In the cold with cutting-edge consumables

Pressure pumping operators face evolving challenges as they strive to minimise costs and optimise efficiency. Pump consumables’ longevity can have a positive impact on both operating expenses and non-productive time (NPT). Recent technological advancements have significantly extended the life of consumables compared to conventional components, particularly for valves and seats, which supports companies’ operational goals.

Pump consumables play a critical role in the hydraulic fracturing process. Conventional seats have approximately an 80 hour lifespan and require frequent maintenance. They are also prone to fatigue and potential failure under harsh site conditions involving higher pressures and extreme temperatures.

Fortunately, new materials and designs are now available that provide greater resistance to wear, cracking and washout – even in the most demanding conditions. Using more durable consumables can be an effective way to decrease maintenance frequency, lower replacement costs and minimise NPT. Pressure pumpers can also reduce the labor costs associated with frequent seat pulling, potentially freeing up crew members to focus on higher-value tasks while enhancing safety.

High-performance pump consumables help streamline and simplify maintenance when service intervals are required, which helps reduce unplanned downtime, enhance operational efficiency and lower total cost of ownership (TCO).

Field-proven to last

The experience of an oilfield services company in Western Canada with multi-well pad operations demonstrates the positive impact long-lasting pump consumables can have on a project. The Montney and Duvernay plays in Canada subject hydraulic fracturing equipment to some of the most challenging fracing environments due to high pressures, high proppant volumes and extremely cold temperatures, which can range from - 5°C to - 30°C (23°F to - 22°F) in the winter.

Due to site characteristics and geological formations, the company routinely pumped high proppant volumes at high pressures, and 5000 t of sand per stage for offset wells – much higher than the typical range of 1200 – 1400 t. These practices led to above-average seat and valve erosion.

In an effort to increase efficiency and reduce NPT, the operator conducted a three-month field trial using advanced consumables on a pump, in this case, the SPM™ EdgeX Carbide Seat. The consumables were subjected to sub-zero temperatures (-20°C/-4°F), pressures up to 12 500 psi and produced water at 100 bpm. An engineering field assist team regularly monitored the high-performance components to compare wear and longevity to the company’s conventional pump consumables.

The advanced durability and design of the new consumables enabled the EdgeX Carbide Seat to reach a useful life of up to 515 hours, potentially increasing seat life by approximately 540% compared to the 80 hour life the company experienced with conventional seats.

Replacing valves and seats is one of the largest expenses an oilfield service operator incurs – and one of the most frustrating. Additionally, there are inherent safety risks involved with this important maintenance activity. Extending the longevity of pump consumables reduced frequent replacements and NPT, allowing the operator’s pumping rate to be maintained for much longer and considerably extending maintenance intervals compared to the consumables previously used.

Compatibility is also an important consideration when contemplating pump consumables options. The high-performance seats could be paired with any tapered fluid end and replaced in the field without special tools, which provided the pressure pumper flexibility. Additionally, the carbide-reinforced seats protected high-wear areas while eliminating the typical installation error sensitivity encountered with other long-life seats, which can cost time and money.

The new valve’s design complemented the new seat to promote greater efficiencies. The high-performance valve optimises its performance when used with its carbide seat counterpart to wear deeper and last twice as long as standard valves without failure risk. A first-of-its-kind material provides exceptional erosion resistance and durability as well as high sand abrasion resistance with every stroke to achieve synergies that drive longer lifespan for both components. The standard 30° strike angle of the new valve maximises interchangeability, and its unique leg design ensures stability through all operating conditions, including high lift.

The extreme adverse temperature and pressure conditions oilfield companies encounter in Western Canada can cause consumables to become brittle and shatter. High-performance components specifically engineered with such harsh environments in mind can provide a competitive advantage by reducing NPT and costs.

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Read the article online at: https://www.oilfieldtechnology.com/special-reports/27122024/in-the-cold-with-cutting-edge-consumables/