HHF1300.1600鉆井泵用戶手冊(cè)(新版)EP

1、table of contentsforword11 safety warning22 brief introduction22.1 use and application22.2 referenced tandards22.3 brief working principle22.4 technical parameters32.5 performance parameters43 general configuration43.1 general structure43.2 overall dimensions54 introductions of main components64.1 p

2、ower end64.2 fluid end85 lubrication115.1 splashing lubrication115.2 pressure lubrication126 unitized drilling pump166.1 diesel engine direct driven drilling pump166.2 compound transmission driven drilling pump166.3 motor driven drilling pump167 mud suction system167.1 suction pipeline (manifold)167

3、.2 suction desurger167.3 suction filter177.4 valves on suction line178 mud discharge system178.1 accessory manifold178.2 relief valve178.3 pressure release line178.4 discharge filter179 drilling pump installation179.1 installation foundation179.2 installation1810 operation and maintenance2010.1 runn

4、ing2110.2 maintenance2311 troubles and troubleshooting2611.1 troubles and troubleshooting for fluid end2611.2 troubles and troubleshooting for power end2712 drilling pump servicing2812.1 fluid power end dismantling 2812.2 main parts assembling of fluid end3012.3 dismantling of power end 3212.4 assem

5、bling the main parts of power end3312.5 replacement of air bag of discharge dampener3713 special tools along with hhf-1300/1600 drilling pump delivery 3814 spare parts along with hhf-1300/1600 drilling pump delivery3915 recommended spare parts list4016 configuration content of a single pump42users m

6、anual of hhf-1300/1600 drilling pump forewordhhf-1300/1600 drilling pump is one of the most important equipments for rig for middle and deep depth well drilling. the parts and components of this drilling pump are designed and manufactured according to api 7k and relevant standards. it can satisfy th

7、e technological requirements for well drilling. this manual generally describes the technical specifications and performance parameters, drive principle, configuration, installation and adjustment, operation and maintenance, frequent failure and troubleshooting, replacement of consumable and other o

8、perational precautions etc.before installation and operation, the operator should read this manual carefully, and do installation, operation and maintenance according to the instructions in manual. if you do not know the related contents, improper installation, operation or servicing may cause human

9、 injury or/ and the equipment damage. the left and right sides of this pump are determined by looking from the power end to the fluid end. this way is also used for determining the left, middle and right sides of equipments such as crosshead, cylinder etc. each pump has a serial number, customers ne

10、ed to point out specially the model and serial number when they order spare parts and inquire about the equipment. there is a recommended spare parts list attached to this manual for part ordering reference, if the needed parts exceed the items listed, please consult the parts list of hhf-1300/1600.

11、users manual for hhf-1300/1600 drilling pump1 safety warningl the personnel who is in charge of installation, operation and maintenance of the equipment should be trained and qualified, and carryout the work with qualification certificate.l the operator should read this manual carefully before opera

12、ting the drilling pump. he can operate or maintain the equipment only when he knows well the functions and operation or maintenance of the equipment.l there must be a chief principal for installation, operation and maintenance; and persons who participate in the work should be assigned clearly; and

13、detailed and reliable safety measures should be taken.l the equipments should be used strictly in accordance with their operation rules and related safety regulations.l ensure to release the pressure of hp pipes or hoses to zero before disconnect them. connect electric apparatus according to related

14、 requirement and ensure to cut off the power supply before servicing operation.l it is forbidden to maintain and repair the equipment during its running. l it is forbidden to overload the equipment.2 brief introduction 2.1 use and applicationhhf-1300/1600 drilling pump is a horizontal, triplex, sing

15、le action piston pump. as an important equipment for drilling operation, it feeds and circulates the high-pressure drilling fluid, which flushes the well bottom and crushes rocks, cools and lubricates drill- bit, and then carries cuttings (rock chips) return to the surface. 2.2 referenced standards

16、the parts and components of this pump are designed and manufactured according to api 7k. specification for drilling and well servicing equipment2.3 brief working principlethe drilling pump mainly consists of two portion, power end and fluid end (see fig. 1). the power end includes pinion shaft, cran

