Wear-resistant and corrosion-resistant steel composition, and high-pressure pump and pump component comprising same

Abstract

The present disclosure relates to a wear and corrosion resistant steel composition including a carbon content from about 0.07% MB to about 0.17% MB, a nickel content from 2% MB to 4.1% MB, a manganese content from about 0.3% MB to about 0.6% MB, a molybdenum content from about 0.5% MB to about 2.0% MB, and a chromium content from about 8% MB to about 10% MB. Further, the present disclosure relates to a hydraulic fracturing pump comprising a fluid end assembly, the fluid end assembly comprising: a cylinder configured to receive a respective plunger from a power end assembly; and a suction opening configured to receive the valve body, the valve seat, and the spring, where the cylinder includes a steel composition.

Description

[0001] This application is a divisional application of the Chinese invention patent application entitled “Wear-resistant and corrosion-resistant steel compositions and high-pressure pumps and pump parts comprising the same”, with an application date of June 18, 2020, application number 202080044995.5, and international application number PCT / US2020 / 038518. Technical Field

[0002] In some embodiments, the present disclosure is directed to wear and corrosion resistant steel compositions (ie, wear and corrosion resistant steel compositions). In some embodiments, the present disclosure is directed to high pressure pumps and pump components (eg, fluid end components of hydraulic fracturing pumps) composed of the wear and corrosion resistant steel compositions. Background Art

[0003] Hydraulic fracturing is a well stimulation technique in which the bedrock is fractured (i.e., broken) by applying a pressurized fracturing fluid. The effectiveness of the fracturing fluid depends not only on pressurization, but also on the composition of one or more proppants (e.g., sand) and chemical additives (e.g., dilute acid, microbicides, breakers, pH adjusters). The pressurized fracturing fluid is applied to existing bedrock fissures to create new cracks in the bedrock and increase the size, scope, and connectivity of existing cracks. This allows more oil and gas to flow out of the rock formation and into the wellbore, from which they can be mined.

[0004] Hydraulic fracturing pumps are generally composed of a power end assembly and a fluid end assembly, wherein the power end assembly pressurizes the fracturing fluid to generate a pressurized fluid, and the fluid end assembly directs the pressurized fluid into the wellbore through a series of conduits. Hydraulic fracturing pump components (e.g., fluid end assemblies) exposed to the fracturing fluid are susceptible to fluid leakage, failure, and other sustainability issues due to wear, corrosion, and degradation caused by their exposure to fracturing fluid components (e.g., proppants, chemical additives) with corrosive or abrasive properties. As a result, hydraulic fracturing pump components need to be frequently replaced at a high cost.

[0005] The composition of hydraulic pump components plays a significant role in both replacement frequency and cost. Although pump components constructed of stainless steel have a lifespan of approximately 2000 operating hours, the prohibitive cost of stainless steel often makes their use cost prohibitive. In contrast, pump components constructed of carbon steel alloys are less expensive, but have a lifespan of only approximately 10-15% (i.e., 200-300 operating hours) compared to their stainless steel counterparts. Therefore, there is a need for hydraulic pump components that are both wear and corrosion resistant (to provide a longer operating life) and are provided at a reasonable price. Summary of the invention

[0006] According to some embodiments, the present disclosure relates to a wear-resistant and corrosion-resistant steel composition having a nickel content of from about 1.75% mass basis (MB) to about 5.75% MB. In some embodiments, the wear-resistant and corrosion-resistant steel composition may have a nickel content of from about 2.0% MB to about 4.1% MB. When exposed to corrosives, the wear-resistant and corrosion-resistant steel composition may exhibit about 5% less to about 50% less pitting corrosion compared to a carbon alloy steel counterpart. When exposed to a fracturing fluid, the wear-resistant and corrosion-resistant steel composition may exhibit an average life in the range of at least 10% to at least 500% longer than a carbon steel alloy counterpart.

[0007] In some embodiments, the wear-resistant and corrosion-resistant steel composition may include one or more of a carbon content from about 0.07% MB to about 0.17% MB; a manganese content from about 0.3% MB to about 0.6% MB; and a chromium content from about 8% MB to about 10% MB. The wear-resistant and corrosion-resistant steel composition may include a copper content of less than about 0.5% MB; a sulfur content of less than about 0.02% MB; and a silicon content of less than about 1% MB. According to some embodiments, the wear-resistant and corrosion-resistant steel composition may include a phosphorus content of less than about 0.04% MB; a molybdenum content from about 0.5% MB to about 2% MB; and a niobium content from about 0.01% MB to about 0.1% MB. The steel composition may include a vanadium content from about 0.01% MB to about 0.1% MB; a titanium content from about 0.0001% MB to about 0.1% MB; a nitrogen content from about 0.02% MB to about 0.07% MB; and an aluminum content of less than about 0.1% MB.

