ProFrac and Seismos Launch Groundbreaking Closed-Loop Fracturing at Commercial Scale

In a significant advancement for the oil and gas industry, ProFrac Holding Corp. and Seismos, Inc. have announced the successful completion of their innovative closed-loop fracturing program. This revolutionary approach emphasizes real-time data collection via in-well subsurface measurements and immediate adjustments on the surface. Conducted between February 13 and March 4, 2026, in the Eagle Ford and Austin Chalk basins, the program involved a four-well pad configuration, with a total of 183 stages completed. This deployment marks a pivotal moment in the pursuit of improved fracturing efficiency and productivity.

The Evolution of Fracturing Technology

Traditional fracturing techniques often depend on indirect measurements from offset wells, which can dilute the precision required for effective treatment optimization. The ProFrac-Seismos system heralds a new era by harnessing direct in-well measurements to monitor performance accurately. This cutting-edge technology detects deviations in real-time and executes corrective actions during the active stage of fracturing, all with an average response time of under five minutes. Future aspirations aim for this response time to drop below two minutes.

Research indicates that improved fluid distribution at the cluster level can potentially enhance productivity by as much as 20%. This not only underscores the importance of real-time measurement but also validates the effectiveness of the ProFrac-Seismos closed-loop system. A recent study published at the URTeC 2024 further emphasizes the need for uniform fluid distribution across all clusters, asserting the methodology's profound impact on overall efficiency.

A Smarter Approach to Intervention

The intervention methodology employed by ProFrac and Seismos activates when intra-stage performance determines a deviation from predefined performance envelopes. When specific criteria are met, Seismos's proprietary measurement system (often referred to as SAFA™) provides recommendations, prompting ProFrac's surface automation technology (ProPilot®) to initiate adjustments during the fracturing operation. Key triggers for adjustments include mid-stage perforation efficiency dipping below 70% or the rapid detection of performance degradation trends.

These real-time adjustments encompass modifications in surface parameters such as rate adjustments for optimizing cluster stimulation and friction reducer tweaks to maintain stable treating pressure, all executed by ProPilot®. The results from closed-loop operations have shown a remarkable 7% increase in mid-stage perforation efficiency and a 7.5% boost in end-of-stage efficiency when compared to stages lacking intra-stage adjustments. Furthermore, the meticulous planning ensured there were no incidences of screen-outs linked to these adjustments, maintaining efficiency and reducing non-productive time (NPT).

Redefining Frac Outcomes

By shifting the paradigm from merely measuring well performance to actively controlling the outcome of fracturing operations, the ProFrac-Seismos collaboration sets a precedent in the industry. Instead of guessing at performance based solely on treating pressure or conducting post-job analyses, this innovative model leverages real-time in-well data to guide operational decisions seamlessly.

The integrated structure of the system not only elevates immediate decision-making capabilities but also fosters a continuous improvement philosophy across multiple stages and pads. This new framework combines real-time execution with ongoing adjustments aimed at perennially enhancing design and operational outcomes.

According to Matt Wilks, Executive Chairman of ProFrac Holding Corp., Closed-loop fracturing begins with accurate, real-time subsurface measurements. However, it's the intelligence derived from these measurements that drives surface execution. Through our ProPilot® automation capabilities and selective chemistry integration, we’re pioneering intra-stage adjustments at an unprecedented scale, truly advancing the industry's first complete closed-loop fracturing architecture.

Seismos's founder and CEO, Panos Adamopoulos, emphasizes the company's role as the core intelligence driver for this groundbreaking system. He stated, By standardizing our approach with the Uniformity Index (UI) as the primary control metric, we guarantee consistency and precision across various crews and operational basins, perfectly aligning real-time processes with measurable production outcomes.

Summary

The foray into closed-loop fracturing not only showcases the capabilities of ProFrac and Seismos but also represents a major shift in how fracturing operations may be established and executed in the future. As both companies continue to refine and expand upon these innovations, the ramifications for the oil and gas sector are profound, potentially maximizing outputs and efficiencies while ensuring optimized economic viability.

For further information about the operational capacities and technologies of ProFrac and Seismos, interested parties can visit their respective websites.