Pumps having components including carbon-manganese-chromium (c-MN-CR) steel alloys and related methods

Abstract

Systems and methods described herein may include pumps and pump components including carbon-manganese-chromium (C—Mn—Cr)-based steel alloys for enhanced resistance to wear or corrosion. A pump component may include one or more components formed of a C—Mn—Cr-based ferrous alloy, which may result in enhanced wear or corrosion resistance. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 696,742, filed Sep. 19, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” and U.S. Provisional Application No. 63 / 696,311, filed Sep. 18, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” the disclosures of which are incorporated herein by reference in their entirety.TECHNICAL FIELD

[0002] The present disclosure relates to pumps having components including carbon-manganese-chromium (C—Mn—Cr) steel alloys and related methods and, more particularly, to pumps having components including C—Mn—Cr steel alloys and related methods for reducing wear and / or corrosion of pump components.BACKGROUND

[0003] Pumping systems may be used in a variety of applications, such as industrial applications where pumping systems are used to elevate a working fluid pressure. For example, hydraulic fracturing systems may use high-pressure pumps to increase a fluid pressure of a working fluid (e.g., fracturing fluid, a slurry, etc.) for injection into an underground formation. The fracturing fluid may often include particulates, which are injected into fissures of the formation via high pressure pumps. As the fracturing fluid is withdrawn from the formation, the particulates may remain and “prop” open the fissures, facilitating flow of oil and gas back to a well bore. The fracturing fluid often includes abrasive and / or corrosive materials, and thus, components of the high-pressure pumps may be subjected to these materials, leading to increased wear rates, corrosion, and / or other forms of degradation.

[0004] For at least these reasons, Applicant has recognized that it may be desirable to provide pumps having components that exhibit enhanced resistance to wear, corrosion, and / or other forms of component degradation, resulting in relatively longer service lives that reduce downtime associated with use in pumps. At least some examples described herein may address one or more of the above-noted potential issues, as well as possibly others.SUMMARY

[0005] As referenced above, Applicant has recognized that it may be desirable to provide pumps having components that exhibit enhanced resistance to wear, corrosion, and / or other forms of component degradation, which may result in relatively longer service lives that reduce maintenance and downtime associated with use in pumps. In some embodiments, pumps may include pump components that incorporate therein C—Mn—Cr-based steel alloys for enhanced resistance to wear and / or corrosion.

[0006] In accordance with one or more embodiments, a pump component may include a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %, thereby to enhance one or more of wear resistance or corrosion resistance of the pump component. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy may include or consist essentially of iron (Fe). In some embodiments, the pump component may include a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the pump component may be a cast component. In some embodiments, the pump component may be a forged component. In some embodiments, the C—Mn—Cr-based ferrous alloy may be an austenitic steel, thereby to improve a work hardenability of the pump component. In some embodiments, a combination of the carbon content and the manganese content of the pump component enhances the wear resistance of the pump component, and the chromium content enhances the corrosion resistance of the pump component. In some embodiments, the pump component may be installed within a pump and may exhibit an average mass loss per hour that is less than about 0.6 grams per hour (g / h) during operation of the pump. In some embodiments, during operation of the pump, the average mass loss per hour may be at least 10 % less than an average mass loss per hour of a VP90 steel pump component installed within the pump. In some embodiments, the pump component has an operational life of at least 50 hours when installed within a pump.

[0007] In accordance with some embodiments, a pump may include one or more pump components, and the one or more pump components may include a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %, thereby to enhance one or more of wear resistance or corrosion resistance of the one or more pump components. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the additional one or more alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy may include or consist essentially of iron (Fe). In some embodiments, the one or more pump components may include one or more of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the one or more pump components may include cast components. In some embodiments, the one or more pump components may include forged components. In some embodiments, the pump may include a reciprocating, positive-stroke displacement pump configured to pump a fracturing fluid that may contain one or more of particulates or corrosives. In some embodiments, the one or more pump components may exhibit an average mass loss per hour less than about 0.6 g / h during operation of the pump. In some embodiments, during operation of the pump, the average mass loss per hour may be at least 10 % less than an average mass loss per hour of a VP90 steel pump component installed within the pump. In some embodiments, the one or more pump components may have an operational life of at least 50 hours. In some embodiments, the C—Mn—Cr-based ferrous alloy may be an austenitic steel, thereby to improve a work hardenability of the one or more pump components. In some embodiments, a combination of the carbon content and the manganese content of the one or more pump components enhances the wear resistance of the one or more pump components, and the chromium content enhances the corrosion resistance of the one or more pump components.

[0008] In accordance with some embodiments, a method for enhancing one or more of wear resistance or corrosion resistance of a pump component may include forming the pump component from a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, thereby to enhance the one or more of the wear resistance or the corrosion resistance of the pump component. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy may include or consist essentially of iron (Fe). In some embodiments, the forming of the pump component may include forming one or more of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the forming of the pump component may include casting the pump component from the C—Mn—Cr-based ferrous alloy, the C—Mn—Cr-based ferrous alloy being an austenitic steel, thereby to yield the pump component with sufficient hardness without heat treatment. In some embodiments, the forming of the pump component may include forging the pump component from the C—Mn—Cr-based ferrous alloy, the C—Mn—Cr-based ferrous alloy being an austenitic steel, thereby to yield the pump component with sufficient hardness without heat treatment.

[0009] In accordance with some embodiments, a method for enhancing one or more of wear resistance or corrosion resistance of a pump may include separating a first pump component from the pump. The method further may include replacing the first pump component with a second pump component, and the second pump component may include a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, thereby to enhance the one or more of the wear resistance or the corrosions resistance of the pump. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy further may include or consist essentially of iron (Fe). In some embodiments, the second pump component may include a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the method may include casting the second pump component from the C—Mn—Cr-based ferrous alloy without subsequent heat treatment, thereby to yield the second pump component. In some embodiments, the method may include forging the second pump component from the C—Mn—Cr-based ferrous alloy without subsequent heat treatment, thereby to yield the second pump component. In some embodiments, the pump may include a reciprocating, positive-stroke displacement pump configured to pump a fracturing fluid that contains one or more of particulates or corrosives. In some embodiments, the method further may include, after replacing the first pump component with the second pump component, pumping a fracturing fluid for at least about 50 hours via operation of the pump without replacing the second pump component, and the fracturing fluid may include one or more of particulates or corrosives. In some embodiments, the second pump component may exhibit an average mass loss per hour less than about 0.6 grams per hour (g / h) during the pumping of the fracturing fluid.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure.

[0011] FIG. 1 is a schematic partial cross-sectional view of an example pump assembly, in accordance with embodiments of the present disclosure.

[0012] FIG. 2 is a schematic partial cross-sectional view of an example sleeved pump assembly, in accordance with embodiments of the present disclosure.

[0013] FIG. 3 is a schematic partial cross-sectional view of an example pump assembly including an example packing sleeve of the pump assembly, in accordance with embodiments of the present disclosure.

[0014] FIG. 4 is a schematic partial cross-sectional view of an example pump assembly including an example stuffing box of the pump assembly, in accordance with embodiments of the present disclosure.

[0015] FIG. 5 is a schematic partial cross-sectional view of an example pump assembly including an example suction bore sleeve of the pump assembly, in accordance with embodiments of the present disclosure.

[0016] FIG. 6 is a graphical representation of a wear study comparison conducted for two example valve assemblies manufactured from two different steel alloys, in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0017] The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0018] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,”“including,”“carrying,”“having,”“containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, in particular, to mean “including but not limited to,” unless otherwise stated. Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. The transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to any claims. Use of ordinal terms such as “first,”“second,”“third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish claim elements. When introducing elements of various embodiments of the present disclosure, the articles “a,”“an,”“the,” and “said” are intended to mean that there are one or more of the elements. Any examples of operating parameters and / or environmental conditions are not exclusive of other parameters / conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment,”“an embodiment,”“certain embodiments,” or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms, such as “above,”“below,”“upper,”“lower,”“side,”“front,”“back,” or other terms regarding orientation or direction, are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. Additionally, like reference numerals may be used for like components, but such use is for convenience purposes and not intended to limit the scope of the present disclosure. Moreover, use of terms, such as substantially or approximately may refer to + / -10 percent. The terms “wt. %,”“vol. %,” or “mol. %,” refer to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt. % of component. The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, these terms are defined to be within 10 %, preferably within 5 %, more preferably within 1 %, and most preferably within 0.5 %. As used herein, “C” refers to carbon, “Mn” refers to manganese, “Cr” refers to chromium, “Si” refers to silicon, “P” refers to phosphorus, “S” refers to sulfur, “Al” refers to aluminum, “N” refers to nitrogen, “Ti” refers to titanium, “V” refers to vanadium, “Ni” refers to nickel, “Co” refers to cobalt, “B” refers to boron, “Cu” refers to copper, “Nb” refers to niobium, and “Mo”refers to molybdenum.

