ProFrac x Seismos at STARS 2025
At ProFrac STARS 2025 in Fort Worth, Matt Wilks and Panos Adamopoulos introduced a major step forward for completions: Closed Loop Fracturing, the integration of Seismos’s subsurface diagnostics with ProFrac’s surface automation.
“We’ve moved from cookie-cutter stages to predefined, real-time changes based on the data we see while we’re pumping.” — Matt Wilks, ProFrac
Seismos’s SAFA (Acoustic Friction Analysis) system measures cluster uniformity and perforation efficiency using high-frequency pressure. This live subsurface data feeds directly into ProFrac’s ProPilot, which automatically adjusts surface parameters such as rate, sand, and friction reducer as each stage progresses.
“Closed loop means we don’t just measure what happens; we actively improve it while it’s happening,” said Panos Adamopoulos, CEO of Seismos. “It’s the first time subsurface intelligence is directly controlling surface execution.”
Operators can run the system in supervised mode, where engineers confirm real-time recommendations, or in unsupervised mode, where ProPilot acts automatically within safe operational limits.
According to independent operator research, even a 10% improvement in fluid distribution can deliver about $300,000 in NPV per well.
In the second half of the episode, Larry Carroll and Steven Bourgoyne explain how the Closed Loop Fracturing system operates in the field. Seismos’ acoustic analytics isolate the pressure signals that describe near-wellbore response, while ProFrac’s ProPilot instantly adjusts the surface parameters that drive stage performance.
The result is a consistent, measurable workflow that helps operators:
- Detect and mitigate non-uniformity in a stage instantly
- Optimize chemical and proppant usage
- Achieve repeatable performance across fleets
“For the first time, engineers are seeing the rock respond as they pump,” said Steven Bourgoyne, Operations Director at Seismos. “That visibility changes how you design, execute, and evaluate every stage.” Larry Carroll, ProFrac’s VP of Engineering & Technology, adds: “Closed loop gives our teams real feedback, not guesswork. It helps us make better design calls in real time and build a foundation for autonomous fracturing.”
Closed Loop Fracturing delivers measurable improvement by connecting subsurface intelligence and surface control. Operators gain:
- Visibility into cluster and perforation behavior
- Control through automated real-time adjustments
- Value from improved efficiency and well economics
The partnership between ProFrac and Seismos is defining a new era of data-driven, adaptive completion that evolves with every stage.
Big thanks to the Collide team for hosting this conversation and creating a platform where real innovation in energy gets shared and debated.