[0008] According to some embodiments, the present disclosure relates to a hydraulic fracturing pump including a fluid end assembly. The fluid end assembly may include a cylinder, a suction opening, and a spring retainer. The cylinder may be configured to receive a corresponding plunger from a power end assembly. The suction opening may be configured to accommodate a valve body, a valve seat, and a spring. In some embodiments, one or more of the cylinder, the suction opening, and the spring retainer may include a steel composition having a nickel content from about 1.75% MB to about 5.75% MB. The fluid end assembly may be non-grooved. The hydraulic fracturing pump may include a suction cap configured to fit into the suction opening and a valve stop attached to the suction cap by a rod, the valve stop being configured to lock under a ridge in the fluid cylinder opening. The suction opening may include one or more grooves. The hydraulic fracturing pump may include a wing valve stop configured to lock in place by the groove.

[0009] In some embodiments, the present disclosure relates to a hydraulic fracturing pump comprising a fluid end assembly and a power end assembly. The power end assembly comprises a crankshaft; a frame; a connecting rod connected to the crankshaft; a crosshead; and a plunger connected to the connecting rod. One or more of the crankshaft, frame, connecting rod, crosshead, and plunger comprises a wear-resistant and corrosion-resistant steel composition having a nickel content of from about 1.75% MB to about 5.75% MB. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Exemplary embodiments of the present disclosure are described herein with reference to the accompanying drawings, wherein like parts are represented by like reference numerals, and in which:

[0011] Figure 1 shows a cross-sectional perspective view of a typical hydraulic fracturing pump;

[0012] Figure 2 shows pitting corrosion on metal parts of a hydraulic fracturing pump caused by exposure to high pressure fluids containing abrasive and corrosive components;

[0013] Figure 3 shows a front perspective view of a hydraulic fracturing pump according to certain exemplary embodiments of the present disclosure;

[0014] Figure 4A shows a front perspective view of a non-grooved fluid end assembly having a valve stop design that locks under a ridge in a fluid cylinder bore in accordance with certain exemplary embodiments of the present disclosure; and

[0015] Figure 4B A front perspective view of a fluid end assembly having a recessed suction opening to lock a valve stop in place is shown in accordance with certain exemplary embodiments of the present disclosure. DETAILED DESCRIPTION

[0016] The present disclosure relates to steel compositions having improved wear or corrosion resistance when compared to carbon alloy steel counterparts (i.e., wear and corrosion resistant steel compositions). Furthermore, the present disclosure relates to wear and corrosion resistant steel compositions having a lower manufacturing cost than a stainless steel counterpart having similar wear or corrosion properties. In some embodiments, the present disclosure relates to a wear and corrosion resistant steel composition having improved wear or corrosion resistance when compared to a carbon steel alloy counterpart and having a sufficiently low manufacturing cost compared to a stainless steel counterpart that the combination of properties is desirable.

[0017] As shown in Table 1, carbon steel alloys are defined by their primary alloying component, carbon, and their properties depend primarily on the percentage of carbon present. As the carbon percentage increases, the hardness of carbon alloy steels increases and the ductility decreases. Carbon alloy steels are generally divided into three categories: low carbon steels, which include carbon between 0.05% and 0.3% MB; medium carbon steels, which include carbon between 0.3% and 0.8% MB; and high carbon steels, which include carbon between 0.8% MB and 2% MB. Although the primary element of interest is carbon, carbon alloy steels may also include, by mass: a manganese content of from 0.75% MB to 1.75% MB, a nickel content of 0.25% MB, a copper content of less than 0.6% MB, a sulfur content of from 0.25% MB to 0.35% MB, a silicon content of from 0.1% MB to 2.2% MB, an aluminum content of from 0.06% MB to 1.25% MB, a phosphorus content of from 0.04% MB to 0.09% MB, a molybdenum content of less than 0.01% MB, a niobium content of less than 0.01% MB, a vanadium content of less than 0.01% MB, a titanium content of less than 0.01% MB, a nitrogen content of from 0.02% MB to 0.07% MB, and any combination thereof. Carbon alloy steels typically include only trace amounts of chromium. Carbon alloy steels are susceptible to wear and corrosion, particularly when exposed to corrosive materials such as fracturing fluids. Carbon alloy steel components (eg, fluid end assemblies constructed of carbon alloy steel) may have a life of up to 100 hours, or up to 150 hours, or up to 200 hours, or up to 250 hours, or up to 300 hours.