[0019] Embodiments of the present disclosure are directed to pumps and pump components (e.g., components of fluid ends) that may include (e.g., may be manufactured from, formed of, and / or fabricated from) a high-manganese steel alloy that may enhance the wear resistance and / or corrosion resistance of such pumps and pump components. More specifically, the high-manganese steel alloy may include a C—Mn—Cr-based ferrous alloy that may be used to produce components of pumps (e.g., fluid ends and / or related components) including, for example, but not limited to: fluid end bodies, plungers, rods, valves, seats, stuffing boxes, packing sleeves, and suction bore sleeves. In addition to offering enhanced strength, at least some embodiments of the C—Mn—Cr-based ferrous alloys disclosed herein contain enhanced amounts of manganese (e.g., from about 10 wt. % to about 30 wt. % Mn). This high-manganese content may facilitate such alloys to undergo severe work hardening after material yielding, which may provide improved wear properties to components formed of these alloys during operation of the pump and / or components thereof.

[0020] Applicant has recognized that high-Mn content alone is insufficient to improve the wear and corrosion resistance of steel alloys for the production of pump components, such as fluid ends. For example, Applicant has experimentally observed that fluid end components fabricated from certain high-manganese steels, including Hadfield steel, which contains about 12 wt. % manganese and about 1.2 wt. % carbon, surprisingly failed to provide increased wear and corrosion resistance during experimental testing. More specifically, it was observed that Hadfield steel surprisingly demonstrated wear at about twice the rate of conventional steel fluid end components. As such, Applicant recognized that it would be desirable to develop different alloying component compositions for use in pump components, such as fluid end components, for example, to achieve improved wear resistance and / or corrosion resistance for pump components.

[0021] The present disclosure is generally directed to pump components including C—Mn—Cr-based ferrous alloys. Embodiments of the C—Mn—Cr-based ferrous alloys may generally include, for example, from about 0.1 wt. % to about 2 wt. % carbon (C), from about 10 wt. % to about 30 wt. % manganese (Mn), and from about 0.1 wt. % to about 20 wt. % chromium (Cr), with optional additional alloying elements, the remainder being iron (Fe). In some embodiments, the optional additional alloying elements are selected from the list including or consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may include, for example, from 0 wt. % to about 5 wt. % of one or more of (e.g., each of) the optional additional alloying elements.

[0022] In some embodiments, the C—Mn—Cr-based ferrous alloys may include austenitic steels, for example, which demonstrate improved work hardenability. Within the composition, Applicant believes that C and Mn may be primarily responsible for providing wear resistance (e.g., increased strength and / or toughness), while Cr may primarily improve corrosion resistance. Within the C—Mn—Cr-based ferrous alloys, the various constituents (including C, Mn, Cr, and Fe) are homogeneously distributed throughout the metal. The alloys may be used to fabricate pump components, including fluid end components, using a casting process or a forging process. Applicant has recognized that, surprisingly, because the alloys include austenitic steels, no heat treatment may be involved or required, for example, after casting or forging, which may desirably increase the efficiency and / or reduce the complexity of manufacturing processes used to produce pump components. In at least some embodiments, pump components including (e.g., manufactured from) the alloys may exhibit enhanced wear resistance and / or corrosion resistance, which may desirably increase the operational life of these components and / or may reduce downtime related to maintenance and / or repair operations of pump components.

[0023] As noted, any metallic component of a pump may be manufactured from the disclosed C—Mn—Cr-based ferrous alloy, and metallic pump components that may typically experience considerable wear and / or corrosion during operation may benefit from being manufactured from the disclosed C—Mn—Cr-based ferrous alloy, according to at least some embodiments. For example, in some embodiments, pumps (e.g., fluid ends) may include one or more components formed of the C—Mn—Cr-based ferrous alloy, and in some embodiments, one or more components of previously manufactured pumps may be retrofitted with replacement components formed of the C—Mn—Cr-based ferrous alloy, according to some embodiments.

[0024] FIGS. 1-5 generally partially illustrate embodiments of pumps, including, for example, fluid ends and components thereof, to provide examples of pump components that may be manufactured from embodiments of the disclosed C—Mn—Cr-based ferrous alloy. It should be appreciated that the pumps and components illustrated and discussed are merely provided as examples, and in some embodiments, any metallic component of a pump or fluid end that experiences wear and / or corrosion during operation may be beneficially manufactured from the disclosed C—Mn—Cr-based ferrous alloy, for example, to extend the operational life of these components, to increase the reliability of these components, and / or to limit or reduce downtime for maintenance or repair of pumps or fluid ends that results from wear and / or corrosion of these components. As will be described herein, systems and methods may be incorporated in various pump or fluid end designs that may include one or more of the systems, in combination or separate from one another. Furthermore, illustration of one of the configurations does not preclude a pump or fluid end that does not include one or more of the configurations, but that does include others.

[0025] FIG. 1 is a schematic partial cross-sectional view of an embodiment of a pump assembly 100, which may also be referred to herein as a reciprocating pump assembly, a displacement pump assembly, or a reciprocating, positive-stroke displacement pump assembly. The pump assembly 100 may be utilized during hydraulic fracturing operations, among other operations, where a working fluid (e.g., a fracturing fluid, slurry, etc.) is drawn into the pump, and energy is added to the working fluid to increase a pressure of the working fluid. Fracturing fluid, by way of example only, may include corrosives and also particulates, such as sand or ceramics, which may be utilized during fracturing operations. These corrosives and particulates may promote or cause erosion within the pump assembly 100, which may undesirably affect fracturing operations and lead to down time to service and / or replace various components. Additionally, the fracturing fluids may include corrosive acids and the like, which may promote degradation of components of the pump assembly 100.

[0026] It should be appreciated that various components of the pump assembly 100 have been removed for clarity with the following discussion. For example, a power end has been removed in favor of focusing on the illustrated fluid end 102 of the pump assembly 100. The power end may include a crankshaft that is driven by an engine or motor to facilitate operations. As shown in FIG. 1, in some embodiments, the fluid end 102 may include a fluid end block 104 that may house one or more components discussed herein. For example, a plunger rod 106 may be driven (e.g., via the crankshaft) to reciprocate within the fluid end block 104 along a plunger axis 108. The plunger rod 106 is positioned within a bore 110 extending through at least a portion of the fluid end block 104. The illustrated bore 110 is arranged along the plunger axis 108 (e.g., a first axis) and intersects a pressure chamber 112, which is arranged along a pressure chamber axis 114 (e.g., a second axis), which may be positioned substantially perpendicular to the plunger axis 108. It should be appreciated that the pump assembly 100 also may include multiple plunger rod and pressure chamber arrangements, which may be referred to as a “plunger throw. ” For example, the pump assembly 100 may be a triplex pump, quadplex pump, quintuplex pump, and the like.

[0027] As shown in FIG. 1, the fluid end block 104 may include an inlet passage 116 and an outlet passage 118, which may be generally coaxial and arranged along the pressure chamber axis 114. For example, the inlet passage 116 and the outlet passage 118 may be axially aligned with respect to one another and / or the pressure chamber 112. In various embodiments, fluid maybe drawn into the pressure chamber 112 via the inlet passage 116, for example, during an intake stroke or suction stroke of the plunger rod 106, and may be driven out of the pressure chamber 112 to an outlet passage 120, for example, during a discharge stroke of the plunger 106.

[0028] As shown in FIG. 1, respective valve assemblies 122, 124 may be arranged within the inlet passage 116 and the outlet passage 118. These valve assemblies 122, 124 may be spring-loaded, for example, as shown in FIG. 1, but it should be appreciated that such an arrangement is for illustrative purposes only. During operation, a differential pressure may drive movement of the valve assemblies 122, 124. For example, as the plunger rod 106 is on the intake or suction stroke, pressure at the inlet passage 116 may overcome the spring force of the valve assembly 122, thereby drawing fluid into the pressure chamber 112. During the discharge stroke, the valve assembly 122 may be driven to a closed position, for example, via a spring associated with the valve assembly 122, while a spring force of the valve assembly 124 is overcome, for example, via pressure produced by the plunger rod 106, thereby forcing the fluid to exit via the outlet passage 120. In one or more embodiments, a sealing element (not shown) may be arranged about the plunger rod 106. In at least one embodiment, one or more shoulders or groove may be formed within the block 104 to receive at least a portion of the sealing elements or components associated with the sealing elements. By way of example, one or more sealing elements may be positioned against a shoulder or groove within a bore and then compressed and / or axially maintained at a location by a sleeve that is secured to the block 104, such as by fasteners, threads, or the like.

