracturing pumps, gas compressors and electric motors work with variable loads, vibrations and temperatures that accelerate the wear of mechanical components. An unplanned failure can halt production and generate extremely high costs.

Therefore, predictive maintenance and the correct selection of parts are key. It is not enough to replace a part: you must choose the right bearing, chain or seal for each application, considering the real operating conditions. A lower-spec part can fail prematurely and cause an even longer downtime.

In this guide we review the most critical components in pumps, compressors and motors, and what to consider when replacing them to maintain operational continuity in the field.

Centrifugal pumps and reciprocating compressors use bearings that must support combined radial and axial loads. Spherical roller bearings are a frequent option in these equipment because they tolerate misalignments and heavy loads. For example, codes such as 22325 or 22318 are used in large pumps and gas compressors.

When selecting a bearing for Vaca Muerta, it is important to verify the internal clearance (for example, C3 to compensate for thermal expansion) and the sealing type (2RS to retain lubricant and exclude contaminants). A poorly specified bearing can overheat and fail in a few weeks.

The quality of the steel and heat treatment must also be considered. Bearings from recognized brands such as SKF or FAG offer dimensional and material consistency, which translates into longer service life under load. In critical applications, it is advisable to opt for bearings with machined cage (MB suffix) to withstand high speeds and vibrations.

Many mud pumps and auxiliary compressors use roller chain drives. Chains must withstand shock loads, abrasive dust and occasional lack of lubrication. In Vaca Muerta, standard pitch chains (such as RS60 or RS25) are used in low and medium power drives.

For more demanding applications, there are high-strength chains with hardened pins and thicker plates. When replacing, you must verify the pitch, the number of strands and the exact length. A stretched chain or with damaged links can jump on the sprocket and damage other components.

Lubrication is essential: in environments with dust and mud, it is recommended to use greases with extreme pressure additives and reapply frequently. It is also advisable to check the alignment between sprockets and chain tension to avoid premature wear.

SNL split housings are the mounting base for bearings with adapter sleeve. In pumps and fans, they allow changing the bearing without disassembling the shaft or misaligning the equipment. Models SNL 211 and SNL 216 are typical examples for 55 mm and 80 mm shafts respectively.

When choosing an SNL housing, you must consider the shaft diameter, radial load and the need for additional seals. In Vaca Muerta, where dust and humidity are constant, it is recommended to use housings with end covers and labyrinth seals to protect the bearing.

Correct mounting is essential: the adapter sleeve must be tightened to the specified torque and the housing must sit on a rigid and level base. A poorly installed housing generates vibrations that shorten the life of the bearing and the equipment.

Fracturing and valve control hydraulic systems work with pressures exceeding 10,000 psi. Hydraulic seals must withstand these pressures without deforming or losing elasticity. Polyurethane and nitrile rubber (NBR) seals are common, but in Vaca Muerta materials resistant to high temperatures and aggressive fluids are recommended.

When replacing a seal, you must verify the exact dimensions (inner diameter, outer diameter and width) and the profile. A poorly dimensioned seal can cause internal leaks that reduce system efficiency and contaminate the hydraulic fluid.

It is also important to check the condition of the sleeves and rods: a scratched or corroded surface will damage the new seal in a short time. In critical equipment, it is recommended to replace the seals at every major maintenance and use complete kits to ensure compatibility.

Couplings connect the motor with the pump or compressor and transmit torque. In equipment with frequent starts or pulsating loads, elastic couplings help damp vibrations and compensate for small misalignments. In gas compressors, disc or diaphragm couplings are common due to their torsional rigidity and high-speed capacity.

When selecting a coupling, you must consider the nominal torque, maximum speed and the type of expected misalignment. An oversized coupling can be as harmful as an undersized one, because it transmits more vibration to the equipment.

Coupling maintenance includes checking the condition of the elastic elements (star, spider or discs) and the laser alignment of the assembly. Incorrect alignment is the main cause of premature failures in bearings and seals.

Lubrication is the most controllable factor to extend component life. In Vaca Muerta, greases must withstand high loads, extreme temperatures and contamination by dust and water. Lithium complex greases with EP (extreme pressure) additives are a good base, but in critical applications synthetic greases with greater thermal stability are recommended.

An effective lubrication plan includes the regreasing frequency, the correct amount and the application method. Excess grease can cause overheating, and lack of it, premature wear. In pump and compressor bearings, it is recommended to regrease with the equipment running and purge old grease.

It is also important to store greases in clean and dry places, and use clean greasing tools to avoid introducing contaminants. Compatibility between greases of different bases must be verified before mixing, to avoid softening or hardening.