[0018] In contrast, stainless steel includes a low carbon content of 0.03% to 0.15% MB and a high level of chromium, which typically ranges from 11% to 30% MB. The high chromium content of stainless steel leads to its high manufacturing cost. Depending on the desired specific characteristics, stainless steel may have different contents of other elements, including copper, manganese, nickel, molybdenum, titanium, niobium, nitrogen, sulfur, phosphorus and selenium. Typically, only trace amounts of aluminum are present in stainless steel. As shown in Table 1, stainless steel has, by mass: a carbon content of from 0.03% MB to 0.15% MB, a silicon content of from 0.75% MB to 1% MB, a sulfur content of from 0.01% MB to 0.03% MB, a nickel content of from 10.5% MB to 28% MB, a manganese content of from 2.0% MB to 7.5% MB, a phosphorus content of less than 0.06% MB, a nitrogen content of less than 0.2% MB, and a chromium content of from 11% MB to 30% MB. For stainless steel, there are no specified or required minimum contents of copper, molybdenum, niobium, vanadium, titanium and aluminum. Table 1 provides examples of stainless steel compositions, but should not be construed as limiting.

[0019] Stainless steel is highly resistant to corrosion and wear, even when exposed to corrosive materials such as fracturing fluids. Stainless steel components (e.g., fluid end components composed of carbon alloy steel) can have a life of at least 1800 hours, or at least 1900 hours, or at least 2000 hours, or at least 2100 hours, or at least 2200 hours.

[0020] The present disclosure relates to wear and corrosion resistant steel compositions (i.e., wear and corrosion resistant steel compositions) including a nickel component ranging from about 1.75% mass basis (MB) to about 5.75% MB nickel by mass, wherein "about" as used in this sentence is plus or minus 0.25% MB. In some embodiments, the wear and corrosion resistant steel composition may include a nickel component ranging from about 2.0% MB to about 4.1% MB.

[0021] Table 2 contains wear-resistant and corrosion-resistant steel compositions according to disclosed embodiments. The disclosed steel compositions are not limited to those listed in Table 1, but include compositions having various concentrations of elements. According to some embodiments, the wear-resistant and corrosion-resistant steel composition may include a carbon content from 0.05% MB to 0.3% MB. For example, the wear-resistant and corrosion-resistant steel composition may have a carbon content of about 0.07% MB to about 0.17% MB, where "about" as used in this sentence is plus or minus 0.01% MB. The wear-resistant and corrosion-resistant steel composition may include a manganese content from about 0.3% MB to about 0.6% MB, where "about" as used in this sentence is plus or minus 0.1% MB. In some embodiments, the wear-resistant and corrosion-resistant steel composition may include a chromium content from about 8% MB to about 10% MB, where "about" as used in this sentence is plus or minus 1% MB. The wear-resistant and corrosion-resistant steel composition may include a copper content of up to about 0.5% MB, where "about" as used in this sentence is plus or minus "0.05%". For example, in some embodiments, the wear-resistant and corrosion-resistant steel composition may include a copper content in the range of about 0.01% MB to 0.05% MB, or 0.01% MB to 0.5%, or 0.05% MB to 0.5%, or about 0.01% MB to 0.5% MB. In some embodiments, the wear-resistant and corrosion-resistant steel composition may include a sulfur content of less than about 0.02% MB, wherein "about" as used in this sentence is plus or minus "0.005%". For example, the wear-resistant and corrosion-resistant steel composition may include a sulfur content of 0% MB, or 0.005% MB, or 0.01% MB, or 0.015% MB or 0.02% MB. The wear-resistant and corrosion-resistant steel composition may include a silicon content of less than about 1% MB, wherein "about" as used in this sentence is plus or minus 0.5% MB. For example, the wear-resistant and corrosion-resistant steel composition may include a silicon content of 0% MB, or 0.25% MB, or 0.5% MB, or 0.75% MB, or 1% MB. According to some embodiments, the wear-resistant and corrosion-resistant steel composition may include an aluminum content of less than about 0.1% MB, where "about" as used in this sentence is plus or minus 0.005% MB. For example, the wear-resistant and corrosion-resistant steel composition may include an aluminum content of 0% MB, or 0.005% MB, or 0.01% MB, or 0.02% MB, or 0.03% MB, or 0.04% MB, or 0.05% MB, or 0.06% MB, or 0.07% MB, or 0.08% MB, or 0.09% MB, or 0.1% MB. The wear-resistant and corrosion-resistant steel composition may include a phosphorus content of less than about .04% MB, where "about" as used in this sentence is plus or minus 0.01% MB. For example, the wear-resistant and corrosion-resistant steel composition may include a phosphorus content of 0% MB, or 0.01% MB, or 0.02% MB, or 0.03% MB, or .04% MB.The wear and corrosion resistant steel composition may include a molybdenum content from about 0.5% MB to about 2% MB, wherein "about" as used in this sentence is plus or minus 0.1% MB. For example, the wear and corrosion resistant steel composition may include a molybdenum content of 0.5% MB, or 0.1% MB, or 1.5% MB, or 2% MB.