[0029] As shown in FIG. 1, in some embodiments, one or more components of the fluid end 102 may be manufactured from the C—Mn—Cr-based ferrous alloy, for example, to improve the wear and / or corrosion resistance of these components. For example, in some embodiments, the fluid end block 104 (also referred to herein as a “fluid end body”) may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, one or more of the valve assemblies 122, 124, including, for example, at least portions of the valves and / or their corresponding valve seats, may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, the plunger rod 106 of the fluid end 102 may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, the fluid end 102 may include other components (e.g., stuffing boxes, packing sleeves, suction bore sleeves, etc.) formed from the C—Mn—Cr-based ferrous alloy.

[0030] FIG. 2 is a schematic partial cross-sectional view of an embodiment of a fluid end 102 of a pump assembly 100. Various embodiments of the present disclosure may further be described with reference to one or more assemblies or systems that may include one or more groups of components, in combination with one another. However, it should be appreciated that an assembly or system may include a singular component or a portion of a group of components. Furthermore, as noted above, various embodiments may remove or add one or more components, which may not be pictured, such as various fasteners, seals, lubricants, and the like.

[0031] As described herein, embodiments of the present disclosure illustrate the fluid end 102 and the plunger 106 extending through the bore 110. During operation of a pump including such a fluid end 102, the plunger 106 reciprocates along the plunger axis 108 to pressurize fluid within the pressure chamber 112. This reciprocating action may result in opening and closing of the inlet and outlet valve assemblies 122, 124. During operation, movement of these components may promote wear and / or component degradation at various component surfaces, for example, due to the abrasive nature of the fluid, which may include particulates, corrosives, and the like. Typical wear areas may include interfaces between movable components, at seal interfaces, threaded interfaces, and contact points between moving components. According to some embodiments, systems and methods described herein may be directed to implementing and / or substituting one or more components that may be subject to such wear or corrosion issues with components formed from C—Mn—Cr-based ferrous alloys that facilitate enhanced wear resistance and corrosion resistance. The different metallurgical properties of these C—Mn—Cr-based components, according to some embodiments, may facilitate less wear, less corrosion, and / or less frequent replacement as compared to components formed from other alloys and / or materials.

[0032] As shown in FIG. 2, in some embodiments, a suction end 200 (e.g., end, suction side, etc.) may include a suction assembly 202 having a suction cover 204 extending into a suction bore 206. In some embodiments, the suction cover 204 may include external threads and may be threaded directly into the fluid end 102, such as to the block 104, which may include corresponding internal threads. In some embodiments, a suction sleeve assembly 208 including a suction bore sleeve 210 may be positioned between at least a portion of the suction cover 204 and the block 104. In such configurations, the suction bore sleeve 210 may be positioned within the suction bore 206 and, in various embodiments, may be retained within the suction bore 206 via, for example, one or more cover retainers 212. As shown in FG. 2, some embodiments further may include a suction ring 214, which may be coupled directly to the block 104 via, for example, one or more ring fasteners 216. In such embodiments, the cover retainer 212 may be arranged within the suction ring 214 and / or may be coupled to one or more threaded components of the suction ring 214. One or more embodiments may include one or more ring shoulders configured to bear against the suction bore sleeve 210, which may secure the suction bore sleeve 210 independently from the suction cover 204. For example, the suction cover 204 may be removed from the suction sleeve assembly 208 without disturbing or otherwise removing the suction bore sleeve 210.

[0033] FIG. 2 further shows a packing sleeve assembly 218 associated with the bore 110 and the plunger 106. In this example embodiment, the packing sleeve assembly 218 may include a packing sleeve 220 positioned within the bore 110. The packing sleeve 220 may be secured within the bore 110 via one or more packing sleeve retainers 222, which may include preloading mechanisms, as will be described herein. In such embodiments, the packing sleeve 220 may be arranged radially outward from the plunger 106 and may be spaced from (e.g., may not be in contact with) the plunger 106. For example, packing components 224 may be positioned between the packing sleeve 220 and the plunger 106. In at least some embodiments, the packing components 224 may not be axially supported via the packing sleeve 220, and one or more rings 226 may be positioned within the bore 110 to axially support the packing components 224.

[0034] As shown in FIG. 2, some embodiments may include one or more sets of valve sleeves 228, which may be positioned to be associated with the inlet and outlet valve assemblies 122, 124. As shown, the valve sleeves 228 may be arranged along the inlet and outlet passages 116, 118, and may be positioned such that one or more components of the valve assemblies 122, 124 engage the valve sleeves 228 during operation, such as a valve member including a strike face configured to be driven against the valve sleeves 228. As described herein, the valve sleeves 228 and / or the valve member may be exposed to high pressure, along with solids-containing fluids and / or corrosive fluids, and as a result, abrasive wear may, over time, degrade (e.g., cause leakage at) the valve assemblies 122, 124, as well as at various other sealing locations. Certain embodiments may incorporate one or more sleeves 210, 220, 228, for example, to protect various components from wear caused by working fluid associated with the fluid end 102.

[0035] One or more components of the fluid end 102 may be manufactured from the C—Mn—Cr-based ferrous alloy, for example, to improve the wear resistance and / or corrosion resistance of these components. For example, in some embodiments, the fluid end block 104 may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, the inlet and outlet valve assemblies 122, 124 may be formed from the disclosed C—Mn—Cr-based ferrous alloy. In some embodiments, the plunger 106 of the fluid end 102 may be formed from the disclosed C—Mn—Cr-based ferrous alloy. In some embodiments, one or more sleeves (e.g., the suction bore sleeve 210, packing sleeve 220, and / or valve sleeves 228) may be formed from the C—Mn—Cr-based ferrous alloy.

[0036] FIGS. 3-5 are schematic partial cross-sectional views of embodiments of a fluid end 102 of a pump assembly 100. For example, FIGS. 3-5 provide alternative views of particular example components that may include (e.g., that may be made of) the C—Mn—Cr-based ferrous alloy, in at least some embodiments. For example, FIG. 3 shows an embodiment of a packing sleeve 220 that may be formed from the disclosed C—Mn—Cr-based ferrous alloy in some embodiments of the fluid end 102. FIG. 4 illustrates an embodiment of a stuffing box 400 that may include (e.g., that may be formed from) the C—Mn—Cr-based ferrous alloy in at least some embodiments of the fluid end 102. FIG. 5 illustrates an embodiment of a suction bore sleeve 210 that may include (e.g., that may be formed from) the C—Mn—Cr-based ferrous alloy in at least some embodiments of the fluid end 102.

[0037] FIG. 6 is a graphical representation of the results of a wear study comparison of two example valve assemblies manufactured from two different steel alloys. The wear study generally involved first weighing the valve assemblies manufactured from different steel alloys, and then installing the valve assemblies into different valve positions (e.g., D1-D4) of a fluid end, before operating the fluid end to pump a fluid containing abrasives and corrosives for a predetermined duration from about seventeen hours to about thirty-one hours. The valve assemblies were then removed from the fluid end and weighed to determine the amount of material that had been lost from the components as a result of wear and / or corrosion over the course of the study.

[0038] The bar graph of FIG. 6 illustrates the mass loss in grams for valve assemblies made from either a Hadfield steel alloy or a VP90 steel alloy. As such, the y-axis of the bar graph indicates mass loss in grams (indicated as Δ(g)) for the valve assemblies during testing. The Hadfield steel valve assemblies had a composition that includes: 1.18 wt. % C, 12.18 wt. % Mn, 0.22 wt. % Si, 0.028 wt. % P, and 0.019 wt. % S, with the remainder being Fe. The VP90 steel valve assemblies had a composition that includes: from 0.17 to 0.23 wt. % C, from 0.60 to 0.95 wt. % Mn, from 0.15 to 0.35 wt. % Si, 0.035 wt. % or less P, 0.04 wt. % or less S, from 0.35 wt. % to 0.65 wt. % Cr, from 0.35 to 0.75 wt. % Ni, and from 0.15 to 0.25 wt. % Mo, with the remainder being Fe. The VP90 steel alloy may also be referred to herein as a carburized carbon steel grade (8620H). The Hadfield steel valve assemblies were evaluated to determine whether high Mn content alone would provide any increase in wear or corrosion resistance relative to the VP90 steel valve assemblies. The VP90 steel is a typical steel than can be used to manufacture fluid end parts and served as a control in this study.

