The Top Three Challenges to Fluid End Longevity – And How to Mitigate Them

Oilfield companies require pressure pumping equipment that meets today’s rigorous demands and are paying closer attention to the longevity of parts on site. One of the top consumables, fluid ends, can directly impact the uptime of hydraulic fracturing pumps and support operational efficiency. Operators can leverage these key approaches to minimize three primary factors that compromise fluid end longevity and enhance job performance.

Material and Manufacturing Quality

The quality of manufacturing processes and materials affect fluid end performance and durability. Low-quality components can be prone to cracking, especially in critical areas like bores and threads. Once a crack develops, a fluid end must be replaced which increases costs and downtime.

SPM™ EXL Fluid Ends employ advanced manufacturing processes and high-quality materials specifically designed to withstand extreme operating conditions. The EXL Fluid End eliminates hand blending in the cross-bore to prevent a common source of fractures. As a result, consistent performance can be achieved, prolonging longevity and reducing failure. 

Increased Wear

When material fatigue occurs prematurely, pressure pumping operations can halt abruptly and cause costly downtime. Seals, valves and packing can degrade over time, negatively impacting performance and increasing the potential for wash. For example, washing that affects packing and suction seals creates gaps which can compromise fluid end integrity.

The EXL Fluid End is engineered for continuous duty and includes the Everbore™ hardened steel packing bore that resists wear and eliminates washboarding or the need to re-sleeve.1 This innovative design allows the EXL Fluid End to last more than 2,500 hours in the field — over 50% longer than conventional fluid ends. By extending service intervals and reducing replacement frequency, operators can lower total cost of ownership (TCO) and enhance operational efficiency.

Preventive Maintenance

With fluid ends, a worn seal or improperly cleaned thread can quickly become a significant issue. Implementing a few preventive maintenance procedures helps avoid unexpected failures and reduces damage to higher-cost components.

A structured preventative maintenance plan helps maximize fluid end lifespan and functionality. Such protocols include routine inspection of threads and seals in addition to manufacturer service guidelines. Technicians can perform visual inspections during scheduled maintenance or when equipment is idle to help identify potential concerns before a more extensive repair is needed.

The EXL Fluid End is engineered to simplify maintenance with rugged construction that reduces the chances of inadvertent damage that can occur during servicing.2 Extensive technician, engineer and parts support is available to reduce non-productive (NPT) time.

Proactively addressing the three most common fluid end challenges provides important benefits for pressure pumping operators. The EXL Fluid End offers the material durability, longevity and maintenance ease that helps minimize NPT, lower TCO and enhance operational efficiency.