[0022] The wear-resistant and corrosion-resistant steel composition may include a niobium content of from about 0.01% MB to about 0.1% MB, wherein "about" as used in this sentence is plus or minus 0.005% MB. For example, the wear-resistant and corrosion-resistant steel composition may include a niobium content of 0.01% MB, or 0.025% MB, or 0.05% MB, or 0.075% MB, or .1% MB. The wear-resistant and corrosion-resistant steel composition may include a vanadium content of from about 0.01% MB to about 0.1% MB, wherein "about" as used in this sentence is plus or minus 0.01% MB. For example, the wear-resistant and corrosion-resistant steel composition may include a vanadium content of 0.01% MB, or 0.025% MB, or 0.05% MB, or 0.075% MB, or .1% MB. The wear-resistant and corrosion-resistant steel composition may include a vanadium content of from about 0.01% MB to about 0.1% MB, wherein "about" as used in this sentence is plus or minus 0.01% MB. For example, the wear-resistant and corrosion-resistant steel composition may include a vanadium content of 0.01% MB, or 0.025% MB, or 0.05% MB, or 0.075% MB, or .1% MB. The wear-resistant and corrosion-resistant steel composition may include a titanium content from about 0.0001% MB to about 0.1% MB, wherein "about" as used in this sentence is plus or minus 0.01% MB. For example, the wear-resistant and corrosion-resistant steel composition may include a titanium content of 0.0001% MB, or 0.025% MB, or 0.05% MB, or 0.075% MB, or .1% MB. The wear-resistant and corrosion-resistant steel composition may include a nitrogen content from about 0.02% MB to about 0.07% MB, wherein "about" as used in this sentence is plus or minus 0.01% MB. For example, the wear and corrosion resistant steel composition may include a nitrogen content of 0.02% MB, or 0.04% MB, or 0.05% MB, or 0.06% MB, or 0.07% MB.

[0023]

[0024] *All values ​​are provided in mass basis (MB).

[0025]

[0026] *All values ​​are provided in mass basis (MB).

[0027] When compared to carbon alloy steel, the wear-resistant and corrosion-resistant steel composition may have enhanced wear resistance, corrosion resistance or a combination thereof. In some embodiments, the wear-resistant and corrosion-resistant steel composition may have an extended life compared to carbon steel alloys. For example, compared to carbon steel alloys exposed to the same conditions, the wear-resistant and corrosion-resistant steel composition may have an average life of at least 10%, at least 25%, or at least 50%, or at least 100%, or at least 125%, or at least 150%, or at least 200%, or at least 250%, or at least 300%, or at least 350%, or at least 400%, or at least 450%, or at least 500% longer than its carbon steel alloy counterpart. In some embodiments, when exposed to a fracturing fluid or a component of a fracturing fluid, the wear-resistant and corrosion-resistant steel exhibits an average life of at least 10% to at least 500% longer than its carbon steel alloy counterpart.

[0028] According to some embodiments, a hydraulic fracturing pump having one or more components made from the disclosed wear and corrosion resistant steel composition may have an average lifespan that is at least 10% longer to at least 500% longer than a corresponding hydraulic fracturing pump having one or more components made from a carbon steel alloy.

[0029] Compared to carbon steel alloys exposed to the same conditions, the wear-resistant and corrosion-resistant steel composition can exhibit less pitting corrosion (indicative of corrosion). For example, compared to its carbon alloy steel counterpart, the wear-resistant and corrosion-resistant steel composition can exhibit at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50% less pitting corrosion. According to some embodiments, a hydraulic fracturing pump having one or more components made of the disclosed wear-resistant and corrosion-resistant steel composition can exhibit from at least 5% less to at least 50% less pitting corrosion compared to a corresponding hydraulic fracturing pump having one or more components made of a carbon steel alloy.

[0030] In some embodiments, the corrosive agent may include fracturing fluid, acid, alkali and combinations thereof. The corrosive agent may include an acid including at least one of hydrochloric acid, sulfuric acid, nitric acid, chromic acid, acetic acid and hydrofluoric acid. In some embodiments, the corrosive agent includes an alkali including ammonium hydroxide, potassium hydroxide, sodium hydroxide and combinations thereof. According to some embodiments, pitting corrosion may be caused at least in part by a response to exposure to particles (e.g., sand) having a size range of about 1 micron to about 3000 microns or more. The particles may have a size of about 1 micron, or about 10 microns, or about 20 microns, or about 30 microns, or about 40 microns, or about 50 microns, or about 60 microns, or about 70 microns, or about 80 microns, or about 90 microns, or about 100 microns, including plus or minus 5 microns. The particles may have a size of about 100 microns, or about 300 microns, or about 600 microns, or about 900 microns, or about 1200 microns, or about 1500 microns, or about 1800 microns, or about 2100 microns, or about 2400 microns, or about 2700 microns, or about 3000 microns, plus or minus about 150 microns inclusive.