[0039] As shown in FIG. 6, despite the substantial Mn content of the Hadfield steel samples, it was unexpectedly and surprisingly observed that the Hadfield steel valve assemblies demonstrated substantially greater mass loss as a result of wear and corrosion as compared to the VP90 steel valve assemblies. For example, after seventeen hours of operation, the Hadfield steel valve assemblies demonstrated a mass loss of about 22.1 grams (g) and about 26.3 g, while the VP90 steel valve assemblies demonstrated a mass loss of only about 11.5 g and about 14.2 g. Furthermore, over the seventeen hours of operation, the Hadfield steel valve assemblies demonstrated an average mass loss of about 1.4 grams per hour (g / h), while the VP90 steel valve assemblies demonstrated an average mass loss of about 0.8 g / h. As such, after seventeen hours of operation, the Hadfield steel valve assemblies experienced a mass loss that was approximately twice the mass loss of the VP90 steel valve assemblies.

[0040] For the results illustrated in FIG. 6, after thirty-one hours of operation, the Hadfield steel valve assemblies demonstrated a mass loss of about 28.5 grams (g) and about 36.5 g, while the VP90 steel valve assemblies demonstrated a mass loss of only about 14.7 g and about 18.3 g. Furthermore, over the thirty-one hours of operation, the Hadfield steel valve assemblies demonstrated an average mass loss of about 1 g / h, while the VP90 steel valve assemblies demonstrated an average mass loss of about 0.5 g / h. As such, after thirty-one hours of operation, the Hadfield steel valve assemblies also demonstrated a mass loss that was approximately twice the mass loss of the VP90 steel valve assemblies.

[0041] The results shown in FIG. 6 surprisingly indicate that high Mn content alone does not appear to impart a desired level of wear resistance or corrosion resistance. The C—Mn—Cr-based ferrous alloy, according to at least some embodiments described herein, includes different amounts of various alloying components, including C, Mn, and Cr, in which the composition of the alloy is surprisingly believed to facilitate the manufacture of pump components that may demonstrate superior wear resistance and / or corrosion resistance as compared to both Hadfield steel and VP90 steel. For example, without wishing to be bound by theory, Applicant believes that pump components (e.g., fluid end components and / or valve assemblies) manufactured from the C—Mn—Cr-based ferrous alloy, according to at least some embodiments, may exhibit an average mass loss per hour that is substantially lower (e.g., at least about 10 % lower, at least about 25% lower, or at least about 50% lower) than the mass loss observed for the VP90 steel valve assemblies. In some embodiments, without wishing to be bound by theory, Applicant believes that pump components (e.g., fluid end components and / or valve assemblies) manufactured from the C—Mn—Cr-based ferrous alloy, according to at least some embodiments, may exhibit an average mass loss per hour that is less than about 0.6 g / h, less than about 0.55 g / h, less than about 0.5 g / h, less than about 0.45 g / h, less than about 0.4 g / h, or less than about 0.35 g / h. In some embodiments, without wishing to be bound by theory, Applicant believes that fluid end components manufactured from the C—Mn—Cr-based ferrous alloy, according to at least some embodiments, may demonstrate an operational life of at least about fifty hours or more before replacement.

[0042] Having now described some illustrative embodiments of the disclosure, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the disclosure. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and / or configurations will depend on the specific application in which the systems, methods, and / or aspects or techniques of the disclosure are used. Those skilled in the art should also recognize or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments of the disclosure. It is, therefore, to be understood that the embodiments described herein are presented by way of example only and that, within the scope of any appended claims and equivalents thereto, the disclosure may be practiced other than as specifically described.

[0043] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 696,742, filed Sep. 19, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” and U.S. Provisional Application No. 63 / 696,311, filed Sep. 18, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” the disclosures of which are incorporated herein by reference in their entirety.

[0044] Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of this disclosure. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiment, and numerous variations, modifications, and additions further may be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.

Examples

Embodiment Construction

[0017]The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0018]The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or compo...

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 696,742, filed Sep. 19, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” and U.S. Provisional Application No. 63 / 696,311, filed Sep. 18, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” the disclosures of which are incorporated herein by reference in their entirety.TECHNICAL FIELD

[0002] The present disclosure relates to pumps having components including carbon-manganese-chromium (C—Mn—Cr) steel alloys and related methods and, more particularly, to pumps having components including C—Mn—Cr steel alloys and related methods for reducing wear and / or corrosion of pump components.BACKGROUND

[0003] Pumping systems may be used in a variety of applications, such as industrial applications where pumping systems are used to elevate a working fluid pressure. For example, hydraulic fracturing systems may use high-pressure pumps to increase a fluid pressure of a working fluid (e.g., fracturing fluid, a slurry, etc.) for injection into an underground formation. The fracturing fluid may often include particulates, which are injected into fissures of the formation via high pressure pumps. As the fracturing fluid is withdrawn from the formation, the particulates may remain and “prop” open the fissures, facilitating flow of oil and gas back to a well bore. The fracturing fluid often includes abrasive and / or corrosive materials, and thus, components of the high-pressure pumps may be subjected to these materials, leading to increased wear rates, corrosion, and / or other forms of degradation.

[0004] For at least these reasons, Applicant has recognized that it may be desirable to provide pumps having components that exhibit enhanced resistance to wear, corrosion, and / or other forms of component degradation, resulting in relatively longer service lives that reduce downtime associated with use in pumps. At least some examples described herein may address one or more of the above-noted potential issues, as well as possibly others.SUMMARY

[0005] As referenced above, Applicant has recognized that it may be desirable to provide pumps having components that exhibit enhanced resistance to wear, corrosion, and / or other forms of component degradation, which may result in relatively longer service lives that reduce maintenance and downtime associated with use in pumps. In some embodiments, pumps may include pump components that incorporate therein C—Mn—Cr-based steel alloys for enhanced resistance to wear and / or corrosion.

[0006] In accordance with one or more embodiments, a pump component may include a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %, thereby to enhance one or more of wear resistance or corrosion resistance of the pump component. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy may include or consist essentially of iron (Fe). In some embodiments, the pump component may include a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the pump component may be a cast component. In some embodiments, the pump component may be a forged component. In some embodiments, the C—Mn—Cr-based ferrous alloy may be an austenitic steel, thereby to improve a work hardenability of the pump component. In some embodiments, a combination of the carbon content and the manganese content of the pump component enhances the wear resistance of the pump component, and the chromium content enhances the corrosion resistance of the pump component. In some embodiments, the pump component may be installed within a pump and may exhibit an average mass loss per hour that is less than about 0.6 grams per hour (g / h) during operation of the pump. In some embodiments, during operation of the pump, the average mass loss per hour may be at least 10 % less than an average mass loss per hour of a VP90 steel pump component installed within the pump. In some embodiments, the pump component has an operational life of at least 50 hours when installed within a pump.

[0007] In accordance with some embodiments, a pump may include one or more pump components, and the one or more pump components may include a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %, thereby to enhance one or more of wear resistance or corrosion resistance of the one or more pump components. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the additional one or more alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy may include or consist essentially of iron (Fe). In some embodiments, the one or more pump components may include one or more of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the one or more pump components may include cast components. In some embodiments, the one or more pump components may include forged components. In some embodiments, the pump may include a reciprocating, positive-stroke displacement pump configured to pump a fracturing fluid that may contain one or more of particulates or corrosives. In some embodiments, the one or more pump components may exhibit an average mass loss per hour less than about 0.6 g / h during operation of the pump. In some embodiments, during operation of the pump, the average mass loss per hour may be at least 10 % less than an average mass loss per hour of a VP90 steel pump component installed within the pump. In some embodiments, the one or more pump components may have an operational life of at least 50 hours. In some embodiments, the C—Mn—Cr-based ferrous alloy may be an austenitic steel, thereby to improve a work hardenability of the one or more pump components. In some embodiments, a combination of the carbon content and the manganese content of the one or more pump components enhances the wear resistance of the one or more pump components, and the chromium content enhances the corrosion resistance of the one or more pump components.

[0008] In accordance with some embodiments, a method for enhancing one or more of wear resistance or corrosion resistance of a pump component may include forming the pump component from a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, thereby to enhance the one or more of the wear resistance or the corrosion resistance of the pump component. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy may include or consist essentially of iron (Fe). In some embodiments, the forming of the pump component may include forming one or more of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the forming of the pump component may include casting the pump component from the C—Mn—Cr-based ferrous alloy, the C—Mn—Cr-based ferrous alloy being an austenitic steel, thereby to yield the pump component with sufficient hardness without heat treatment. In some embodiments, the forming of the pump component may include forging the pump component from the C—Mn—Cr-based ferrous alloy, the C—Mn—Cr-based ferrous alloy being an austenitic steel, thereby to yield the pump component with sufficient hardness without heat treatment.

