Crude Oil Pump Production Process Flow

1. Mechanical Processing

The main mechanical processing equipment includes lathes, drilling machines, boring mills, grinders, gear hobbing machines, etc.

Reducer Box Manufacturing Process Flow:

  • Based on the company’s production plan, procure raw materials and externally purchased/co-manufactured components. After quality inspection, store the components. Raw materials are inspected and stored, then processed according to production needs. Finished products are stored after passing quality inspection.
  • All externally purchased/co-manufactured components and self-produced finished parts are issued from the warehouse and transferred to the assembly workshop for assembly. After assembly completion and passing quality inspection, the products are stored.

Mechanical Processing Production Flow for Product Components and Accessories:

  • According to the company’s production plan, procure raw materials. After quality inspection, store the materials. Raw materials are issued from the warehouse and transferred to the mechanical processing workshop for machining. After machining completion and passing quality inspection, the parts are stored for shipping or for subsequent production processes.

See Figure 2-1 for the reducer box production process flow.

  1. Inspection and Assembly
  2. Raw Material Mechanical Processing
  3. Inspection and Storage of Co-Manufactured Components

Figure 2-1: Reducer Box Production Process Flow Chart

2. Oil Casing Processing

Oil casing processing includes oil casing and coupling production.

Oil Casing Production Process Flow:

  • Tubular materials are inspected using a magnetic flux leakage tester. Qualified products are machined using CNC tube threading machines. After inspection, they are stored for future use.
  • Coupling blanks are machined for threading using CNC tube threading machines. After inspection, they are tested using a magnetic flux leakage tester. Qualified couplings are marked and connected to tubular materials using a coupling machine. After inspection, the assemblies are marked using a marking machine. They undergo hydrostatic testing (water pressure ranges from 0 to 70 MPa, depending on the tube diameter), length measurement, and weighing. Protective rings are installed on both ends of the tubes. An automatic painting machine applies anti-corrosion epoxy asphalt paint uniformly to the outer surface of the tubes. After marking, the final inspection is conducted, followed by packaging and storage in the product storage area.

See Figure 2-2 for the oil casing production process flow.

  1. Tubular Materials Non-Destructive Testing, Threading, Inspection
  2. Coupling
  3. Coupling Blanks Threading, Inspection, Marking
  4. Coupling Connection, Inspection, Marking
  5. Hydrostatic Testing, Length Measurement, Weighing, Protective Rings Installation, Anti-Corrosion Painting, Marking, Final Inspection, Packaging

Figure 2-2: Oil Casing Processing Production Process Flow Chart

3. Crude Oil Pump Manufacturing

Main production equipment includes CNC cutting machines, profile cutting machines, saws, assembly welding stands, electric welding machines, etc.

Crude Oil Pump Production Process Flow:

  • According to the company’s production plan, procure raw materials and externally purchased/co-manufactured components. After quality inspection, store the components. Raw materials are issued from the warehouse and transferred to the mechanical processing process. After machining completion, transfer to the riveting/welding assembly station for welding and assembly. Externally purchased/co-manufactured components are issued from the warehouse and transferred to the assembly process. After whole machine assembly completion, conduct whole machine testing. Store the machine after passing quality inspection.

See Figure 2-3 for the crude oil pump production process flow.

  1. Riveting/Welding Assembly, Assembly
  2. Raw Material Inspection, Mechanical Processing
  3. Inspection and Storage of Co-Manufactured Components

Figure 2-3: Crude Oil Pump Production Process Flow Chart

4. Pump Rod Manufacturing

Pump Rod Production Process Flow:

  1. Rod Material Inspection
  2. Straightening, Magnetic Particle Inspection, Upsetting
  3. Cleaning and Friction Welding
    • First-level friction pressure: 2.2 MPa, time: 10 seconds;
    • Second-level friction pressure: 5.5 MPa, time: 14 seconds;
    • Upsetting pressure: 10.5 MPa.
  4. Heat Treatment
    • Quenching heat treatment parameters: quenching temperature: 900°C ± 10%, heating time: 100 seconds; holding time: 60 seconds; cooling using circulating water.
    • Recommended tempering heat treatment parameters: tempering temperature: 625°C ± 10%, heating time: 120 seconds; holding time: 180 seconds.
  5. Straightening
  6. Shot Blasting
  7. Head Machining and Assembly
  8. Coating and Corrosion Protection, Inspection, Packaging, Storage

See Figure 2-4 for the pump rod production process flow.