[0031] The wear and corrosion resistant steel composition may exhibit improved life expectancy, reduced pitting corrosion, or a combination thereof as compared to a carbon alloy steel counterpart.

[0032] Wear and corrosion resistant steel compositions may have a manufacturing cost that is less than that of stainless steel counterparts. For example, wear and corrosion resistant steel compositions may have a manufacturing cost that is at least 5% lower, or at least 10% lower, or at least 15% lower, or at least 20% lower, or at least 30% lower, or at least 40% lower, or at least 50% lower, or at least 60% lower than a stainless steel composition having comparable lifespan and / or wear and corrosion resistance properties. According to some embodiments, a hydraulic fracturing pump having one or more components made of the disclosed wear and corrosion resistant steel composition may have a manufacturing cost that is at least 5% lower to at least 60% lower than a corresponding hydraulic fracturing pump having one or more components made of a stainless steel composition.

[0033] In some embodiments, the wear and corrosion resistant steel composition may have a manufacturing cost that is at least 5% lower, or at least 10% lower, or at least 15% lower, or at least 20% lower, or at least 30% lower, or at least 40% lower, or at least 50% lower, or at least 60% lower than that of the stainless steel composition when valued as cost per average operating hour.

[0034] According to some embodiments, a hydraulic fracturing pump having one or more components made of the disclosed wear-resistant and corrosion-resistant steel composition may have a manufacturing cost that is at least 5% lower to at least 60% lower when valued as a cost per average operating hour compared to a corresponding hydraulic fracturing pump having one or more components made of a stainless steel composition. For example, if the stainless steel composition has a life of 2,000 operating hours at a cost of $3 per pound, the cost of the stainless steel composition is $0.0015 per hour.

[0035] In some embodiments, the wear and corrosion resistant steel composition may have reduced eutectoid reactions when compared to a carbon steel alloy counterpart.

[0036] The present disclosure further relates to hydraulic fracturing pumps and pump components composed of the wear and corrosion resistant steel compositions. Figure 1 The basic components of a hydraulic fracturing pump 100 are shown. In general, the hydraulic fracturing pump 100 is composed of a power end assembly 105 and a fluid end assembly 110. The power end assembly 105 drives the reciprocating motion of the plunger 115, and the fluid end assembly 110 directs the flow of fracturing fluid from the pump to a conduit leading to the wellbore. Figure 1 As shown, the components of the basic power end assembly 105 include a frame 120 , a crankshaft 125 , a connecting rod 130 , a wrist pin 135 , a crosshead 140 , a crosshead housing 155 , a short sucker rod 145 , a short sucker rod clamp 150 , and a plunger 115 .

[0037] like Figure 1 As disclosed in , the crankshaft 125 is rotated by a power source such as an engine when housed in the frame 120. One or more connecting rods 130 have ends rotatably mounted to the crankshaft 125, wherein the opposite end of each connecting rod 130 is pivotally connected to the crosshead 140. The rotational motion of the crankshaft 125 is converted into linear motion by the crosshead 140. Each crosshead 140 is reciprocally carried in a stationary crosshead housing 155. A short sucker rod 145 is attached to the end of the crosshead 140 opposite the crankshaft 125. The plunger 115 is mounted to the end of the short sucker rod 145 by a short sucker rod clamp 150. The short sucker rod 145 moves or impacts the plunger 115 within the cylinder of the fluid end assembly. A toggle pin 135 or piston pin secures the plunger 115 to the connecting rod 130 and provides a bearing so that the connecting rod 130 pivots as the plunger 115 moves.

[0038] like Figure 1As shown in FIG. 1 , the components of the basic fluid end assembly 110 include a cylinder 160, a discharge cap 165, valves 170, 172, suction openings 175, 177, springs 180, 182, a valve stop 185, a packing 190, a fluid cylinder 195, a cap 197, and an inlet port 199. The packing 190 and the cylinder 160 are configured to receive a plunger 115 from the power end assembly 105 side of the hydraulic fracturing pump 100. The insertion and removal of the plunger 115 creates positive and negative pressure loads within the components of the fluid end assembly 110 that draw low pressure fracturing fluid from the reservoir and then convert it to high pressure fracturing fluid that is purged through the discharge cap 165 to be received by the wellbore. The upward stroke of the plunger 115 applies pressure to the spring 180, which opens the valve 170 and allows the low pressure fracturing fluid to be received through the inlet port 199. The fracturing fluid travels through the inlet port 199, then through the suction opening 175 and into the body of the fluid end assembly 110. The cap 197 acts as a stop point for the plunger 115. The valve stop 185 provides a stop point actuator for the maximum open position of the valve 170, which includes a valve body and a valve seat. The downward stroke of the plunger 115 closes the valve 170 and opens the valve 172. The now high pressure fracturing fluid can travel through the open valve 172, the fluid cylinder 19 and the discharge cap 165 to be transported down the wellbore to create fractures in the deep rock formation to stimulate the flow of natural gas, oil and brine.

