News Details

1、 Material and Structural Innovation: Collaborative Upgrade of Steel Skeleton Reinforcement and Wear Resistance Performance

The core competitiveness of industrial grade APIDN150 drilling hoses lies in the deep integration of its steel skeleton reinforcement technology and wear-resistant materials. The inner lining layer is made of a composite material of hydrogenated nitrile rubber (HNBR) and polytetrafluoroethylene (PTFE). The former provides excellent oil resistance (can withstand API standard drilling fluid containing 30% barite powder), while the latter reduces the friction coefficient to 0.04, significantly reducing the erosion of mud on the pipe wall. Laboratory tests have shown that the wear rate of the composite liner when transporting drilling fluid with a sand content of 12% is only 0.015mm per thousand hours, which is five times longer than the service life of traditional chloroprene rubber liners.

 

The steel skeleton design adopts a composite structure of "double helix high carbon steel wire+stainless steel woven mesh". High carbon steel wire (diameter 0.4mm, tensile strength ≥ 2100MPa) is wound in a double helix form with a pitch of 15mm, providing a burst pressure of ≥ 20MPa; Stainless steel woven mesh (made of 304 material with a weaving density of 92%) serves as a secondary reinforcement layer, which can resist external sharp object impacts. In a test conducted on a platform in the South China Sea, the deformation of the hose was controlled within 2.2% when subjected to an instantaneous pressure impact of 5MPa, and there was no structural damage. The outer sheath is made of chlorosulfonated polyethylene (CSM) rubber, and by adding silicon carbide (SiC) wear-resistant particles, the Akron wear is reduced to 0.05cm ³/1.61km, which can resist salt spray corrosion and mechanical wear in marine environments.

 

The joint design is certified by both API 7K and DNV GL, using carbon steel forged flanges (ASTM A694 F65) with a surface hardness of HRC55-60. It is paired with metal wound gaskets and O-rings for dual sealing. Under a pressure of 15MPa and a high temperature of 120 ℃, the leakage rate is less than 5 × 10 ⁻¹⁰ Pa · m ³/s, meeting the sealing requirements of API 6A standard Class 6000. The application of a deep-sea drilling platform shows that after 12 months of continuous operation, the bolt pre tightening force attenuation rate of the joint is less than 3%, and the maintenance cost is reduced by 65%.

 

2、 Ocean platform full scene adaptation: customized solutions from drilling to oil extraction

1. High pressure wear-resistant requirements in drilling operations

In deep-sea drilling operations, DN150 hoses need to withstand the impact of high-pressure (10-15MPa) and high flow rate (8-12m/s) drilling fluid. The surface of the hose lining is etched with laser technology to form diamond shaped pits (with a side length of 1mm and a depth of 0.15mm), transforming the fluid from laminar to turbulent flow and reducing the risk of mud deposition. The matching wear-resistant joint is equipped with a ceramic liner (hardness HRA90), which can resist direct erosion of hard particles in drilling fluid. In a drilling operation on a certain platform in Bohai, this design extended the service life of the hose from 3 months of traditional products to 18 months, and reduced the annual replacement cost by 80%.

 

2. Corrosion resistance and fatigue resistance challenges in oil production gathering and transportation

In response to the corrosion of sulfur-containing crude oil (H ₂ S concentration 50-200ppm) and seawater in oil extraction conditions, the surface of the hose steel skeleton is treated with galvanized nickel alloy (thickness ≥ 25 μ m), combined with corrosion inhibitor microcapsules in the outer sheath, to reduce the corrosion rate to 0.005mm/year. At the same time, the hose adopts a segmented corrugated structure (with a corrugated spacing of 200mm) and a small bending radius of R=5D, which can adapt to the limited space and complex pipeline layout of offshore platforms. In a test on a certain oil production platform in the South China Sea, the hose did not show inner wall corrosion or outer layer cracking when continuously transporting water containing crude oil (with a water content of 70%), and its operational stability was improved by 40%.

