Mud Pump Bomco LGF-1000 Operations Manual
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Transcript of Mud Pump Bomco LGF-1000 Operations Manual
Operating Instructions
For LGF-1000 Drilling Pump
Sichuan Gaosheng Machinery Manufacturing Co., Ltd.
Tel: 028-85730676 , 028-85730698
Add.: Jiaolong Industrial Zone, Shuangliu County, Chengdu, China
CONTENTS
1. Overview
2. Technical Specifications
3. Flow Rate vs. Pressure
4. Features of Main Components
5. Assembly and Disassembly of Main Components
6. Assembly, Startup and Running Monitoring of Drilling Pump
7. Maintenance
8. Troubleshooting
9. Notes for Storage
10. Special Lubrication Oil and Grease
11. List of Supplied Special Tools
12. Recommended Order List
13. List of LGF-1000 Drilling Pump Drawings
14. List of Spare Parts
1
1. Overview
LGF-1000 drilling pump is a kind of horizontal triplex single-acting piston pump,
made up of power end and fluid end, designed with advanced structure, small size,
reliable operation mechanism, exchangeable components, and easy maintenance. The
consumables, bearings, sealing parts and technical parameters of this pump are the
same as those of F-1000 pump.
The power end includes framework, pinion shaft assembly, crank shaft assembly,
crosshead assembly and pony rod, etc. The fluid end includes module, valve assembly,
liner, piston assembly, suction manifold, etc. In order to avoid gas lock and reduce the
pressure pulsation at the discharge outlet, a suction pulsation dampener and a
discharge pulsation dampener are installed respectively at the suction pipe and the
pump outlet. And a shear-pin safety valve is installed at the other end of the pump
outlet to ensure the pump pressure not to exceed the rated working pressure.
Splash lubrication and forced lubrication are combined for the gears, bearings and
crosshead at the power end to ensure sufficient lubrication, while the water supplied
by spray pump is used to lubricate, clean and cool the liner and piston at the fluid end.
A special set of handling (assembly and disassembly) tools are provided for routine
maintenance of the drilling pump.
When LGF-1000 drilling pump remains in good condition it will be an excellent
partner of every drilling worker and bring you great benefits.
2
2. Technical Specifications
No. Description Parameters
1 Type Horizontal, triplex single-acting piston
pump
2 Rated input power (HP) 735KW(1000HP)
3 Rated strokes 140
4 Stroke length 254 mm (10in.)
5 Gear type Herringbone tooth
6 Gear ratio 4.207:1(122:29)
7 Suction connection size 12” flange
8 Discharge connection size 5-1/8”flange 5000#API
9 Pinion shaft diameter and
extension (mm/in.) 196.85/7-3/4 ×336.55/13-1/4”
10 Key connection size (mm/in.) 50.8×50.8 / 2”×2”
11 Module API 6#142.875/5-5/8”
mm 4269×3167×1818 12 Dimensions
in. 168”×124-5/8”×71-1/16”
13 Base width (mm/in.) 1790/70 1/2”
14 Pump weight (kg/lb) 18790/41420
3. Flow Rate vs. Pressure
Liner ID (in) 6 3/4″ 6 1/2″ 6 1/4″ 6″ 5 1/2″ 5″ 4 1/2″
Rated WP (MPa) 16.4 17.6 19.1 20.7 24.6 29.8 34.5
Strokes per Power(HP) Flow Rate (L/s)
3
Minute
(spm)
KW HP
140 735 1000 41 38 35.2 32.4 27.2 22.5 18.2
130 683 929 38.07 35.28 32.68 30.1 25.26 20.89 16.9
120 630 857 35.14 32.57 27.86 27.77 23.3 19.28 15.6
110 578 786 32.21 29.85 27.66 25.46 21.37 17.68 14.3
100 525 714 29.28 27.14 25.14 23.14 19.43 16.07 13
1 5.25 7.14 0.293 0.271 0.251 0.231 0.194 0.161 0.130
Assuming the mechanical efficiency η =90%,fill factor α =100%, and volumetric
efficiency=100%.
4. Features of Main Components
LGF-1000 pump consists of 2 parts, power end and fluid end. The power end is used
to provide adequate power to the fluid end, and the fluid end is used to convert the
mechanic energy to the internal energy of the fluid to convey drilling mud. The
combination connection of framework, base support, cylinder, suction pipe and
discharge pipe forms the whole set, characteristic of small in size, high in strength,
and compact in structure. Please refer to Fig. 1.