  1. Rod Body Inspection
  2. Magnetic Particle Inspection, Upsetting, Straightening
  3. Friction Welding, Heat Treatment
  4. Straightening
  5. Shot Blasting
  6. Head Machining and Assembly
  7. Coating and Corrosion Protection, Inspection, Packaging, Storage

Figure 2-4: Pump Rod Production Process Flow Chart

5. Continuous Oil Tubing

The main components of continuous oil tubing engineering equipment are primarily outsourced or subcontracted. Within the factory premises, the primary tasks include component inspection, assembly, whole vehicle assembly, inspection, and testing. See Figure 2-5 for the specific production process flow.

  1. Chassis Outsourcing
  2. Design
  3. Import or Outsourced Manufacturing of Hydraulic/Electric Control System, Welding Equipment
  4. Component Inspection
  5. Assembly
  6. Inspection and Testing
  7. Storage and Whole Vehicle Testing
  8. Whole Vehicle Assembly and Inspection

Figure 2-5: Continuous Oil Tubing Engineering Equipment Production Process Flow Chart

6. Specialized Pipe Industry

Specialized pipe industry mainly produces two types of composite pipes: fiberglass-reinforced plastic (FRP) composite pipes and epoxy fiberglass composite pipes, primarily used for surface transportation and downhole tubing in oilfields.

FRP Composite Pipe Main Process Flow:

  • Mix PVC and coloring agents in a mixer, then send to the extruder to produce PVC pipes. After cooling, cut the PVC pipes to the required length using a cutter. Fix the cut PVC pipes on the winding machine.
  • Weigh a certain amount of polyester resin and methyl ethyl ketone peroxide, mix them in a mixer, and transport the mixture to the polyester reservoir. Pass the glass fibers through the polyester reservoir to coat them with polyester resin. Wind the coated glass fibers uniformly around the PVC pipe to form an FRP composite pipe. Cut the pipe to the required length, grind the conical ends using a cone grinder, install the ends manually, and perform a 100% hydrostatic test (pressure: 6–7 MPa). Pack the qualified products and store them in the product storage area.

Process flow: Raw Materials → Mixing → PVC Pipe Extrusion → Inner Liner Winding → Cutting Flat Ends → Grinding Conical Ends → Installing Ends → Flaring → Hydrostatic Testing → Packing → Storage

Epoxy Fiberglass Composite Pipe Main Process Flow:

  • Weigh a certain amount of epoxy resin and curing agent (methylnaltrexone) and mix them in a mixer. Transport the mixture to the epoxy resin reservoir. Pass the glass fibers through the epoxy resin reservoir to coat them with epoxy resin. Wind the coated glass fibers around the rotating mold to the required thickness to form an epoxy fiberglass pipe. Introduce steam into the sealed mold to cure the pipe. Remove the mold and transport the cured pipe to the machining area for threading using a CNC lathe. Perform a 100% hydrostatic test. Pack the qualified products and store them in the product storage area.

Process flow: Raw Materials → Mixing → Glass Fiber Winding → Curing and Demolding → Internal/External Threading → Hydrostatic Testing → Packing → Storage

7. Electrical Control Systems

The production process for drilling rigs, explosion-proof power supply, and screw pump electrical control systems starts with designing the electrical and mechanical systems based on customer needs. Procure the main electrical and mechanical components according to the design requirements. Some components are machined in-house. Then, assemble the electrical components. After assembly completion, conduct inspections and electrical testing. Deliver the system after passing the inspection.

Process flow: Electrical and Mechanical Design → Partial Mechanical Component Machining → Component Procurement and Fabrication → Electrical Assembly → Inspection and Testing → On-Site Commissioning → Delivery