17、kshaft, connecting rod, crosshead sliding block device. it can supply power to fluid end and change the rotary motion to reciprocating motion. with the power from the power end, the piston of fluid end do reciprocating motion in liner and work together with suction valve and discharge valve to compr

18、ess low pressure mud and discharge high pressure mud. 1 frame assembly 2 crankshaft assembly 3 pinion shaft assembly4 crosshead assembly 5 fluid end assemblyfig. 1 drilling pump transmission principle2.4 technical parameterstable 1itemmodelhhf-1300hhf-16001 typehorizontal, triplex, single acting pis

19、ton pump2 rated input power 1300hp（969kw）1600hp（1193kw）3 max. liner dia.7（177.8mm）4length of stroke12（304.8mm）5 rated strokes120 spm6 gear typeherringbone 7 gear ratio4.206:18size of valve potapi 79weight of main body25,850kg26,100kg2.5 performance parameters table 2stroke spmcylinder liner size and

20、 rated pressureliner size7 178mm6-3/4 171mm6-1/2 165mm6 152mm5-1/2 140mm5 127mmhhf-13002786 19.2psi mpa2998 20.7psi mpa3232 22.3psi mpa3792 26.1psi mpa4516 31.1psi mpa5000 34.5psi mpahhf-16003430 23.6psi mpa3690 25.4psi mpa3978 27.4psi mpa4668 32.2psi mpa5000 34.5psi mpa5000 34.5psi mpa rated powerd

21、isplacementhhf-1300hhf-16001301408 hp1050 kw1733 hp1292 kw780 gpm49.21 l/s725 gpm45.74 l/s672 gpm42.40 l/s573 gpm36.15 l/s481 gpm30.35 l/s398 gpm25.11 l/s120 *1300 hp*969 kw*1600 hp*1193 kw*720 gpm45.42 l/s669 gpm42.21 l/s621 gpm39.18 l/s529 gpm33.37 l/s444 gpm28.01 l/s367 gpm23.15 l/s1101192 hp889

22、kw1467 hp1094 kw660 gpm41.64 l/s613 gpm38.67 l/s569 gpm35.90 l/s485 gpm30.60 l/s407 gpm25.68 l/s337 gpm21.26 l/s1001083 hp808 kw1334 hp995 kw600 gpm37.85 l/s558 gpm35.20 l/s517 gpm32.62 l/s441 gpm27.82 l/s370 gpm23.34 l/s306 gpm19.31 l/s90975 hp727 kw1200 hp895 kw540 gpm34.07 l/s502 gpm31.67 l/s465

23、gpm29.34 l/s397 gpm25.05 l/s333 gpm21.01 l/s275 gpm17.35 l/s80867 hp646 kw1067 hp796 kw480 gpm30.28 l/s446 gpm28.14 l/s414 gpm26.12 l/s353 gpm22.27 l/s296 gpm18.67 l/s245 gpm15.46 l/s70758 hp565 kw933 hp696 kw420 gpm26.50 l/s390 gpm24.61 l/s362 gpm22.84 l/s308 gpm19.43 l/s259 gpm16.34 l/s214 gpm13.5

24、0 l/s16.00 gpm0.3785l/s5.58 gpm0.3520 l/s5.17 gpm0.3262 l/s4.41 gpm0.2782l/s3.70 gpm0.2334 l/s3.06 gpm0.1931l/snote: a. calculated as per the volumetric efficiency of 100% and the mechanical efficiency of 90%. b. sign shows the rated stroke numbers of operation and rated input power corresponding to

25、 rated strokes.3 general configuration 3.1 general structure as shown in fig. 2, it mainly consists of two parts: the power end and the fluid end. the power end included frame assembly, drive shaft assembly, crankshaft assembly, crosshead assembly etc； the fluid end includes cylinder, valve assembly

26、, liner, piston assembly, suction manifold, discharge manifold, discharge pulsation dampener, safety (relief) valve, spraying device etc. the drilling pump is equipped with a lifting device and a set of special tool for daily maintenance. 1 frame assembly 2 crankshaft assembly 3 pinion shaft assembl

27、y 4 crosshead assembly 5 fluid end assembly 6 shockproof pressure gauge 7 ja-3 shear pin relief valve 8 kb-75 dampener 9 accessory manifold 10 discharge manifold 11 suction manifold 12 hydraulic cylinder assembly 13 discharge filter assembly 14 spraying device 15 lifting devicefig. 2 drilling pump g