4
Pinion Shaft Assembly Discharge
Pipe Fluid End Assembly
Crosshead AssembliesCrankshaft
Assembly Framework Assembly
Fig.1 Structural Schematics of LGF-1000 Drilling Pump
1) Power End
The power end includes framework, pinion shaft assembly, crank shaft assemb
crosshead assembly.
a. Framework
The framework is the base of the LGF-1000 pump, all pump components are i
on the framework. It is welded in the form with steel plates. And stresses hav
treated already, with high rigidity and high strength. All necessary oil pools
passages are designed in the framework, used for lubrication and cooling.
b. Pinion Shaft Assembly
The pinion shaft is made of forged alloy, with herringbone teeth and mediu
tooth surface. It turns smoothly and has a high efficiency and a long servi
Roller bearings are placed at the journal area without retaining edge at the inn
so as to facilitate the repair check. Both ends of the shaft extend out, belt w
chain wheel can be mounted at either end, with the other end installed with
sheave which drives spray pump or charge pump.
c. Crank Shaft Assembly
The bull gear, connecting rod and bearings can be installed respectively
crankshaft.
The bull gear will engage with the gears on the pinion shaft. A tight fit exists b
SuctionPipe
ly, and
nstalled
e been
and oil
m-hard
ce life.
er race,
heel or
pulley
on the
etween
5
the inside of the bull gear and the crank shaft, with 12 bolts to connect and locknuts to
tighten.
d. Crosshead Assembly
The coaxiality between the crosshead and the guide can be adjusted by inserting
spacers at the lower guide.
The crosshead and the connecting rod are connected by rabbet locating bolts, to
ensure the two aligned axially. The bolts are tightened according to required torque
value, and locking wires used.
A crosshead pin is used at the middle of the crosshead to connect with the small end
of the connecting end. For easy assembly and disassembly, a tapered fit is used
between the crosshead and the pin, with a clamp plate pressed tightly the crosshead at
the big end, and bolts tightened with the torque required, and locked by wires.
2) Fluid End
The fluid end includes 3 exchangeable modules. A set of suction valves and discharge
valves are mounted inside each module.
DischargePipe
Safety Valve
Dampener
Pr e
The 3 modules are secur
above the cylinder, with
one side, while an elbow
valve and anti-shock p
Anti-shock essure Gaug
Fig. 2
ed on
disch
pipe
ressur
Discharge FilterHolder
A
Structure of Discharge Manifold
the framework by bolts. Discharge manifold is instal
arge outlets at both sides. And a filter can be installed
installed at the other side. Pulsation dampener, saf
e gauge can be installed on the elbow pipe. For
Elbow
Cylinderssembly
led
at
ety
the
6
structure of the discharge manifold, please refer to Fig. 2.
a. Module
Straight-way type module is adopted, made of forged steel alloy. The fluid flow rates
in all the modules are the same, preventing the valve assembly from the influence of
the cross flows discharged out of other modules. The valve sizes conform to the API
standards.
b. Liner, Piston, and Clamp
Bi-metal quality liner is used. The inner is made of wearable forged steel, hardness up
to HBC 60-65, and the ID surface has high fineness. The liner is variable in several in
ID sizes, and the same as the sizes of the piston matching with the liner. Liners and
pistons of different ID’s are used for different drilling conditions.
The piston is consisted of piston core, rubber cup, clamp plate, and snap spring. The
piston and piston rod have a cylindrical surface fit, sealed by seal parts, and lock nuts
with lock rings used to press tight, which can not only lock the nut after tightening but
also seal there between.
The piston rod and the pony rod are connected by clamps, has rabbet locating device
at the juncture to ensure the axiality.
c. Cylinder lid, cylinder lid plug, and cylinder lid flange
The cylinder lid flange connects with the cylinder by studs, with the cylinder lid by
saw tooth threads. Press inside the cylinder lid plug, which has a central screw hole
used to install pull bar to dismount the cylinder lid plug.
d. Valve Assembly
The suction valve and the discharge valve are exchangeable. The external conical
surface with a 1:6 taper engages with the internal conical surface of the cylinder valve
seat. The sizes are as required by API 6.
