Enhancing Sustainability in Rigless Operations: Dual Trial Evaluation of Diesel Fuel Additives for Reduced Consumption and Emissions

Abstract This study evaluates the effectiveness of diesel fuel additives in reducing fuel consumption and carbon emissions in rigless oil and gas operations—a domain where such applications remain underexplored. Two independent field trials were conducted across distinct operational environments to assess the performance, efficiency, and environmental benefits of additive-enhanced diesel fuel used in power generation systems critical to remote field operations. The trials focused on diesel-powered Volvo Penta generators equipped with modern electronic control units, allowing for precise, real-time data collection. Key performance indicators included Brake-Specific Fuel Consumption (BSFC), fuel consumption, turbocharger pressure, engine load, and visual emissions. Fuel filter conditions were also assessed pre- and post-trial to evaluate improvements in fuel system cleanliness and reliability. In Trial 1, conducted under routine rigless operation, the additive delivered a 3.7% reduction in BSFC and a marked reduction in visible black smoke emissions. A second site in the same trial reported a 2.4% improvement in fuel efficiency, along with notable enhancements in fuel filter cleanliness and fewer operational disruptions. Field personnel provided positive feedback regarding smoother engine performance and reduced maintenance demands. Trial 2, conducted as part of a broader decarbonization initiative, tested a refined additive formulation under variable and extended load conditions to better reflect real-world challenges. Results indicated an average 4.5% improvement in fuel efficiency, accompanied by a significant reduction in particulate emissions and carbon output. The prolonged test period also revealed improved engine health, extended fuel filter life, and reduced downtime, supporting the additive's long-term operational value. These trials confirm that diesel fuel additives can meaningfully improve operational efficiency, reduce emissions, and enhance system reliability in rigless upstream operations. The dual-site, multi-condition approach strengthens the applicability of findings across diverse field environments. Moreover, the study contributes novel field-validated data to a domain traditionally lacking such insights, bridging a critical gap between laboratory research and real-world implementation. The outcomes offer practical guidance for operators seeking to improve sustainability, reduce costs, and maintain performance under demanding field conditions.