28、eneral structure 3.2 overall dimensions as shown in fig. 3fig. 3 overall dimensions 4 introduction of main components 4.1 power endthe power end is composed of frame assembly, pinion shaft assembly, crankshaft assembly and crosshead assembly etc.4.1.1 frame assembly the frame assembly includes frame

29、 (housing), back cover, skid, little lifting device etc. the housing is a box type weldment of steel plates, after stress relief treatment, rough and finish machining, the housing is formed. it is the base part of drilling pump. all components of drilling pump are installed into it. oil sump and lub

30、rication oil pipeline are set inside the housing to supply lubrication oil for gear, bearing, crosshead etc. a small lifting device with capacity of 500 kg is installed on housing for lifting liner.4.1.2 pinion shaft assembly1 key 2 pinion shaft 3 wearable sleeve 4 end cover 5 gasket 6 gasket 7 bear

31、ing carrier 8 retainer 9 gasket 10 oil collecting box 11 bolt 12 bolt 13 oil seal 14 bearing 15 washer 16 washer 17 cranking flange 18 bolt 19 washerfig. 4 pinion shaft assembly pinion and shaft are integral structure as shown in fig. 4. it adopts herringbone gear. support bearing is a kind of cylin

32、derical roller bearing, without retaining rib, which is very convenient to assembling and disassembling for servicing. the extension of the two shaft ends are the same, and power can be input from either end or both ends together in the same way. 4.1.3 crankshaft assembly the crankshaft assembly con

33、sists of crankshaft, big gear rim, connecting rod, crankshaft bearing and connecting rod bearing (eccentric) etc. it is installed on frame through self-aligning roller bearing（see fig. 5）1 end cover 2 main bearing carrier 3 gasket 4 internal retainer 5 external retainer 6 connecting rod 7 positionin

34、g ring 8 crank shaft 9 positioning ring 10 big gear ring 11 bolt 12 spacer 13 bearing carrier 14 retainer ring 15 clamping plate 16 bolt, main bearing 17 adjusting shims 18 screw 19 lock nut 20 bolt 21 bolt 22 eccentric bearing 23 main bearing 24 washer 25 locking wire 26 locking wire 27 thread seal

35、ant 28 boltfig.5 crankshaft assemblythe crankshaft is an integral cast eccentric shaft. the 3 cranks locate at 360 degrees equally.the left and right spiral gear rings are integrated to become a herringbone gear rim without cutting groove, which is installed on crankshaft with bolts.the 3 big end be

36、arings of connecting rod are single row short cylindrical roller bearings installed respectively at three eccentric cranks. the connecting rod small end is connected to the crosshead pin through double row long cylindrical roller bearing.4.1.4 crosshead assembly the crosshead assembly consists of cr

37、osshead, guide plate, crosshead pin and crosshead extension rod（intermediate rod）etc. the upper and lower guide plates are assembled on frame and guide plate holes are formed; through crosshead pins, crosshead is driven by connecting rod to do reciprocating motion inside guide plate hole; then the c

38、rosshead extension rod installed on crosshead is connected to piston rod and drive piston to do reciprocating motion in liner.4.2 fluid end the fluid end mainly consists of cylinder block, liner, piston, valve, suction manifold, discharge manifold, discharge pulsation dampener, relief valve and spra

39、ying device etc. for details, please see fig. 61 liner seal 2 wear plate 3 liner thread ring 4 liner lock 5 liner 6 lock ring 7 piston rod 8 piston 9 piston seal ring 10 lock nut 11 alignment ring 12 valve stem guide 13 guide retainer (insert) 14 cylinder head seal 15 cylinder head plug 16 cylinder

40、head 17 valve pot cover seal 18 valve pot cover 19 baffle 20 suction manifold 21 discharge manifoldfig. 6 fluid end assembly4.2.1 cylinder blockthe suction chamber and discharge chamber are integrated in a vertical cylinder block (according to iadc, over & under valves front-loading). the valve pot