3). Suction Pulsation Dampener and Discharge Pulsation Dampener
a. Suction Pulsation Dampener
The suction pulsation dampener is installed at the side of the suction manifold, to
dampen the suction pulsation to improve the volumetric efficiency.
7
b. Discharge Pulsation Dampener
Installed at the discharge elbow pipe, see Fig. 2, consisting of housing, bladder, press
board and throat flange.
The volume and the pressure load capability meet the drilling pump requirements.
Nitrogen or air can be charged inside the air dampener, but not combustible gases like
oxygen or hydrogen.
The maximum precharge pressure of the pulsation dampener is 4.5 MPa (650psi). The
stop valve will be closed after charging, to protect the pressure gauge.
c. Shear-pin Safety Valve
The shear-pin safety valve is installed at one side of the elbow pipe of the discharge
manifold, see Fig. 2, to vent quickly once the pump pressure exceeds the
predetermined value, so as to ensure the safety of the equipment. Levels of pressures
are marked on the shear plate; the pressure is adjusted by inserting the safety pin in
different holes. Take care that only 1 pin can be inserted on the pin plate. And this
valve must be installed before the stop valve, to prevent the pump from startup before
the stop valve opened.
4). Spray Pump Assembly
The assembly includes spray pump, water tank, and spray pipe, used to cool and
lubricate the liner and piston during the pump running, increase the working life of
liner and piston.
The spray pump is a centrifugal pump, driven by the driving shaft through belt wheel
(or driven by the motor separately). The water is used as the cooling and lubrication
fluid.
The spray pipe can be mounted on the clamp which connects the pony rod and the
piston rod. It can reciprocate with the piston, or fixed at a proper location, to ensure
the cooling & lubrication fluid always flush the interface of the piston and liner.
5). Charging System
This charging system can be configured as necessary, including charging pump,
support base, butterfly valve and manifold. It is driven by a motor, installed at a
8
proper place according to actual situations, normally close to the outlet at the side of
the mud tank.
5. Assembly and Disassembly of Main Components
1) Disassembly of Main Components of Fluid End
a. Disassembly of Piston
Put a round bar into the hole of the cylinder lid, to remove the lid. Then take off the
cylinder lid plug, pull out suction valve guide, and remove the clamp connecting the
piston rod and the pony rod. And rotate the pump to separate the pony rod and the
piston rod. And another bar is forced between the pony rod and the piston rod, and the
piston can be pushed out of the liner by turning the pump. The piston then can be
taken out of the liner bore of the cylinder.
b. Disassembly of Liner and Piston
First remove the cylinder lid, lid plug, suction valve, guide and the clamp connecting
the piston rod and the pony rod as described above, and then remove the cylinder liner
cover plate, and separate the piston rod and pony rod by turning the pump. And then
use a copper bar to knock evenly the peripheral edge of the liner to separate the liner
from the liner seat, and the liner and piston can be then taken out of the cylinder lid
hole at the front of the cylinder.
c. Disassembly of Upper Valve Seat
Plug a round bar into the valve pot cover hole to remove the valve pot cover, then take
out the valve spring and the valve assembly. And then use the hydraulic handling tool
provided along to remove the upper valve seat.
d. Disassembly of Lower Valve Seat
After the upper valve seat removed as above, use the special valve-seat handling tool
to take the lower valve seat out of the cylinder lid hole.
2) Assembly of Main Components of Fluid End
a. Installation of Module
Lift the 3 modules onto the framework, and secure with bolts (not too tight). The
modules should keep upright and balanced with each other. Then install the suction
9
manifold and discharge manifold. After all adjusted well, use the torque spanner to
tighten the connection bolts of the suction pipe, discharge pipe and framework to the
module to the required torque value. Note Letai gel shall be applied to the bolts and
nuts before tightening. The tightening torques for the bolts are as following.
LGF-1000
Thread size Toque (N.m)
Connection with suction pipe 7/8-9UNC-2A 298-338
Connection with discharge pipe 1-1.4-8UN-2B 1287-1355
Connection with the framework 1-1/2-8UN-2B 2134-2202
Connection with cylinder lid flange 1-3/8-8UN-2B 1775-1842
Cylinder Model
Pump
b. Installation of Valve, Valve Seat and Valve Pot Cover
Assemble the valve body, valve rubber, and valve nut together. Clean the external
conical surface of the valve seat, and make sure no nick or burrs. Then put the valve
seat inside the conical hole of the valve pot which is also cleaned already (Note: It is
prohibited to apply oil on the external conical surface of the valve seat and the
internal conical surface of the valve seat bore.). When assembling the valve seat, it’s
preferable to put an old valve body on the seat and use the iron bar to hammer 3 times
and later take away the old valve seat to check whether the valve seat is secured or not.
