During a recent outage we were able to record how the castings stood up to a year of service. The media being pumped was hot water, bitumen, quartz/feldspar sand mixture with 5” minus rocks.
Wear on the switching wye leg and the downstream leg was negligible, the only recorded wear was in the 5-7 o’clock position at the bottom of the upstream spool.
The customer was very pleased with the finding and as a result has not scheduled another inspection for a year.
These spools are used in Hydrotransport of bitumen and ore, similar CCO (chromium carbide overlay) spools are used downstream in tailings. Typically the CCO will require weld repair after six-week service, if no weld repair takes place the spool will often wear through the pipe after nine weeks.
The customer has seen a dramatic increase in wear life and decreased cost of maintenance and lost production.
As the result the customer is looking for other application to utilize white iron in their facility.
Lateral showing legs
Interior of lateral
Wall thickness after one year of service
5-7 o’clock position at the bottom of the upstream spool
A major Oil Sands facility replaced CCO (chromium carbide overlay) 28″wye and lateral piping assemblies with bi metallic piping from Penticton Foundry.
The mine found that the CCO wyes and laterals that transported bitumen in their hydrotransport piping was a very high wear component. Outages and maintenance downtime were a major cost concern.
We proposed an assembly that would have a solid high chrome white iron casting inserted into a steel pressure boundary shell.
There are a number of advantages to the design. One of the major issues was increased wear life. The minimum wall of the casting was 1.25″ but in high wear areas (crotch of the wye and lateral) we increased the casting thickness to as much as 8″.
The other advantage was rebuild, the assembly is designed to have the casting replaced once the liner has reached its maximum service life. This is a major cost saving to our customer as the pressure shell can be reused.
Wye pipe for bitumen transport
Bi-metallic wyes and laterals for bitumen transport installed
Published on Thursday, March 1st, 2012 and filed under New Products.
7000 lb Solid Chrome Elbow made by Penticton Foundry
Penticton Foundry recently shipped a 60 degree solid chrome elbow to a mine in the Alberta Oil Sands.
The elbow was specifically made to increase production from the customer’s cyclone launders. The elbow was designed to have double the wall thickness on the outside radius where the majority of wear takes place.
This customer expects at least four times the life from the cast elbow over the CCO fabrication it is replacing.
Penticton Foundry supplies ASTM A532 chrome iron fracking components that outlast fabricated components
The blender tubs, liner and mixing impellers used in the fracking process are ASTM A532 CLIII A (or 3A) chrome iron castings. The cast components usually last at least 6 times longer than T1 fabricated plate overlayed with CCO. (chromium carbide overlay)
The impeller is cast, machined and balanced. Hardness is >550 BHN (55RC)
One of our customers trialed a sample ASTM A532 chrome iron cast impeller. It was finally replaced after pumping 50,000 tons (100 million pounds) of proppant. The prior steel impellers wore out after only 8,000 tons.
An oil sands customer had a problem with extreme high wear on pump spools in the hydrotransport line for oil sands.
We worked with the customer to design a reusable spool that houses a 1 ¼” thick wall 27% chrome iron liner >650 Brinnell.
Not only will the chrome iron liner wear longer than the CCO, the fabrication is reusable. Once the liners wear out, the fabrications will be shipped back to Penticton to have another liner installed and put back into service.
Prior to using our insert spool the customer used fabricated spools made from chromium carbide overlay plate (CCO). The customer found the CCO did not have the wear life required and that the cost of fabricating CCO was prohibitive.