[0039] In general, if Figure 1 When the fluid end assembly of the hydraulic fracturing pump shown is exposed to high pressure fluid and sand, the components begin to deteriorate, resulting in pitting corrosion. Figure 2 Pitting corrosion of hydraulic fracturing pump components due to exposure of the fracturing fluid end assembly to abrasive and corrosive components is shown. Pitting corrosion of pump components causes pressure irregularities and leads to areas of pressure concentration. For example, as pitting corrosion becomes larger, high-pressure fluid gathers in the pitting corrosion location, thereby generating specific pressure points or concentrated stress areas, which leads to increased degradation of the pitting corrosion site. In addition, with the accumulation of pitting corrosion and concentrated stress areas, the overall system pressure may be affected, resulting in performance degradation. The accumulation of back pressure or simple wear causes the seals and metal parts of the pump to deteriorate, resulting in fluid leakage and pump failure. In addition, a common failure of hydraulic fracturing pump components caused by exposure to fracturing fluid is fatigue cracking, in which the components fail due to excessive pressure loading. Fatigue cracking can be initiated on the surface of the component or at an internal location. It can be initiated by surface defects (such as the pitting corrosion described above). In addition, common locations for cracking are at the intersection openings in the fluid end assembly. Other components such as valve seats typically crack inside the valve of the fluid end assembly.

[0040] Figure 3A front perspective view of a hydraulic fracturing pump 300 according to a particular exemplary embodiment of the present disclosure is shown, wherein the hydraulic fracturing pump 300 includes components comprising a wear-resistant and corrosion-resistant steel composition as described herein. Any component of the hydraulic fracturing pump 300 may be made of the wear-resistant and corrosion-resistant steel composition, including but not limited to the crankcase 322, the fluid end assembly 310, the power end assembly 305, the cover 397, and the inlet 399.

[0041] like Figure 3 As shown in FIG. 3 , the hydraulic fracturing pump 300 includes a fluid end assembly 310. The fluid end assembly can be designed to have various configurations. For example, Figure 4A and Figure 4B 1 shows perspective views of different fluid end assembly designs according to certain exemplary embodiments of the present disclosure. Figure 4A As shown in , the fluid end assembly 400 can be non-grooved and have a valve stop 402 design that locks under a ridge in the fluid cylinder opening 495 and is held in place by a rod 404 in the suction cap 497. The non-grooved design can desirably reduce the occurrence of scouring or corrosion that causes the valve to leak through. The non-grooved design can prevent stress cracks that tend to start to form in the grooves. The non-grooved design can allow for increased pumping durations, pressures, and flow rates. Additionally, in some embodiments, the fluid end assembly can have a grooved suction opening. As shown in FIG. Figure 4B As shown in , the fluid end assembly 401 may include a grooved suction opening 491 that utilizes a flutter valve stop 493 that is locked in place by a groove 497 machined into the suction opening 491 . Figure 4A and Figure 4B Any of the components of the fluid end assembly shown in may be made from the wear and corrosion resistant steel composition.

[0042] When compared to a comparable hydraulic fracturing pump component composed of a carbon alloy steel (hereinafter referred to as a carbon alloy pump component), a hydraulic fracturing pump component (e.g., a fluid end component, hereinafter referred to as a wear and corrosion resistant pump component) composed of a wear and corrosion resistant steel composition may have enhanced wear resistance, corrosion resistance, or a combination thereof. In some embodiments, the wear and corrosion resistant pump component (e.g., a fluid end component) may have an extended life compared to the carbon alloy pump component. For example, compared to a carbon alloy pump component exposed to the same conditions, the wear and corrosion resistant pump component may have an average life that is at least 10% longer, at least 25% longer, or at least 50% longer, or at least 100% longer, or at least 125% longer, or at least 150% longer, or at least 200% longer, or at least 250% longer, or at least 300% longer, or at least 350% longer, or at least 400% longer, or at least 450% longer, or at least 500% longer than its carbon alloy counterpart.