[0009] In accordance with some embodiments, a method for enhancing one or more of wear resistance or corrosion resistance of a pump may include separating a first pump component from the pump. The method further may include replacing the first pump component with a second pump component, and the second pump component may include a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, thereby to enhance the one or more of the wear resistance or the corrosions resistance of the pump. The C—Mn—Cr-based ferrous alloy may include a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %, a manganese content ranging from about 10 wt. % to about 30 wt. %, and a chromium content ranging from about 0.1 wt. % to about 20 wt. %. In some embodiments, the C—Mn—Cr-based ferrous alloy further may include one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may range from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements. In some embodiments, a remainder of the C—Mn—Cr-based ferrous alloy further may include or consist essentially of iron (Fe). In some embodiments, the second pump component may include a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve. In some embodiments, the method may include casting the second pump component from the C—Mn—Cr-based ferrous alloy without subsequent heat treatment, thereby to yield the second pump component. In some embodiments, the method may include forging the second pump component from the C—Mn—Cr-based ferrous alloy without subsequent heat treatment, thereby to yield the second pump component. In some embodiments, the pump may include a reciprocating, positive-stroke displacement pump configured to pump a fracturing fluid that contains one or more of particulates or corrosives. In some embodiments, the method further may include, after replacing the first pump component with the second pump component, pumping a fracturing fluid for at least about 50 hours via operation of the pump without replacing the second pump component, and the fracturing fluid may include one or more of particulates or corrosives. In some embodiments, the second pump component may exhibit an average mass loss per hour less than about 0.6 grams per hour (g / h) during the pumping of the fracturing fluid.BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure, and together with the detailed description, serve to explain principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the embodiments discussed herein and the various ways in which they may be practiced. According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate embodiments of the disclosure.

[0011] FIG. 1 is a schematic partial cross-sectional view of an example pump assembly, in accordance with embodiments of the present disclosure.

[0012] FIG. 2 is a schematic partial cross-sectional view of an example sleeved pump assembly, in accordance with embodiments of the present disclosure.

[0013] FIG. 3 is a schematic partial cross-sectional view of an example pump assembly including an example packing sleeve of the pump assembly, in accordance with embodiments of the present disclosure.

[0014] FIG. 4 is a schematic partial cross-sectional view of an example pump assembly including an example stuffing box of the pump assembly, in accordance with embodiments of the present disclosure.

[0015] FIG. 5 is a schematic partial cross-sectional view of an example pump assembly including an example suction bore sleeve of the pump assembly, in accordance with embodiments of the present disclosure.

[0016] FIG. 6 is a graphical representation of a wear study comparison conducted for two example valve assemblies manufactured from two different steel alloys, in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0017] The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0018] The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or components. The terms “comprising,”“including,”“carrying,”“having,”“containing,” and “involving,” whether in the written description or the claims and the like, are open-ended terms, in particular, to mean “including but not limited to,” unless otherwise stated. Thus, the use of such terms is meant to encompass the items listed thereafter, and equivalents thereof, as well as additional items. The transitional phrases “consisting of” and “consisting essentially of,” are closed or semi-closed transitional phrases, respectively, with respect to any claims. Use of ordinal terms such as “first,”“second,”“third,” and the like in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish claim elements. When introducing elements of various embodiments of the present disclosure, the articles “a,”“an,”“the,” and “said” are intended to mean that there are one or more of the elements. Any examples of operating parameters and / or environmental conditions are not exclusive of other parameters / conditions of the disclosed embodiments. Additionally, it should be understood that references to “one embodiment,”“an embodiment,”“certain embodiments,” or “other embodiments” of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Furthermore, reference to terms, such as “above,”“below,”“upper,”“lower,”“side,”“front,”“back,” or other terms regarding orientation or direction, are made with reference to the illustrated embodiments and are not intended to be limiting or exclude other orientations or directions. Additionally, like reference numerals may be used for like components, but such use is for convenience purposes and not intended to limit the scope of the present disclosure. Moreover, use of terms, such as substantially or approximately may refer to + / -10 percent. The terms “wt. %,”“vol. %,” or “mol. %,” refer to a weight, volume, or molar percentage of a component, respectively, based on the total weight, the total volume of material, or total moles, which includes the component. In a non-limiting example, 10 grams of component in 100 grams of the material is 10 wt. % of component. The terms “about” or “approximately” are defined as being close to as understood by one of ordinary skill in the art. In one non-limiting embodiment, these terms are defined to be within 10 %, preferably within 5 %, more preferably within 1 %, and most preferably within 0.5 %. As used herein, “C” refers to carbon, “Mn” refers to manganese, “Cr” refers to chromium, “Si” refers to silicon, “P” refers to phosphorus, “S” refers to sulfur, “Al” refers to aluminum, “N” refers to nitrogen, “Ti” refers to titanium, “V” refers to vanadium, “Ni” refers to nickel, “Co” refers to cobalt, “B” refers to boron, “Cu” refers to copper, “Nb” refers to niobium, and “Mo”refers to molybdenum.

[0019] Embodiments of the present disclosure are directed to pumps and pump components (e.g., components of fluid ends) that may include (e.g., may be manufactured from, formed of, and / or fabricated from) a high-manganese steel alloy that may enhance the wear resistance and / or corrosion resistance of such pumps and pump components. More specifically, the high-manganese steel alloy may include a C—Mn—Cr-based ferrous alloy that may be used to produce components of pumps (e.g., fluid ends and / or related components) including, for example, but not limited to: fluid end bodies, plungers, rods, valves, seats, stuffing boxes, packing sleeves, and suction bore sleeves. In addition to offering enhanced strength, at least some embodiments of the C—Mn—Cr-based ferrous alloys disclosed herein contain enhanced amounts of manganese (e.g., from about 10 wt. % to about 30 wt. % Mn). This high-manganese content may facilitate such alloys to undergo severe work hardening after material yielding, which may provide improved wear properties to components formed of these alloys during operation of the pump and / or components thereof.

[0020] Applicant has recognized that high-Mn content alone is insufficient to improve the wear and corrosion resistance of steel alloys for the production of pump components, such as fluid ends. For example, Applicant has experimentally observed that fluid end components fabricated from certain high-manganese steels, including Hadfield steel, which contains about 12 wt. % manganese and about 1.2 wt. % carbon, surprisingly failed to provide increased wear and corrosion resistance during experimental testing. More specifically, it was observed that Hadfield steel surprisingly demonstrated wear at about twice the rate of conventional steel fluid end components. As such, Applicant recognized that it would be desirable to develop different alloying component compositions for use in pump components, such as fluid end components, for example, to achieve improved wear resistance and / or corrosion resistance for pump components.

[0021] The present disclosure is generally directed to pump components including C—Mn—Cr-based ferrous alloys. Embodiments of the C—Mn—Cr-based ferrous alloys may generally include, for example, from about 0.1 wt. % to about 2 wt. % carbon (C), from about 10 wt. % to about 30 wt. % manganese (Mn), and from about 0.1 wt. % to about 20 wt. % chromium (Cr), with optional additional alloying elements, the remainder being iron (Fe). In some embodiments, the optional additional alloying elements are selected from the list including or consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si). In some embodiments, the C—Mn—Cr-based ferrous alloy may include, for example, from 0 wt. % to about 5 wt. % of one or more of (e.g., each of) the optional additional alloying elements.

[0022] In some embodiments, the C—Mn—Cr-based ferrous alloys may include austenitic steels, for example, which demonstrate improved work hardenability. Within the composition, Applicant believes that C and Mn may be primarily responsible for providing wear resistance (e.g., increased strength and / or toughness), while Cr may primarily improve corrosion resistance. Within the C—Mn—Cr-based ferrous alloys, the various constituents (including C, Mn, Cr, and Fe) are homogeneously distributed throughout the metal. The alloys may be used to fabricate pump components, including fluid end components, using a casting process or a forging process. Applicant has recognized that, surprisingly, because the alloys include austenitic steels, no heat treatment may be involved or required, for example, after casting or forging, which may desirably increase the efficiency and / or reduce the complexity of manufacturing processes used to produce pump components. In at least some embodiments, pump components including (e.g., manufactured from) the alloys may exhibit enhanced wear resistance and / or corrosion resistance, which may desirably increase the operational life of these components and / or may reduce downtime related to maintenance and / or repair operations of pump components.