If no old valve body available, a copper bar can be used to knock around the upper
edge of the valve seat to seek a tight fit with the cylinder. Note the lower valve seat
should be installed before the upper valve seat.
Then mount the valve assembly onto the valve seat, with the valve spring at the center
of the valve body. The suction valve shall be installed after the liner and piston being
installed.
Grease the seal ring of the valve pot cover, and install it on the cleaned cylinder
shoulder. After the valve pot cover, valve stem guide and the baffle are installed,
apply lubrication oil on the threads of the valve pot cover and tighten with a round
bar.
c. Assembly of Piston and Liner
10
When assembling the piston, pay attention to put in O rings between the piston and
the piston rod. Otherwise the drilling mud will damage the piston and piston rod.
Then can the piston be mounted and piston nuts tightened. The torque value for
1-1/2-OUN-2B nuts is 1625-2165.
The piston can be put inside the liner after the liner be mounted on the pump body, or
it can be assembled with the liner outside the pump first, and later installed into the
cylinder together. The assembly procedure is in reverse to the disassembly procedure.
When assembling the piston into the liner, calcium grease must be precoated on the
inner surface of the liner and the external surface of the piston. Then the liner seal
rings, liner locating tool can be installed. And then the suction valve body, valve
spring, valve guide and clips will be installed. And finally the cylinder plug be
installed and cylinder lid tightened, and the clamp connecting the piston rod and the
pony rod is installed.
3) Disassembly of Main Components of Power End
a. Disassembly of Crankshaft
Take off the clamp, together with the pony rod and its packing box.
Remove the left and right crosshead pins, and then the pin at the center of the
crosshead (or remove the press board of the central crosshead pin and then
dismount the crosshead and the crank shaft together,).
Take off the left and right main bearing caps and the cap at the back. And take off
the cap of the main bearing seat. Then the crankshaft can be lifted up with a crane.
And the other parts can be disassembled as required.
b. Disassembly of Pinion Shaft
Take off the bearing caps at both ends of the framework, remove the main bearing
sleeve bolts at either end of the pinion shaft, and take the pinion shaft and the
bearing sleeve at the end without bolts out of the bore. The inner race of the
bearing is detachable.
If the pinion shaft to be dismounted without the need to disassemble the
crankshaft assembly, first support the 2 ends of the crankshaft, pull out the
bearing sleeve, making the pinion gear separate from the bull gear, and then pull
11
the pinion gear out of the framework.
If damaged bearings are to be taken out without the need to disassemble the
pinion shaft from the framework. The bearing sleeve shall be pulled out, and then
the inner race of the bearing is pulled out along the pinion shaft.
4) Assembly of Main Components of Power End
a. Assembly of Pinion Shaft Assembly (see Fig. 3)
Pinion amay be comp
Note: Be
of c Wh
dow Tig
② Assembl
Main Bear
End Cap
Fig.3nd shaft belongleted after mou
sure that the paap are positioneen mounting bnward and tow
hten the bolts ony of Crankshaf
Main Bearing
ing Cover
Bearings P
Structure of Pin to an integral mnting bearings a
cking ring of pd correctly.
earing sleeve anard discharge ho bearing sleevet Assembly(see
Crosshead Bear
Pony Rod
inion Shaft
ion Shaft Assemblyachine componen
nd spacer rings of
inion bearing slee
d cap, the oil grle.
with torque 190~ Fig. 4) ing
Bull gear
Eccentr
Bearing Housing
t. Therefore assembling oil sealings.
ve and the packing ring
ooves on them must be
255 N⋅m.
ic Cam Bearing
Bearing Housing
12
Fig. 4 Schematics of Crankshaft Assembly Assembly of bull gear:
Put bull gear on crankshaft flange. Thoroughly clean the match surfaces of the bull gear and the crank-shaft flange. Then secure the bull gear, tightening all bolts with torque 1055 N⋅m.