 

3. Rapid deployment and safety under emergency conditions

To cope with sudden leaks on offshore platforms, hoses are equipped with quick couplings (connection time ≤ 3 minutes) and double-layer explosion-proof structures. When the inner hose ruptures, the outer explosion-proof sleeve (Kevlar fiber reinforced) can withstand a pressure of 5MPa to buy time for repair. In addition, the hose is equipped with built-in fiber optic sensors that can monitor temperature (accuracy ± 0.2 ℃), pressure (accuracy ± 0.03MPa), and deformation (sensitivity 0.003mm) in real time, and the data is transmitted to the land control center via satellite. In an emergency drill on a certain platform, the system provided a 2-hour advance warning of the risk of local wear and tear exceeding the limit, avoiding an unplanned shutdown accident.

 

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

1. Strict production testing system

The production of APIDN150 hoses follows the dual system standards of API Q1 and ISO 9001, and 18 testing processes are required from raw materials to finished products:

 

Raw material testing: Rubber Mooney viscosity (ML1+4 @ 100 ℃) fluctuation range ± 1, steel wire tensile strength ≥ 2100MPa;

Process monitoring: Real time recording of vulcanization temperature ± 0.3 ℃, pressure ± 0.03MPa, and deviation of steel skeleton winding angle ≤ ± 0.3 °;

Finished product testing: burst pressure ≥ 30MPa (1.5 times the design pressure), pulse fatigue life ≥ 1 million times (pressure cycle 0-15MPa), low-temperature brittleness (-50 ℃ without cracks).

2. Digital traceability and predictive maintenance

Each hose is equipped with an RFID chip and QR code, storing over 500 data items such as production batches, inspection reports, installation locations, etc. In the application of a certain ocean engineering company, the system increased inventory turnover by 60% and reduced fault location time from an average of 72 hours to 1 hour. At the same time, the MEMS sensors embedded in the hose can monitor vibration (frequency range 0-1kHz), acceleration (± 50g), and displacement (accuracy ± 0.1mm), predict remaining life through machine learning algorithms, and improve maintenance plan accuracy by 70%.

 

3. Trends in Green and Intelligent Technologies

In the future, hose technology will evolve in the following directions:

 

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

Lightweight design: using titanium alloy skeleton and carbon fiber reinforced composite material, reducing weight by 30% without compromising strength;

Energy self-sufficiency: Integrating flexible solar films on the outer layer of the hose to power sensors and communication modules, reducing platform energy consumption.

4、 Industry Application Case: Practical Verification from Shallow Sea to Deep Sea

Shallow water platform: A shallow water platform of CNOOC uses DN150 hoses to connect drilling pumps and risers. When transporting drilling fluid containing drilling cuttings (density 1.8g/cm ³), the wear resistance of the hose lining is excellent. After continuous operation for one year, the inner wall wear depth is less than 0.5mm, reducing maintenance frequency by 90% compared to traditional products.

Deep sea platform: A Brazilian ultra deep water platform (at a depth of 2200 meters) uses this hose to transport high-temperature and high-pressure well control fluids (at a temperature of 180 ℃ and a pressure of 20MPa). The steel skeleton reinforcement structure is combined with high-temperature resistant rubber to achieve zero leakage operation, and the efficiency of single well operations is increased by 25%.

Polar drilling: A Norwegian Arctic drilling platform tested the low-temperature performance of flexible hoses in an environment of -40 ℃. The outer sheath's resistance to brittle cracking met the requirements, and the steel frame showed no cold brittleness, providing technical support for polar oil and gas development.

conclusion

The industrial grade APIDN150 drilling hose steel skeleton reinforced wear-resistant marine platform pipeline has constructed a technical system that adapts to complex marine conditions through material innovation, structural optimization, and intelligent integration. From the high-pressure wear-resistant requirements of drilling operations, to the corrosion and fatigue resistance challenges of oil production and gathering, to the rapid deployment and safety of emergency conditions, its performance has verified the deep integration of API standards and domestic technology. In the future, as offshore oil and gas development evolves towards deepwater, polar, and intelligent directions, such products will play a more critical role in improving operational efficiency, reducing maintenance costs, and ensuring safe production, driving the marine engineering equipment industry to a higher level.