[0023] As noted, any metallic component of a pump may be manufactured from the disclosed C—Mn—Cr-based ferrous alloy, and metallic pump components that may typically experience considerable wear and / or corrosion during operation may benefit from being manufactured from the disclosed C—Mn—Cr-based ferrous alloy, according to at least some embodiments. For example, in some embodiments, pumps (e.g., fluid ends) may include one or more components formed of the C—Mn—Cr-based ferrous alloy, and in some embodiments, one or more components of previously manufactured pumps may be retrofitted with replacement components formed of the C—Mn—Cr-based ferrous alloy, according to some embodiments.

[0024] FIGS. 1-5 generally partially illustrate embodiments of pumps, including, for example, fluid ends and components thereof, to provide examples of pump components that may be manufactured from embodiments of the disclosed C—Mn—Cr-based ferrous alloy. It should be appreciated that the pumps and components illustrated and discussed are merely provided as examples, and in some embodiments, any metallic component of a pump or fluid end that experiences wear and / or corrosion during operation may be beneficially manufactured from the disclosed C—Mn—Cr-based ferrous alloy, for example, to extend the operational life of these components, to increase the reliability of these components, and / or to limit or reduce downtime for maintenance or repair of pumps or fluid ends that results from wear and / or corrosion of these components. As will be described herein, systems and methods may be incorporated in various pump or fluid end designs that may include one or more of the systems, in combination or separate from one another. Furthermore, illustration of one of the configurations does not preclude a pump or fluid end that does not include one or more of the configurations, but that does include others.

[0025] FIG. 1 is a schematic partial cross-sectional view of an embodiment of a pump assembly 100, which may also be referred to herein as a reciprocating pump assembly, a displacement pump assembly, or a reciprocating, positive-stroke displacement pump assembly. The pump assembly 100 may be utilized during hydraulic fracturing operations, among other operations, where a working fluid (e.g., a fracturing fluid, slurry, etc.) is drawn into the pump, and energy is added to the working fluid to increase a pressure of the working fluid. Fracturing fluid, by way of example only, may include corrosives and also particulates, such as sand or ceramics, which may be utilized during fracturing operations. These corrosives and particulates may promote or cause erosion within the pump assembly 100, which may undesirably affect fracturing operations and lead to down time to service and / or replace various components. Additionally, the fracturing fluids may include corrosive acids and the like, which may promote degradation of components of the pump assembly 100.

[0026] It should be appreciated that various components of the pump assembly 100 have been removed for clarity with the following discussion. For example, a power end has been removed in favor of focusing on the illustrated fluid end 102 of the pump assembly 100. The power end may include a crankshaft that is driven by an engine or motor to facilitate operations. As shown in FIG. 1, in some embodiments, the fluid end 102 may include a fluid end block 104 that may house one or more components discussed herein. For example, a plunger rod 106 may be driven (e.g., via the crankshaft) to reciprocate within the fluid end block 104 along a plunger axis 108. The plunger rod 106 is positioned within a bore 110 extending through at least a portion of the fluid end block 104. The illustrated bore 110 is arranged along the plunger axis 108 (e.g., a first axis) and intersects a pressure chamber 112, which is arranged along a pressure chamber axis 114 (e.g., a second axis), which may be positioned substantially perpendicular to the plunger axis 108. It should be appreciated that the pump assembly 100 also may include multiple plunger rod and pressure chamber arrangements, which may be referred to as a “plunger throw. ” For example, the pump assembly 100 may be a triplex pump, quadplex pump, quintuplex pump, and the like.

[0027] As shown in FIG. 1, the fluid end block 104 may include an inlet passage 116 and an outlet passage 118, which may be generally coaxial and arranged along the pressure chamber axis 114. For example, the inlet passage 116 and the outlet passage 118 may be axially aligned with respect to one another and / or the pressure chamber 112. In various embodiments, fluid maybe drawn into the pressure chamber 112 via the inlet passage 116, for example, during an intake stroke or suction stroke of the plunger rod 106, and may be driven out of the pressure chamber 112 to an outlet passage 120, for example, during a discharge stroke of the plunger 106.

[0028] As shown in FIG. 1, respective valve assemblies 122, 124 may be arranged within the inlet passage 116 and the outlet passage 118. These valve assemblies 122, 124 may be spring-loaded, for example, as shown in FIG. 1, but it should be appreciated that such an arrangement is for illustrative purposes only. During operation, a differential pressure may drive movement of the valve assemblies 122, 124. For example, as the plunger rod 106 is on the intake or suction stroke, pressure at the inlet passage 116 may overcome the spring force of the valve assembly 122, thereby drawing fluid into the pressure chamber 112. During the discharge stroke, the valve assembly 122 may be driven to a closed position, for example, via a spring associated with the valve assembly 122, while a spring force of the valve assembly 124 is overcome, for example, via pressure produced by the plunger rod 106, thereby forcing the fluid to exit via the outlet passage 120. In one or more embodiments, a sealing element (not shown) may be arranged about the plunger rod 106. In at least one embodiment, one or more shoulders or groove may be formed within the block 104 to receive at least a portion of the sealing elements or components associated with the sealing elements. By way of example, one or more sealing elements may be positioned against a shoulder or groove within a bore and then compressed and / or axially maintained at a location by a sleeve that is secured to the block 104, such as by fasteners, threads, or the like.

[0029] As shown in FIG. 1, in some embodiments, one or more components of the fluid end 102 may be manufactured from the C—Mn—Cr-based ferrous alloy, for example, to improve the wear and / or corrosion resistance of these components. For example, in some embodiments, the fluid end block 104 (also referred to herein as a “fluid end body”) may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, one or more of the valve assemblies 122, 124, including, for example, at least portions of the valves and / or their corresponding valve seats, may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, the plunger rod 106 of the fluid end 102 may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, the fluid end 102 may include other components (e.g., stuffing boxes, packing sleeves, suction bore sleeves, etc.) formed from the C—Mn—Cr-based ferrous alloy.

[0030] FIG. 2 is a schematic partial cross-sectional view of an embodiment of a fluid end 102 of a pump assembly 100. Various embodiments of the present disclosure may further be described with reference to one or more assemblies or systems that may include one or more groups of components, in combination with one another. However, it should be appreciated that an assembly or system may include a singular component or a portion of a group of components. Furthermore, as noted above, various embodiments may remove or add one or more components, which may not be pictured, such as various fasteners, seals, lubricants, and the like.

[0031] As described herein, embodiments of the present disclosure illustrate the fluid end 102 and the plunger 106 extending through the bore 110. During operation of a pump including such a fluid end 102, the plunger 106 reciprocates along the plunger axis 108 to pressurize fluid within the pressure chamber 112. This reciprocating action may result in opening and closing of the inlet and outlet valve assemblies 122, 124. During operation, movement of these components may promote wear and / or component degradation at various component surfaces, for example, due to the abrasive nature of the fluid, which may include particulates, corrosives, and the like. Typical wear areas may include interfaces between movable components, at seal interfaces, threaded interfaces, and contact points between moving components. According to some embodiments, systems and methods described herein may be directed to implementing and / or substituting one or more components that may be subject to such wear or corrosion issues with components formed from C—Mn—Cr-based ferrous alloys that facilitate enhanced wear resistance and corrosion resistance. The different metallurgical properties of these C—Mn—Cr-based components, according to some embodiments, may facilitate less wear, less corrosion, and / or less frequent replacement as compared to components formed from other alloys and / or materials.

[0032] As shown in FIG. 2, in some embodiments, a suction end 200 (e.g., end, suction side, etc.) may include a suction assembly 202 having a suction cover 204 extending into a suction bore 206. In some embodiments, the suction cover 204 may include external threads and may be threaded directly into the fluid end 102, such as to the block 104, which may include corresponding internal threads. In some embodiments, a suction sleeve assembly 208 including a suction bore sleeve 210 may be positioned between at least a portion of the suction cover 204 and the block 104. In such configurations, the suction bore sleeve 210 may be positioned within the suction bore 206 and, in various embodiments, may be retained within the suction bore 206 via, for example, one or more cover retainers 212. As shown in FG. 2, some embodiments further may include a suction ring 214, which may be coupled directly to the block 104 via, for example, one or more ring fasteners 216. In such embodiments, the cover retainer 212 may be arranged within the suction ring 214 and / or may be coupled to one or more threaded components of the suction ring 214. One or more embodiments may include one or more ring shoulders configured to bear against the suction bore sleeve 210, which may secure the suction bore sleeve 210 independently from the suction cover 204. For example, the suction cover 204 may be removed from the suction sleeve assembly 208 without disturbing or otherwise removing the suction bore sleeve 210.