Mount outer races and outer retaining rings of the connecting rod bearings on three connecting rods separately. Draw-off tray must be located just under the working connecting rod. Tighten bolts of the bearing retaining ring with torque 60-90 N⋅m and lock them with wires.
When assembling connecting rods, the middle one must be installed at first, and locating ring be mounted.
When assembling lateral connecting rods, bolts on the inner retaining rings must be tightened with torque 60-90 N⋅m.
Mount the crankshaft assembly onto the framework. Before lifting the crankshaft, put wooden supporting block on each of the guides (see Fig.5).
C
Cushio
Fig
Lift the crankshaft acrosshead already mounNote that the oil catchmupward. The retainer plmiddle one be installed a
There are 2 method
Calculation me Measure th Measure th
directly fro The actu
=0.25-[0.10 Tighten the
11923N.m.
Uonnecting Rod
n Plate Lower Slide
. 5 Schematics of Wooden Su
nd put it into the framewted there. The torque value ent ditches of the retainer pates at 2 sides should be ccording to the location ofs to adjust the clearance of
thod: e outside diameter of the me diameter of the inner borm the end face of the bearinal thickness required-(A-B)]mm; main bearing bolts, 2-1
pper Slide
C
pporting B
ork, and of 6 1" -8lates of t
installed the crossh the main
ain bearine of the mg seat on of
/2-8UN-2
rosshead
lock
then connect it with the UN bolts is 225-240N⋅m. he crosshead should face at the outside, while the ead pin.
bearing.
g housing, A; ain bearing seat (or read
the framework ); the support block
A bolts, by a torque of
13
Test and adjustment method: Insert 0.50mm steel spacer at the binding face of the main bearing
cover; Put a lead wire at the middle part of the engagement area between the
inside bearing cover hole and the bearing. Tighten the main bearing cover bolts with required torque value; Remove the bearing cover, and measure the thickness of the lead wire; The pre-compression of the bearing cover is 0.10mm; The actual thickness required of the spacer =0.50mm (thickness of the
adjustment spacer)-the thickness of the compressed lead wire – 0.10mm (pre-compression of the bearing).
−
Main BearingMain Bearing Bolt
Main Bearing HousingLead Wire
6. Pump St
1) Installatio
a. The mud p
tilted to the fl
b. The mud p
should be pla
pump.
c. The suctio
tank bottom,
suction pipe s
d. Secure all
Be
a
n
u
u
u
c
n
a
h
s
aring Cover
Shim
Fig. 6 A
rtup after In
mp should be in
id end (at an inc
mp should be in
ed as high as p
end of the pum
nd the ID of the
all not face the i
uction and disc
djustment of Main Bearing C
stallation and Runnin
stalled on a foundation h
lination ≤3º), to ease the f
stalled at a level as low as
ossible, to improve the s
p suction pipe should be
suction pipe must be co
nlet of the mud tank.
harge pipelines, to prev
lear
g M
oriz
low
po
ucti
300
nsta
ent
C
ance
on
ontal
of th
ssible
on ef
mm
nt, th
unne
rank Shaft
itoring
ly placed or slightly
e lubrication oil.
, while the mud tank
ficiency of the mud
higher than the mud
e suction end of the
cessary stresses and
14
minimize vibration. The pipelines are prohibited to hang around the pump without
firm support.
1) Pump Startup
a. Preparation before startup
Check the bottom of the framework of the power end. Discharge all lubrication
oil if any and clean the oil tank. If the oil has been discharged already, check to
see if the tank is clean. Then feed lubrication oil to the maximum level. The
lubrication oil used is as following.
Season Summer Winter
Lube N320 moderate-extreme pressure
gear oil (S-P type ) plus 10%
4#antirust compound, or 200#
moderate-extreme pressure gear
oil (S-P type ) plus 10%
4#antirust compound
N220 moderate-extreme pressure
gear oil (S-P type ) plus 10%
4#antirust compound, or 120#
moderate-extreme pressure gear
oil (S-P type ) plus 10% 4#antirust
compound
Open the upper peephole cap of the mud pump, feed sufficient lubrication oil into the
oil ditches of the pinion bearing and the crosshead, keeping all friction faces of the
pump lubricated before startup.
