Application of Steel Castings in Petroleum Fracturing Equipment Components
Fracturing equipment is the core equipment for shale oil and tight oil and gas production and development. It works for a long time under "high pressure, alternating load, sand erosion, oil and gas medium corrosion, and high and low temperature alternation" conditions. The core pressure bearing, overcurrent, and load-bearing components are mostly made of cast steel. Compared to forgings and welded plates, cast steel has the advantage of being suitable for complex internal cavities, irregular flow channels, and multi interface integrated structures. It has flexible forming and controllable batch costs. Through material selection and casting process optimization, it can meet the strict requirements of fracturing conditions; At the same time, there are also control difficulties such as compactness, non-destructive testing, and heat treatment.
The fracturing pump is the heart of the fracturing truck/sled, with its hydraulic end directly in contact with the sand carrying fracturing fluid. It is the most commonly used part for casting steel
Valve body, valve box, valve seat body, suction and discharge manifold, cylinder head (pump head), etc
Diverter, manifold block, tee, four-way, variable diameter valve body, flange integrated casting, throttle valve body.
Characteristics: Multiple branching channels, multiple openings, and complex shapes. If forged by a forging machine, the material removal rate is extremely high, the cost is high, and the processing cycle is long; Cast steel integrated molding reduces welding joints and lowers the risk of leakage.
Fracturing tree, fracturing wellhead body, gate valve body, plug valve body, and plug base.
Working conditions: high-pressure sealing, hydrogen sulfide/carbon dioxide corrosion environment (sulfur-containing well). At this time, sulfur resistant cast steel is selected, such as low-carbon quenched and tempered cast steel, with matching sulfur resistance requirements. The hardness should be controlled to ≤ 22HRC to avoid sulfide stress cracking.
Fracturing sled base support, pump support housing, gearbox housing, buffer tank housing, guide bracket.
This type of steel does not withstand ultra-high internal pressure and mainly withstands impact loads and vibrations. Carbon cast steel or low-alloy cast steel is generally selected to balance toughness and cost.
Sand mixer shell, mortar distribution chamber, mixing support. The medium is a high sand content fluid, with a focus on erosion resistance, cast steel substrate+wear-resistant coating/weld overlay.