[0043] The wear-resistant and corrosion-resistant pump component may exhibit less pitting corrosion (indicative of corrosion) than a carbon alloy pump component exposed to the same conditions. For example, the wear-resistant and corrosion-resistant pump component may exhibit at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50% less pitting corrosion than its carbon alloy steel counterpart.

[0044] The wear and corrosion resistant pump components may exhibit average service life, less pitting corrosion, or a combination thereof, compared to carbon alloy pump components.

[0045] Wear-resistant and corrosion-resistant pump components can have a manufacturing cost lower than that of corresponding pump components made of stainless steel (hereinafter referred to as stainless steel pump components). For example, wear-resistant and corrosion-resistant pump components can have a manufacturing cost that is at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60% lower than that of stainless steel pump components with comparable lifespan and / or wear-resistant and corrosion-resistant properties. In some embodiments, when calculated by cost per average number of working hours, wear-resistant and corrosion-resistant pump components can have a manufacturing cost that is at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 30%, or at least 40%, or at least 50%, or at least 60% lower than that of stainless steel pump components. For example, if a stainless steel pump component has a lifespan of 2,000 working hours at a cost of $3 per pound. The cost of the stainless steel pump component is $0.0015 per hour.

[0046] Those skilled in the art who have the benefit of this disclosure will appreciate that other equivalent or alternative compositions, devices, and disclosed steel components including hydraulic fracturing pump systems with barrier element sand separators may be conceived without departing from the description contained in this application. Therefore, the manner of carrying out the present disclosure as shown and described is to be construed as illustrative only.

[0047] Without departing from the scope of the present disclosure, those skilled in the art may make various changes in the shape, size, quantity and / or arrangement of the parts. For example, the position and quantity of the connecting rods may vary. In some embodiments, the plungers may be interchangeable. In addition, the size of the device and / or system may be scaled up or down to accommodate the needs and / or expectations of the practitioner. According to some embodiments, each disclosed process, system, method and method step may be performed in association with any other disclosed method or method step, and in any order. When the verb "may" appears, it is intended to convey an optional and / or permissible condition, but unless otherwise specified, its use is not intended to imply any lack of operability. When using open terms such as "having" or "including", a person of ordinary skill in the art will recognize that the disclosed features or steps may optionally be combined with additional features or steps. Such options may not be exercised, and in fact, in some embodiments, the disclosed systems, compositions, devices and / or methods may exclude any other features or steps other than the features disclosed in the present application. Unlisted elements, compositions, devices, systems, methods and method steps may be included or excluded as desired or required. Various modifications may be made to methods of making and using the disclosed compositions, devices, and / or systems by those skilled in the art.

[0048] In addition, where a range has been provided, the disclosed endpoints can be processed as exact values ​​and / or approximate values ​​as desired or required by a particular embodiment. Where the endpoints are approximate, the degree of flexibility can vary in proportion to the order of magnitude of the range. For example, on the one hand, the range endpoint of about 50 in the context of a range of about 5 to about 50 may include 50.5, but not 52.5 or 55, and on the other hand, the range endpoint of about 50 in the context of about 0.5 to about 50 may include 55, but not 60 or 75. In addition, in some embodiments, it may be desirable to mix and match range endpoints. In addition, in some embodiments, each of the disclosed figures (e.g., in one or more of the examples, tables, and / or figures) may form the basis of a range (e.g., depicting a value of + / - about 10%, depicting a value of + / - about 50%, depicting a value of + / - about 100%) and / or a range endpoint. With regard to the former, the value of 50 depicted in the examples, tables, and / or figures may form the basis of a range of, for example, about 45 to about 55, about 25 to about 100, and / or about 0 to about 100. Disclosed percentages are by volume unless otherwise indicated.

[0049] All or part of the disclosed steel hydraulic fracturing pump may be constructed and arranged to be disposable, repairable, interchangeable and / or replaceable. These equivalents and alternatives, together with obvious changes and modifications, are intended to be included within the scope of the present disclosure. Therefore, the foregoing disclosure is intended to illustrate but not limit the scope of the present disclosure as shown in the appended claims.

[0050] The title, abstract, background, and headings are provided pursuant to statute and / or for the convenience of the reader. They do not constitute an admission of the scope and content of the prior art, nor do they constitute limitations applicable to all disclosed embodiments.

Claims

1. A wear-resistant and corrosion-resistant steel composition, comprising: A carbon content of from about 0.07% MB to about 0.17% MB; Nickel content from 2% MB to 4.1% MB; a manganese content of from about 0.3% MB to about 0.6% MB; a molybdenum content from about 0.5% MB to about 2.0% MB; Chromium content from about 8% MB to about 10% MB.