Check the crosshead clearance. The clearance between the upper crosshead
surface and the slide shall not be less than 0.5mm (0.02in.). The clearance of the
crosshead can be larger. This is because the working properties of the triplex
pump. The load of the crosshead is always exerted on the lower slide during
forward running of the pump. While during reverse running, the load of the
crosshead is exerted on the lower slide. So the clearance of the slides must be
controlled between 0.45~0.55mm (0.0177~0.0217in.).
Check the cooling lubrication oil in the oil tank of the spraying pump to see if it
meets the requirements.
Tighten all bolts. Check the valve pot cover and cylinder lid to see if they are
tightened enough. And check the bolts of the connecting clamp of the piston rod
15
and the pony rod are tightened or not. Take out the supporting block at the
crosshead hole to see any unnecessary objects inside the pump or the framework.
Check all valves on the mud lines to see if they are properly opened or closed as
required before the startup.
Check the charging pressure of the discharge air dampener, if reaching 4.5MPa.
Open the suction and discharge valves of the spray pump system and the charging
system (if necessary).
Check the discharge safety valves and the pressure gauges to see if they are
equipped complete and sensitive.
Fill the suction valve pots with water or mud to vent out all air.
b. Startup
Start at a speed as low as possible, and then speed up gradually, so as to improve
volumetric efficiency.
When the charging pump is not used, lower the maximum speed of the pump to a
value which can keep the pump work normally. If the pump speed needs to be
quickened, the charging pump must be used.
Check the readings on the pressure gauges along the lubrication oil loop. If no
readings, repair in time.
Check temperatures all around, no local overheating is permitted.
Operator and inspector should be contacted before pump startup.
The inspector must watch the pressure readings on the gauges when the pump is
started. The workers cannot leave the air switches before the mud returns to the
surface.
When engaging the clutch, 2-time startup method is adopted, which can give a
chance for the pump to move, and also can observe if any obstacles exist during
pump startup. If all normal, engage the clutch.
c. Monitoring the Pump Running
Check to see any abnormal noise in the clamp connecting the piston rod and the
pony rod. Check all screw caps on the cylinder and all valve pot cover to see if
they are loose or not. Any anomalies found, find the reasons and solve them in
16
time.
Check to see any leakage at high pressure sealing points, any spur leakage at
pump valves or cylinder, if any problems found, solve in time.
Note variations of pump pressure, solve properly if any anomaly found.
Check to see if the water/oil supply to the spray pump normal or not.
Check if the temperatures is too high or not at all bearings, crosshead slides and
other moving parts.
Check to see if the pressure gauges on the lubrication oil loop of the power end
behind the framework work normally or not.
7. Pump Maintenance
Proper and timely maintenance of mud pump is necessary to ensure normal work and
a long working life of the pump. Attention should be paid to every pump in this
respect when it is in operation.
1). Daily Maintenance
a. Check the oil level of the power end after the pump shut down. If it is chain driven,
the oil level in the chain box should also be checked.
b. Check the running condition of the liner and the piston. It’s normal if small
amounts of mud leaks, the pump can continue working. If the leakage exceeds the
limit, the liner and the piston must be changed.
c. Check the liner bore of the framework. If there is large mud precipitation, clean it.
d. Check if there is sufficient cooling lubrication oil inside the oil tank of the spray
pump. If the oil has been contaminated, replace the oil, the same time the oil tank
must be cleaned.
e. Check the charging pressure of the discharge pulsation dampener to see if it meets
the operating requirements.
f. Regularly check the reliability of the safety valves.
g. Loosen the connecting clamp daily, turn the piston 1/4 round, and then retighten the
clamp again. This will make the piston surface worn evenly, so as to elongate the life
of the piston and the liner.
17
h. Before tightening the cylinder lid and the valve pot cover, apply lubrication grease
to the threads. And check every 4 hours to see if they are loose or not.
2) Weekly Maintenance
a. Dismount the valve pot cover and the cylinder lid once a week, remove the sludge
and clean, and apply supramoly calcium-base compound lubrication grease. Check the
inner sleeve of the valve guide sleeve, if it is worn too much (the clearance between
the valve guide stem and the guide sleeve exceeds 3mm), replace it.
b. Check the condition of the valves and the valve seats. Replace the seriously worn
or pierced valve seats, valve rubber elements and valve seats (the valve bodies will be
replaced together when the valve seats are replaced.).
c. Check the piston-locking nuts. Replace if they are corroded or damaged (Normally,
the seal rings inside the nuts will not lock any more if having been tightened 3 times.).
d. Drain off the water through the plug at the drainer cap once a week, till oil comes
out.
