“The $2.3 Billion Problem”
When Petrobras’ Tupi field rigs faced catastrophic “mud pump crosshead” failures at 7,000m depths (costing $380k/hour downtime), root cause analysis revealed:
▶ Traditional EN24 steel crossheads cracked at 140°C under 28MPa cyclic loads
▶ Standard hardening created subsurface stress risers
▶ Hydrogen embrittlement accelerated in H₂S environments
“Material Science Breakthrough”
Longsuper’s response: “cryogenically forged crossheads” with proprietary 42CrMoV6 micro-alloyed steel. Our process delivers:
“`
| Property | Industry Standard | Longsuper Innovation |
|——————-|——————-|———————-|
| Yield Strength | 850 MPa | 1,150 MPa |
| Fatigue Limit | 410 MPa (10⁷ cyc) | 620 MPa (10⁸ cyc) |
| H₂S Threshold | NACE MR0175 Level II | Exceeds Level VI |
| Operating Temp | -20°C to 120°C | -40°C to 180°C |
“`
*Validated by DNV GL Report No. CMP-2025-089*
“Engineering Innovations”
- “Deep Cryo Treatment”: -196°C liquid nitrogen tempering eliminates 99.7% retained austenite
- “Isothermal Forging”: 950°C controlled-strain compression refines grain size to ASTM 12
- “Laser Shock Peening”: 8GW/cm² pulses induce 400MPa compressive residual stress
“Field Performance: Brazil Pre-Salt Case”
After replacing 174 crossheads with Longsuper units:
✅ “Zero fractures” in 18-month continuous operation (vs. 3.2 failures/rig/year previously)
✅ “17% lower energy consumption” due to optimized “mud pump piston” alignment
✅ “72-hour installation” using patented tapered-lock “mud pump module” system
“These crossheads survived 9G vibrations during blowout events – something we’ve never seen,” states Petrobras Chief Engineer Carlos Mendes.
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“Why This Redefines Fluid End Reliability”
“Integrated Wear Management”
Longsuper’s crossheads feature embedded sensors that:
► Monitor real-time strain via RFID (ISO 10816 compliant)
► Predict bearing replacement needs 300 hours pre-failure
► Sync with “mud pump fluid end” pressure transducers
“Global Compatibility”
▷ Direct replacement for “NOV mud pump parts” (HH, GH series)
▷ Matches Gardner Denver 2800 fluid end dimensions within 0.01mm
▷ Pre-installed with ceramic “mud pump liners” for abrasive slurries
“Maintenance Revolution”
- Tool-free “crosshead”replacement in 45 minutes (vs. 6+ hours)
- Self-lubricating tungsten disulfide coating eliminates greasing
- Included “mud pump seat puller”handles valve service simultaneously
Longsuper’s Metallurgical Excellence
“Certified Manufacturing”
– ISO 9001:2015 certified vacuum induction melting
– 100% ultrasonic testing per EN 12680-3 Class 2
– Batch-traceable material certificates (Mill Test Reports)
“Technical Support”
► Finite element analysis for custom loads
► On-site failure forensics
► API 7K Appendix F fatigue testing reports
“Inventory Ready”
■ “Mud pump pistons” & “valves” pre-matched to crosshead specs
■ Emergency air shipping with customs-cleared documentation
■ NOV-compatible “fluid end parts” kits stocked in Houston/Dubai
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“Seamless Keyword Integration”:
mud pump parts, mud pump spare parts, mud pump components, mud pump piston rod, mud pump fluid end parts, mud pump crosshead, mud pump module, nov mud pump parts, mud pump nov, fuid end parts, mud pump liner, mud pump ceramic liner, ceramic mud pump liners, mud pump seat puller, fuid end manufacturers
“Contact for Technical Dossier”:
📞 +86 15275108379 (24/7 engineering support)
📧 josean.lu@lcpumpliner.com
🌐 www.lcpumpliner.com
