News Details

1、 Material Innovation and Structural Optimization: Dual Breakthrough in Oil and Corrosion Resistance Performance

The core competitiveness of API certified DN100 petroleum conveying hose lies in its breakthroughs in material science and precise optimization of structural design. The inner lining layer is made of high nitrile content nitrile rubber (NBR), with an acrylonitrile content of 42% -45%, significantly improving oil resistance and chemical stability. Laboratory test data shows that after soaking in ASTM Oil No.3 standard oil for 168 hours, the volume expansion rate of the material is only 6.8% (ordinary NBR is 15% -20%), and the mass change rate is ≤ 2.5%. It can withstand various hydrocarbon media such as crude oil, diesel, and lubricating oil. In response to the sulfur-containing environment in oil fields, sulfur carriers and anti-aging agent 4020 are added to the rubber formula to reduce the corrosion rate of hydrogen sulfide to 0.008mm/year (ASTM G31 standard), which extends the service life of traditional rubber by three times.

 

The reinforcement layer design adopts a composite structure of "steel wire winding+aramid fiber". Steel wire diameter of 0.3mm, winding density of 95%, providing a burst pressure of ≥ 12MPa; Aramid fibers are cross woven at ± 55 ° to form an impact resistant buffer layer. When subjected to an instantaneous pressure impact of 3MPa, the deformation is controlled within 2.8%. On site testing in a certain oil field showed that the structure has a fatigue life of 800000 cycles (pressure 0-10MPa) under frequent start stop pumping conditions, which is 2.5 times that of ordinary braided hoses. The outer sheath is made of chlorosulfonated polyethylene (CSM) rubber, and the tear strength is increased to 40kN/m by adding nano silica filler, which can resist mechanical damage from oilfield gravel and saline alkali environment.

 

The hose joint has passed API 7K certification and is made of forged carbon steel material (ASTM A105) with a surface hardness of HRC58-62. It is matched with duplex stainless steel (2205) overlay to significantly improve corrosion resistance. The flange sealing surface adopts a concave convex surface+metal wrapped gasket structure. Under a pressure of 10MPa and a high temperature of 150 ℃, the leakage rate is less than 1 × 10 ⁻⁹ Pa · m ³/s, meeting the sealing requirements of API 6A standard Class 3000. The application of a certain oil field gathering station shows that after 18 months of continuous operation, the bolt pre tightening force attenuation rate of the joint is less than 4%, and the maintenance cost is reduced by 60%.

 

2、 Oilfield scene adaptation: customized solutions from oil extraction to gathering and transportation

In the oil extraction process, DN100 hoses need to cope with high water content and high sand volume conditions. A certain oil field adopts surface microstructure treatment technology for lining, forming spiral grooves (pitch 5mm, depth 0.2mm) through laser etching, transforming the solid-liquid two-phase flow state from "bed load" to "suspended load", and maintaining a conveying efficiency of ≥ 90% even when the sand content reaches 5%. The matching sand control joint is equipped with a built-in filter screen (with a pore size of 0.5mm), which can intercept more than 95% of sand particles and avoid pump body wear. In a certain block of Changqing Oilfield, this design reduced the failure rate of pumping units by 45% and reduced annual maintenance costs by 1.2 million yuan.

 

The gathering and transportation system has higher requirements for the temperature and pressure resistance of hoses. For high-temperature crude oil (120 ℃ -150 ℃), graphene thermal conductive filler is added to the inner lining of the hose to increase the thermal conductivity to 0.3W/m · K. Combined with an outer insulation coating (thermal conductivity ≤ 0.05W/m · K), the temperature difference between the inside and outside is ≤ 30 ℃. In a high-temperature well site test in Tarim Oilfield, the hose operated continuously for 30 days at 150 ℃ without softening or cracking. At the same time, the hose adopts a segmented corrugated structure with a small bending radius of R=4D (D is the inner diameter), which can adapt to the complex terrain and spatial limitations of oil fields.

