SPM^™ EdgeX Valve and Carbide Seat

The Innovation

An oilfield services provider in Western Canada subjects its fracking equipment to some of the most challenging conditions that exist in the industry. It routinely pumps high volumes of proppant at pressures up to 12,500 psi during harsh winter operations (–20 °C | –4 °F). Standard seats typically have an average life of 80 hours. During a three-month field trial with the SPM^™ EdgeX Valves and Carbide Seat, the engineered seats ran a record-breaking 515 hours—a 540% increase compared to previous seats—and valve life doubled compared to previous valves, dramatically increasing safety and reducing nonproductive time (NPT).

The Challenge

The Montney and Duvernay plays in Canada subject hydraulic fracturing equipment to some of the most challenging fracing environments there are due to high pressures, high proppant volumes and extreme winter temperatures, ranging from –5 to –15°C (23 to –4°F). These unforgiving conditions prevent the use of less-durable fracking equipment and components.

An oilfield services provider operates pumps in both shale plays and wanted to carve out greater efficiencies to further streamline their multi-well pad operations and reduce their NPT. Pulling valves and seats is the most labor-intensive part of fluid-end maintenance, increasing NPT when fluid ends are offline. While 80 hours is a typical life span, the company was eager to extend maintenance intervals and eliminate seat replacement and maintenance on the pad.

Pumping 2°C (36°F) water in –20°C (–4°F) weather has been known to cause tungsten carbide fluid-end seats to become brittle or shatter, increasing consumables and labor costs. Additionally, the oilfield service provider pumped 5,000 tons of sand rather than the typical 1,200–1,400 tons of sand used in offset wells, subjecting their seats and valves to significantly more erosion.

The Approach

SPM Oil & Gas proposed a three-month field comparison, monitoring the SPM EdgeX Carbide Seats and EdgeX Valves to track their performance against conventional pump expendables on a single pump. The operating conditions of the testing sites were 12,500 psi, 350 tons of sand/stage, produced water, 100 bpm and temperatures well below freezing (–20°C | –4°F). The SPM Edge Engineering Field Assist Team supervised the test, checking sets at regular maintenance intervals and comparing them for wear.

The Result

The SPM EdgeX Carbide Seats produced dramatic results for the oilfield services provider. Unlike tungsten carbide seats which can become brittle or shatter in cold weather, the SPM EdgeX Carbide Seats were unaffected by the cold temperatures and lasted 6x longer than the previously used seats.

SPM Oil & Gas ran the SPM EdgeX Carbide Seats a record-breaking 515 hours compared to the 80-hour average life span of conventional seats—increasing seat life approximately 540%. In fact, the operator finished the job before the seats could be run to failure, which gave the crew confidence that the new SPM EdgeX Carbide Seats may last even longer.

Additionally, the SPM EdgeX Valves lasted 120 hours. This was a 100% increase in valve life, as the previously used valves lasted 60 hours.

Based on this successful field trial, the operator immediately ordered SPM EdgeX Carbide Seats and EdgeX Valves to outfit their fleet. These components eliminated the need to pull seats on-site, leading to longer pumping time, reduced maintenance and increased satisfaction.