3) Monthly Maintenance
a. Check all studs and nuts at the fluid end. Such as nuts on the flange of the cylinder
lid, nuts used to connect cylinder and the framework, and the bolts and nuts
connecting the suction pipelines and discharge pipelines. They must be retightened
with required torques if found loose.
b. Check the seal rings inside the packing box of the pony rod. Replace if found worn.
However, they must be replaced once every 3 months at least. Please pay attention to
the directions of the oil seals when replacing. See Fig. 7.
18
S
Upper Slide
Fig. 7 Schematics of
c. Dismount the filter inside the discharge m
d. Replace the dirty oil in the oil reservoir
ditch of the crosshead once every 6 months
4). Yearly Maintenance
a. Check to see if the crosshead slides got
the crosshead complies with the requirem
spacers under the slides). The crosshead c
the crankshaft assembly.
b. It is recommended to make an overall ch
whether or not the main bearings, connec
and driving shaft bearings are worn or d
unable to be used any more.
c. Check the gears. Reassemble both the d
way if it is found seriously worn, use the un
5) Other Maintenance Concerns
a. Clean the 25°conical surface before mo
and the piston rod.
b. The liner seals must be replaced together
c. Drain all the mud inside the valve pot
winters.
d. All the check holes or windows of the
ingle-lip Oil Seal
D
Crossh
Assembly of Oil Seals
anifold and clean it
at the power end an
, and flush the oil dit
loose or not, if the
ents or not (can b
an be rotated by 18
eck of the pump eve
ting rod bearings, c
amaged. Replace ne
riving shaft and the
worn gear surfaces.
unting the clamp co
with the liner.
and the liner after th
pump must be cov
ouble-lip Oil Seal
ead pony rod
.
d in the oil deposition
ches.
operation clearance of
e adjusted by adding
0°when disassembling
ry 2 or 3 years. Check
rosshead pin bearings,
w ones if it is found
driven shaft the other
nnecting the pony rod
e pump shut down in
ered to prevent dirt or
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sands from mixing with the lubrication oil.
e. Only inert gases like nitrogen can be charged in the discharge pulsation dampener.
Combustible or explosive gases like oxygen or hydrogen must be inhibited.
8. Troubleshooting
1) Fluid End
Problems Causes Solution
1. Readings on the pressure gauge drop. The displacement volume reduces or no displacement.
1. Air got inside the pump due to the inefficient sealing at the suction pipe. 2. The suction filter is completely blocked.
1. Tighten the flange bolts of the suction pipe or replace the gaskets. 2. Shut down the pump, and then pull up the suction pipe to clean the filter.
2. The fluid discharge is unsteady, with fluid surges. The readings on the pressure gauge vary a lot. The suction pipe makes loud noises.
1. One piston or one valve is seriously damaged or worn. 2. Air got inside the pump cylinder.
1. Replace the damaged piston: open the valve pot cover to check if it is damaged or stuck. 2. Check to see if the suction pipe and the valve pot cover have a good seal.
3. Violent knocking sounds heard out of the liner.
1. The piston nut got loose. 2. The cylinder lid got loose.
1. Tighten the piston nut. 2. Tighten the cylinder lid.
4. Mud leakage found out of the valve pot.
1. The valve pot cover not tightened enough. 2. The seal rings are damaged.
1. Tighten the valve pot cover. 2. Replace the seal rings.
5. The discharge pulsation dampener cannot be charged with gas or the gas leaks out soon after it is charged.
1. The gas charging joint is plugged. 2. The bladder in the dampener is broken. 3. The needle valve is not well sealed.
1. Clean the charging joint. 2. Replace the rubber bladder. 3. Repair or replace the needle valve.
6. Too much load on the diesel engine.
1. The discharge filter is plugged.
Disassemble the filter, clean away the impurities and flush clean.
2) Power End
Problems Causes Solutions
1. High temperature at 1. Oil pipe or oil holes are 1. Flush the oil pipe and
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the bearings. plugged. 2. Lubrication oil is dirty. 3. Rolling bearings are worn or damaged.
oil holes. 2. Replace new clean oil. 3. Disassemble the bearings, seek causes and replace if necessary.