 

For hazardous chemical transportation scenarios, hoses are equipped with multiple safety protections. The outer sheath is coated with flame retardant (oxygen index ≥ 35%) and has passed UL94 V-0 certification; Built in anti-static guide wire (resistance<10 ⁶ Ω) ensures timely dissipation of static electricity generated by medium friction. In an emergency drill at a chemical injection station in a certain oil field, the hose withstood 20 minutes of flame roasting without structural failure during a simulated toluene leakage accident, which saved critical time for emergency response.

 

3、 Quality control and intelligent upgrade: full lifecycle digital management

The production of API certified DN100 hoses follows the dual system standards of API Q1 and ISO 9001, and 15 testing processes are required from raw materials to finished products:

 

Raw material testing: Rubber Mooney viscosity (ML1+4 @ 100 ℃) fluctuation range ± 1.5, steel wire tensile strength ≥ 1960MPa;

Process monitoring: Real time recording of vulcanization temperature ± 0.5 ℃, pressure ± 0.05MPa, winding angle deviation ≤± 0.5 °;

Finished product testing: burst pressure ≥ 18MPa (1.5 times the design pressure), pulse fatigue life ≥ 600000 times (pressure cycle 0-10MPa), low-temperature brittleness (no cracks at -40 ℃).

The digital traceability system realizes full lifecycle management. Each hose is equipped with an RFID chip, which stores over 300 data items such as production batches, inspection reports, installation locations, etc. In the application of a gathering and transportation station in Shengli Oilfield, the system increased inventory turnover by 50% and reduced fault location time from an average of 48 hours to 1.5 hours. In addition, the hose is equipped with built-in fiber optic sensors that can monitor temperature (accuracy ± 0.3 ℃), pressure (accuracy ± 0.05MPa), and deformation (sensitivity 0.005mm) in real time. The data is wirelessly transmitted to the central control platform through LoRa for predictive maintenance.

 

In the future, hose technology will evolve towards intelligence and greenization. Research directions include:

 

Self repairing material: embedded with microcapsule repair agent, automatically filled when microcracks occur, extending service life;

Lightweight design: using carbon fiber reinforced composite materials, reducing weight by 25% without compromising strength;

Energy recovery: Integrating piezoelectric materials on the outer layer of the hose to convert fluid pressure energy into electrical energy, providing power for oilfield IoT devices.

4、 Industry Application Case: Practical Verification from Land to Ocean

Land oil field: A certain oil production plant in Daqing Oilfield uses DN100 hoses to connect the injection well and water distribution room. When transporting polymer oil displacement agents (pH 11-12), the lining of the hose exhibits excellent corrosion resistance. After continuous operation for 2 years, there are no obvious corrosion marks on the inner wall, reducing maintenance costs by 70% compared to traditional steel pipes.

Offshore platform: A certain offshore platform of CNOOC uses this hose to transport crude oil with a water content of 60%. In the environment of salt spray corrosion and wave impact, the carbon steel flange is protected by a combination of cathodic protection and anti-corrosion coating. The corrosion depth is less than 0.1mm for 5 years, which meets the API RP 2A standard.

Shale gas development: The Fuling shale gas field uses DN100 hoses to transport fracturing flowback fluid (with a sand content of 8% -10%), and the lining microstructure design is matched with sand control joints to increase the sand particle pass rate to 98%, avoiding the risk of blockage and increasing the single well fracturing efficiency by 20%.

conclusion

API certified DN100 petroleum conveying hose made of nitrile rubber, which is resistant to oil and corrosion, is a specialized pipeline for oil fields. Through material innovation, structural optimization, and intelligent integration, a technical system suitable for complex working conditions in oil fields has been constructed. From the challenges of high water content and high sand content in the oil extraction process, to the high temperature and high pressure requirements of the gathering and transportation system, and to the safety guarantee of hazardous chemical transportation, its performance has verified the deep integration of API standards and domestic technology. In the future, with the intelligent transformation of oil fields and the increasing demand for green development, such products will play a more critical role in digital oil fields, deep-sea oil and gas development, and other fields, promoting the petroleum equipment industry to move towards efficiency, safety, and sustainability.