[0033] FIG. 2 further shows a packing sleeve assembly 218 associated with the bore 110 and the plunger 106. In this example embodiment, the packing sleeve assembly 218 may include a packing sleeve 220 positioned within the bore 110. The packing sleeve 220 may be secured within the bore 110 via one or more packing sleeve retainers 222, which may include preloading mechanisms, as will be described herein. In such embodiments, the packing sleeve 220 may be arranged radially outward from the plunger 106 and may be spaced from (e.g., may not be in contact with) the plunger 106. For example, packing components 224 may be positioned between the packing sleeve 220 and the plunger 106. In at least some embodiments, the packing components 224 may not be axially supported via the packing sleeve 220, and one or more rings 226 may be positioned within the bore 110 to axially support the packing components 224.

[0034] As shown in FIG. 2, some embodiments may include one or more sets of valve sleeves 228, which may be positioned to be associated with the inlet and outlet valve assemblies 122, 124. As shown, the valve sleeves 228 may be arranged along the inlet and outlet passages 116, 118, and may be positioned such that one or more components of the valve assemblies 122, 124 engage the valve sleeves 228 during operation, such as a valve member including a strike face configured to be driven against the valve sleeves 228. As described herein, the valve sleeves 228 and / or the valve member may be exposed to high pressure, along with solids-containing fluids and / or corrosive fluids, and as a result, abrasive wear may, over time, degrade (e.g., cause leakage at) the valve assemblies 122, 124, as well as at various other sealing locations. Certain embodiments may incorporate one or more sleeves 210, 220, 228, for example, to protect various components from wear caused by working fluid associated with the fluid end 102.

[0035] One or more components of the fluid end 102 may be manufactured from the C—Mn—Cr-based ferrous alloy, for example, to improve the wear resistance and / or corrosion resistance of these components. For example, in some embodiments, the fluid end block 104 may be formed from the C—Mn—Cr-based ferrous alloy. In some embodiments, the inlet and outlet valve assemblies 122, 124 may be formed from the disclosed C—Mn—Cr-based ferrous alloy. In some embodiments, the plunger 106 of the fluid end 102 may be formed from the disclosed C—Mn—Cr-based ferrous alloy. In some embodiments, one or more sleeves (e.g., the suction bore sleeve 210, packing sleeve 220, and / or valve sleeves 228) may be formed from the C—Mn—Cr-based ferrous alloy.

[0036] FIGS. 3-5 are schematic partial cross-sectional views of embodiments of a fluid end 102 of a pump assembly 100. For example, FIGS. 3-5 provide alternative views of particular example components that may include (e.g., that may be made of) the C—Mn—Cr-based ferrous alloy, in at least some embodiments. For example, FIG. 3 shows an embodiment of a packing sleeve 220 that may be formed from the disclosed C—Mn—Cr-based ferrous alloy in some embodiments of the fluid end 102. FIG. 4 illustrates an embodiment of a stuffing box 400 that may include (e.g., that may be formed from) the C—Mn—Cr-based ferrous alloy in at least some embodiments of the fluid end 102. FIG. 5 illustrates an embodiment of a suction bore sleeve 210 that may include (e.g., that may be formed from) the C—Mn—Cr-based ferrous alloy in at least some embodiments of the fluid end 102.

[0037] FIG. 6 is a graphical representation of the results of a wear study comparison of two example valve assemblies manufactured from two different steel alloys. The wear study generally involved first weighing the valve assemblies manufactured from different steel alloys, and then installing the valve assemblies into different valve positions (e.g., D1-D4) of a fluid end, before operating the fluid end to pump a fluid containing abrasives and corrosives for a predetermined duration from about seventeen hours to about thirty-one hours. The valve assemblies were then removed from the fluid end and weighed to determine the amount of material that had been lost from the components as a result of wear and / or corrosion over the course of the study.

[0038] The bar graph of FIG. 6 illustrates the mass loss in grams for valve assemblies made from either a Hadfield steel alloy or a VP90 steel alloy. As such, the y-axis of the bar graph indicates mass loss in grams (indicated as Δ(g)) for the valve assemblies during testing. The Hadfield steel valve assemblies had a composition that includes: 1.18 wt. % C, 12.18 wt. % Mn, 0.22 wt. % Si, 0.028 wt. % P, and 0.019 wt. % S, with the remainder being Fe. The VP90 steel valve assemblies had a composition that includes: from 0.17 to 0.23 wt. % C, from 0.60 to 0.95 wt. % Mn, from 0.15 to 0.35 wt. % Si, 0.035 wt. % or less P, 0.04 wt. % or less S, from 0.35 wt. % to 0.65 wt. % Cr, from 0.35 to 0.75 wt. % Ni, and from 0.15 to 0.25 wt. % Mo, with the remainder being Fe. The VP90 steel alloy may also be referred to herein as a carburized carbon steel grade (8620H). The Hadfield steel valve assemblies were evaluated to determine whether high Mn content alone would provide any increase in wear or corrosion resistance relative to the VP90 steel valve assemblies. The VP90 steel is a typical steel than can be used to manufacture fluid end parts and served as a control in this study.

[0039] As shown in FIG. 6, despite the substantial Mn content of the Hadfield steel samples, it was unexpectedly and surprisingly observed that the Hadfield steel valve assemblies demonstrated substantially greater mass loss as a result of wear and corrosion as compared to the VP90 steel valve assemblies. For example, after seventeen hours of operation, the Hadfield steel valve assemblies demonstrated a mass loss of about 22.1 grams (g) and about 26.3 g, while the VP90 steel valve assemblies demonstrated a mass loss of only about 11.5 g and about 14.2 g. Furthermore, over the seventeen hours of operation, the Hadfield steel valve assemblies demonstrated an average mass loss of about 1.4 grams per hour (g / h), while the VP90 steel valve assemblies demonstrated an average mass loss of about 0.8 g / h. As such, after seventeen hours of operation, the Hadfield steel valve assemblies experienced a mass loss that was approximately twice the mass loss of the VP90 steel valve assemblies.

[0040] For the results illustrated in FIG. 6, after thirty-one hours of operation, the Hadfield steel valve assemblies demonstrated a mass loss of about 28.5 grams (g) and about 36.5 g, while the VP90 steel valve assemblies demonstrated a mass loss of only about 14.7 g and about 18.3 g. Furthermore, over the thirty-one hours of operation, the Hadfield steel valve assemblies demonstrated an average mass loss of about 1 g / h, while the VP90 steel valve assemblies demonstrated an average mass loss of about 0.5 g / h. As such, after thirty-one hours of operation, the Hadfield steel valve assemblies also demonstrated a mass loss that was approximately twice the mass loss of the VP90 steel valve assemblies.

[0041] The results shown in FIG. 6 surprisingly indicate that high Mn content alone does not appear to impart a desired level of wear resistance or corrosion resistance. The C—Mn—Cr-based ferrous alloy, according to at least some embodiments described herein, includes different amounts of various alloying components, including C, Mn, and Cr, in which the composition of the alloy is surprisingly believed to facilitate the manufacture of pump components that may demonstrate superior wear resistance and / or corrosion resistance as compared to both Hadfield steel and VP90 steel. For example, without wishing to be bound by theory, Applicant believes that pump components (e.g., fluid end components and / or valve assemblies) manufactured from the C—Mn—Cr-based ferrous alloy, according to at least some embodiments, may exhibit an average mass loss per hour that is substantially lower (e.g., at least about 10 % lower, at least about 25% lower, or at least about 50% lower) than the mass loss observed for the VP90 steel valve assemblies. In some embodiments, without wishing to be bound by theory, Applicant believes that pump components (e.g., fluid end components and / or valve assemblies) manufactured from the C—Mn—Cr-based ferrous alloy, according to at least some embodiments, may exhibit an average mass loss per hour that is less than about 0.6 g / h, less than about 0.55 g / h, less than about 0.5 g / h, less than about 0.45 g / h, less than about 0.4 g / h, or less than about 0.35 g / h. In some embodiments, without wishing to be bound by theory, Applicant believes that fluid end components manufactured from the C—Mn—Cr-based ferrous alloy, according to at least some embodiments, may demonstrate an operational life of at least about fifty hours or more before replacement.