2. The wear-resistant and corrosion-resistant steel composition according to claim 1, further comprising at least one of the following: A copper content of less than about 0.5% MB; A sulfur content of less than about 0.02% MB; A silicon content of less than about 1% MB; A phosphorus content of less than about 0.04% MB; A niobium content of from about 0.01% MB to about 0.1% MB; a vanadium content of from about 0.01% MB to about 0.1% MB; A titanium content of from about 0.0001% MB to about 0.1% MB; A nitrogen content of from about 0.02% MB to about 0.07% MB; and Aluminum content of less than about 0.1% MB.

3. A hydraulic fracturing pump comprising a fluid end assembly, the fluid end assembly comprising: a cylinder configured to receive a corresponding plunger from a power end assembly; as well as a suction opening configured to receive the valve body, the valve seat, and the spring; The cylinder body comprises a steel composition, the steel composition comprising: Nickel content from 2% MB to 4.1% MB; a manganese content of from about 0.3% MB to about 0.6% MB; a molybdenum content from about 0.5% MB to about 2.0% MB; Chromium content from about 8% MB to about 10% MB.

4. The hydraulic fracturing pump according to claim 3, wherein the steel composition further comprises at least one of the following: A carbon content of from about 0.07% MB to about 0.17% MB; A copper content of less than about 0.5% MB; A sulfur content of less than about 0.02% MB; A silicon content of less than about 1% MB; A phosphorus content of less than about 0.04% MB; A niobium content of from about 0.01% MB to about 0.1% MB; a vanadium content of from about 0.01% MB to about 0.1% MB; A titanium content of from about 0.0001% MB to about 0.1% MB; A nitrogen content of from about 0.02% MB to about 0.07% MB; and Aluminum content of less than about 0.1% MB.

5. The hydraulic fracturing pump of claim 3, further comprising a suction cap configured to fit into the suction opening and a valve stopper attached to the suction cap by a rod, the valve stopper configured to lock under a ridge in the fluid cylinder opening.

6. The hydraulic fracturing pump of claim 3, wherein the suction opening comprises a groove.

7. A hydraulic fracturing pump, comprising a fluid end assembly and a power end assembly, wherein the power end assembly comprises: Crankshaft; frame; a connecting rod connected to the crankshaft; Crosshead; as well as a plunger connected to the connecting rod; The frame comprises a wear-resistant and corrosion-resistant steel composition, wherein the wear-resistant and corrosion-resistant steel composition comprises: A nickel content of from about 1.75% MB to about 5.75% MB; a manganese content of from about 0.3% MB to about 0.6% MB; a molybdenum content from about 0.5% MB to about 2.0% MB; Chromium content from about 8% MB to about 10% MB.

8. The hydraulic fracturing pump according to claim 7, wherein the wear-resistant and corrosion-resistant steel composition further comprises at least one of the following: A carbon content of from about 0.07% MB to about 0.17% MB; A copper content of less than about 0.5% MB; A sulfur content of less than about 0.02% MB; A silicon content of less than about 1% MB; A niobium content of from about 0.01% MB to about 0.1% MB; a vanadium content of from about 0.01% MB to about 0.1% MB; A titanium content of from about 0.0001% MB to about 0.1% MB; A nitrogen content of from about 0.02% MB to about 0.07% MB; and Aluminum content of less than about 0.1% MB.

9. A hydraulic fracturing pump, comprising a fluid end assembly and a power end assembly, wherein the fluid end assembly comprises: a cylinder configured to receive a corresponding plunger from a power end; as well as A suction opening configured to accommodate a valve body, a valve seat, and a spring; and, The power end assembly comprises: Crankshaft; frame; a connecting rod connected to the crankshaft; Crosshead; and a plunger connected to the connecting rod; The cylinder block and the frame comprise a wear-resistant and corrosion-resistant steel composition, wherein the wear-resistant and corrosion-resistant steel composition comprises: A nickel content of from about 1.75% MB to about 5.75% MB; a manganese content of from about 0.3% MB to about 0.6% MB; a molybdenum content from about 0.5% MB to about 2.0% MB; Chromium content from about 8% MB to about 10% MB.

10. The hydraulic fracturing pump according to claim 9, wherein the wear-resistant and corrosion-resistant steel composition further comprises at least one of the following: A carbon content of from about 0.07% MB to about 0.17% MB; A copper content of less than about 0.5% MB; A sulfur content of less than about 0.02% MB; A silicon content of less than about 1% MB; A phosphorus content of less than about 0.04% MB; A niobium content of from about 0.01% MB to about 0.1% MB; a vanadium content of from about 0.01% MB to about 0.1% MB; A titanium content of from about 0.0001% MB to about 0.1% MB; A nitrogen content of from about 0.02% MB to about 0.07% MB; and Aluminum content of less than about 0.1% MB.

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