41、structure and dimensions meet api 7k specifications. the cylinder blocks are fixed on the frame through bolts.4.2.2 liner the drilling pump adopts bimetallic liner. liners with different diameters can be selected according to different drilling conditions. the liner is fixed on cylinder block with b

42、olts through liner thread ring and liner lock. the liner and piston and piston rod can be lift and put in or taken out from the opening on the top of frame with the help of small lifting device mounted on frame.4.2.3 piston the piston consists of piston core, piston rubber, clamping bar, circlip. th

43、e piston rod is connected to extension rod through clamp, the piston and piston rod are connected by piston nut. 4.2.4 liner spraying device liner spraying device is consisted of spray pump, water tank, spraying manifold etc. its function is to wash, lubricate and cool liner and piston during mud pu

44、mp running in order to prolong the service life of liner and piston. the spraying pipe position is shown in fig. 7.1. holder 2. pipe joint 3. spraying pipe fig. 7 liner spraying pipe4.2.5 valve device the valve device consists of valve body, valve seat, valve spring, valve stem guide device etc. the

45、 suction valve is fixed by cylinder head, cylinder head plug, alignment ring and valve guide retainer (insert piece) through cylinder thread ring, and the discharge valve is fixed by valve pot cover.4.2.6 suction manifold the suction manifold is connected to 3 cylinder blocks simultaneously. it has

46、three ports at left , middle and right. the drilling fluid can be sucked in from left, right or middle port according to your desire.4.2.7 discharge manifold the discharge manifold is connected with 3 cylinder blocks simultaneously too. it has two ports at left and right side. the drilling fluid can

47、 be discharged from left side or right side.4.2.8 discharge pulsation dampener the discharge pulsation dampener is mainly consisted of housing, cover, bladder, discharge valve, pressure gauge etc. the discharge pulsation dampener is installed at the accessory manifold (5-way joint or 4-way joint). t

48、he pressure fluctuation can be decreased when it works normally . 4.2.9 relief valvethe drilling pump adopts shear pin relief valve installed at accessory manifold (5-way joint or 4-way joint) . when it is used properly, the discharge pressure of mud pump can be limited to ensure operation safety. 4

49、.2.10 spraying devicethe spraying device consisted of spray pump, water tank, spraying pipe etc. the spray pump is installed at the side of the pump, and the water tank is installed below the frame, and the spraying pipe is fixed on frame above liner. the spraying water jetted out from spraying pipe

50、 onto liner and piston for washing, lubricating and cooling. 5 lubricationthe gears, bearings, crosshead sliding ways of power end all adopt the combination of splash lubrication mode and forced lubrication mode. and the forced lubrication includes built-in mode and outer layout mode. the liners and

51、 pistons of fluid end are lubricated, flushed and cooled with the water supplied by spray pump. 5.1 splash lubricationthe splash lubrication system of drilling pump is independent to the pressure lubrication system. in splash lubrication system，the big gear ring brings oil up from oil sump, after th

52、e oiled big and small gears are meshed, the oil is squeezed out and splashed into each oil channel on frame to lubricate pinion gear shaft bearing and crosshead bearing and guide plate.（see fig. 8） the crosshead bearings lubrication oil line is shown in fig. 8. the oil collected in crosshead upper o

53、il chamber, through oil nipple, flows into the crosshead pin baffle, and into the oil passage, and then to lubricate the crosshead bearing. 1 oil nozzle 2 crosshead pin baffle 3 bolt 4 crosshead pin 5 oil passagefig. 8 lubrication passage of crosshead bearing5.2 pressure lubrication the drilling pum

54、ps pressure lubrication system is shown in fig. 9. in this system，through the connector holder ii, the oil pump sends oil to pinion shaft nozzle, main bearing oil pipe and crosshead chamber connector holder i，then through connector seat i distribute oil to crosshead, crosshead bearing and crosshead

55、extension rod.1 suction oil filter 2 connector holder 3 oil pipe 3a pinion shaft nozzle 4 main bearing tubing 4a crosshead chamber connector holder i 5 pressure gauge 6 relief valve 7 oil channel 8 oil pipe 9 oil pumpfig. 9 pressure lubrication systemthe lubrication oil pump has two installation modes of “built-in mode” and “outside mode” for user to choose. if the user does not request specially, the mode “built-in” shall be used generally, no matter w