[0042] Having now described some illustrative embodiments of the disclosure, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the disclosure. In particular, although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. Those skilled in the art should appreciate that the parameters and configurations described herein are exemplary and that actual parameters and / or configurations will depend on the specific application in which the systems, methods, and / or aspects or techniques of the disclosure are used. Those skilled in the art should also recognize or be able to ascertain, using no more than routine experimentation, equivalents to the specific embodiments of the disclosure. It is, therefore, to be understood that the embodiments described herein are presented by way of example only and that, within the scope of any appended claims and equivalents thereto, the disclosure may be practiced other than as specifically described.

[0043] This application claims priority to, and the benefit of U.S. Provisional Application No. 63 / 696,742, filed Sep. 19, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” and U.S. Provisional Application No. 63 / 696,311, filed Sep. 18, 2024, titled “PUMPS HAVING COMPONENTS INCLUDING CARBON-MANGANESE-CHROMIUM (C—MN—CR)STEEL ALLOYS AND RELATED METHODS,” the disclosures of which are incorporated herein by reference in their entirety.

[0044] Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of this disclosure. Accordingly, various features and characteristics as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiment, and numerous variations, modifications, and additions further may be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.

Examples

Embodiment Construction

[0017]The drawings include like numerals to indicate like parts throughout the several views, the following description is provided as an enabling teaching of exemplary embodiments, and those skilled in the relevant art will recognize that many changes may be made to the embodiments described. It also will be apparent that some of the desired benefits of the embodiments described may be obtained by selecting some of the features of the embodiments without utilizing other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations to the embodiments described are possible and may even be desirable in certain circumstances. Thus, the following description is provided as illustrative of the principles of the embodiments and not in limitation thereof.

[0018]The phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein, the term “plurality” refers to two or more items or compo...

Claims

1. A pump component including a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, the C—Mn—Cr-based ferrous alloy comprising:a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %;a manganese content ranging from about 10 wt. % to about 30 wt. %; anda chromium content ranging from about 0.1 wt. % to about 20 wt. %,thereby to enhance one or more of wear resistance or corrosion resistance of the pump component.

2. The pump component of claim 1, wherein the C—Mn—Cr-based ferrous alloy further includes one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si).

3. The pump component of claim 2, wherein the C—Mn—Cr-based ferrous alloy ranges from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements.

4. The pump component of claim 1, wherein a remainder of the C—Mn—Cr-based ferrous alloy includes iron (Fe).

5. The pump component of claim 1, wherein the pump component comprises one of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve.

6. The pump component of claim 1, wherein the pump component is a cast component.

7. The pump component of claim 1, wherein the pump component is a forged component.

8. The pump component of claim 1, wherein the C—Mn—Cr-based ferrous alloy is an austenitic steel, thereby to improve a work hardenability of the pump component.

9. The pump component of claim 1, wherein a combination of the carbon content and the manganese content of the pump component enhances the wear resistance of the pump component, and the chromium content enhances the corrosion resistance of the pump component.

10. The pump component of claim 1, wherein the pump component is installed within a pump and exhibits an average mass loss per hour that is less than about 0.6 grams per hour (g / h) during operation of the pump.

11. The pump component of claim 10, wherein, during operation of the pump, the average mass loss per hour is at least 10 % less than an average mass loss per hour of a VP90 steel pump component installed within the pump.

12. The pump component of claim 1, wherein the pump component has an operational life of at least 50 hours when installed within a pump.

13. A pump including one or more pump components, the one or more pump components including a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, the C—Mn—Cr-based ferrous alloy comprising:a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %;a manganese content ranging from about 10 wt. % to about 30 wt. %; anda chromium content ranging from about 0.1 wt. % to about 20 wt. %,thereby to enhance one or more of wear resistance or corrosion resistance of the one or more pump components.

14. The pump of claim 13, wherein the C—Mn—Cr-based ferrous alloy further includes one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si).

15. The pump of claim 14, wherein the C—Mn—Cr-based ferrous alloy ranges from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements.

16. The pump of claim 13, wherein a remainder of the C—Mn—Cr-based ferrous alloy includes iron (Fe).

17. The pump of claim 13, wherein the one or more pump components comprise one or more of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve.

18. The pump of claim 13, wherein the one or more pump components include cast components.

19. The pump of claim 13, wherein the one or more pump components include forged components.

20. The pump of claim 13, wherein the pump comprises a reciprocating, positive-stroke displacement pump configured to pump a fracturing fluid that contains one or more of particulates or corrosives.

21. The pump of claim 13, wherein the one or more pump components exhibit an average mass loss per hour less than about 0.6 grams per hour (g / h) during operation of the pump.

22. The pump of claim 21, wherein, during operation of the pump, the average mass loss per hour is at least 10 % less than an average mass loss per hour of a VP90 steel pump component installed within the pump.

23. The pump of claim 13, wherein the one or more pump components have an operational life of at least 50 hours.

24. The pump of claim 13, wherein the C—Mn—Cr-based ferrous alloy is an austenitic steel, thereby to improve a work hardenability of the one or more pump components.

25. The pump of claim 13, wherein a combination of the carbon content and the manganese content of the one or more pump components enhances the wear resistance of the one or more pump components, and the chromium content enhances the corrosion resistance of the one or more pump components.

26. A method for enhancing one or more of wear resistance or corrosion resistance of a pump component, the method comprising:forming the pump component from a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy, the C—Mn—Cr-based ferrous alloy comprising:a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %,a manganese content ranging from about 10 wt. % to about 30 wt. %, anda chromium content ranging from about 0.1 wt. % to about 20 wt. %,thereby to enhance the one or more of the wear resistance or the corrosion resistance of the pump component.

27. The method of claim 26, wherein the C—Mn—Cr-based ferrous alloy further includes one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si).

28. The method of claim 27, wherein the C—Mn—Cr-based ferrous alloy ranges from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements.

29. The method of claim 26, wherein a remainder of the C—Mn—Cr-based ferrous alloy includes iron (Fe).

30. The method of claim 26, wherein the forming of the pump component comprises forming one or more of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve.

31. The method of claim 26, wherein the forming of the pump component comprises casting the pump component from the C—Mn—Cr-based ferrous alloy, the C—Mn—Cr-based ferrous alloy being an austenitic steel, thereby to yield the pump component with sufficient hardness without heat treatment.

32. The method of claim 26, wherein the forming of the pump component comprises forging the pump component from the C—Mn—Cr-based ferrous alloy, the C—Mn—Cr-based ferrous alloy being an austenitic steel, thereby to yield the pump component with sufficient hardness without heat treatment.

33. A method for enhancing one or more of wear resistance or corrosion resistance of a pump, the method comprising:separating a first pump component from the pump; andreplacing the first pump component with a second pump component, the second pump component including a carbon-manganese-chromium (C—Mn—Cr)-based ferrous alloy comprising:a carbon content ranging from about 0.1 weight percent (wt. %) to about 2 wt. %,a manganese content ranging from about 10 wt. % to about 30 wt. %, anda chromium content ranging from about 0.1 wt. % to about 20 wt. %,thereby to enhance the one or more of the wear resistance or the corrosion resistance of the pump.

34. The method of claim 33, wherein the C—Mn—Cr-based ferrous alloy further includes one or more additional alloying elements selected from the group consisting of: aluminum (Al), nitrogen (N), titanium (Ti), vanadium (V), nickel (Ni), cobalt (Co), boron (B), copper (Cu), niobium (Nb), and silicon (Si).

35. The method of claim 34, wherein the C—Mn—Cr-based ferrous alloy ranges from about 0 wt. % to about 5 wt. % of each of the one or more additional alloying elements.

36. The method of claim 33, wherein a remainder of the C—Mn—Cr-based ferrous alloy includes iron (Fe).

37. The method of claim 33, wherein the second pump component comprises one of a fluid end body, a plunger, a rod, a valve, a valve seat, a valve sleeve, a stuffing box, a packing sleeve, or a suction bore sleeve.

38. The method of claim 33, further comprising casting the second pump component from the C—Mn—Cr-based ferrous alloy without subsequent heat treatment, thereby to yield the second pump component.

39. The method of claim 33, further comprising forging the second pump component from the C—Mn—Cr-based ferrous alloy without subsequent heat treatment, thereby to yield the second pump component.

40. The method of claim 33, wherein the pump comprises a reciprocating, positive-stroke displacement pump configured to pump a fracturing fluid that contains one or more of particulates or corrosives.

41. The method of claim 33, further comprising, after replacing the first pump component with the second pump component, pumping a fracturing fluid for at least about 50 hours via operation of the pump without replacing the second pump component, the fracturing fluid comprising one or more of particulates or corrosives.

42. The method of claim 41, wherein the second pump component exhibits an average mass loss per hour less than about 0.6 grams per hour (g / h) during the pumping of the fracturing fluid.

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