2 . Knocking sounds
come from the power end.
1. The crosshead or the guides are damaged. 2. The crosshead bearings are worn. 3. The driving shaft bearings, driven shaft bearings or the bearings at the big end of the connecting rod are worn.
1. Adjust the clearance or replace the worn guides. 2. Replace the crosshead bearings. 3. Replace the bearings.
9. Notes for Storage
1) The mud pump must be sealed up for storage if it will not be used for a long time.
2) Before the storage, the pump must be cleaned thoroughly without any dirty
material remaining. Drain, flush and dry up all parts of the fluid end.
3) Drain the machine oil at the bottom of the gear case at the power end, and clean the
bottom.
4) Viscous oil shall be applied to the machining surfaces of bearings, crosshead, gears,
piston rod, and pony rod.
5) Grease shall be applied to the machining surfaces of all parts of the fluid end.
6) The suction and discharge ends shall be covered with blank plates.
7) The end cap, back cap and peephole cap of the crosshead should be tightly covered.
10. Lubrication Oil and Lubrication Grease for the Pump
1) For lubrication of gears, bearings, and crosshead
In winter, 22# hyperbola gear oil (code: HL57-22), or N220 moderate-extreme
pressure gear oil (S-P type) plus 10% 4# antirust compound.
In summer, 28# hyperbola gear oil (code: HL57-28), or N320 moderate-extreme
pressure gear oil (S-P type) plus 10% 4# antirust compound.
2) For lubrication and cooling of liner and piston, fresh water is used.
3) Supramoly calcium-base compound grease is used for lubrication of threads.
4). Calcium-base grease is used for piston and liner.
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11. List of Supplied Special Tools
NO. Drawing No. Descriptions Material
Qty. Unit weight
Total weight
Note
1 LGF3101-25.01 Sleeve 2″ 35CrMo 1 1.34 1.34
2 LGF3101-25.02 Sleeve 2-3/16″ 35CrMo 1 1.5 1.5
3 LGF3101-25.03 Sleeve 2-3/8″ 35CrMo 1 1.7 1.7
4 LGF3101-25.04 Sleeve 3-3/8″ 35CrMo 1 2.0 2.0
5 LGF3101-25.05 Joint 1″ 35CrMo 1 0.38 0.38
6 LGF3101-25.06 Extension bar 8″ 35CrMo 1 1.6 1.6
7 LGF3101-25.07 Extension bar 24
″
35CrMo 1 2.35 2.35
8 LGF3101-25.08.00
Liner plug puller welded 1 2.5 2.5
9 LGF3101-25.09.00
Valve stem guide handling tool
welded 1 0.81 0.81
10 LGF3101-25.10.00
Liner retainer puller
welded 1 2.7 2.7
11 LGF3101-25.11.00
Hydraulic valve puller
welded 1 73.4 73.4
12 LGF3101-25.12 Transition taper sleeve
35CrMo 1 1.21 1.21
13 LGF3101-25.13 Compression sleeve
35CrMo 1 2.74 2.74
14 LGF3101-25.14 Sleeve 1-1/2″ 35CrMo 1 0.85 0.85
15 LGF3101-25.15 Sleeve 1-5/8″ 35CrMo 1 0.95 0.95
16 LGF3101-25.16.00
Long sleeve
1-5/16″
Q235A 1 7.45 7.45
12. Recommended Order List
No. Drawing No. Descriptions Qty. Note
22
1 LGF3101-05.17.00 Valve assembly (API 6#)
6
2 LGF3101-05.17.05 Valve rubber (API 6#) 6 3 LGF3101-25.22A
Liner 6-1/2″ 3 common
LGF3101-25.22A Common 4 LGF3101-25.22 Liner 6-1/4″ 3
Bi-metal LGF3101-25.22A Common 5 LGF3101-25.22 Liner 6″ 3
Bi-metal LGF3101-25.22A Common 6 LGF3101-25.22 Liner 5-1/2″ 3
Bi-metal LGF3101-25.22A Common 7 LGF3101-25.22 Liner 5″ 3
Bi-metal 8 LGF3101-05.22.19.06.00 Piston 6-1/2″and
rubber 3
9 LGF3101-05.22.19.05.00 Piston 6-1/4″and rubber
3
10 LGF3101-05.22.19.04.00 Piston 6″and rubber 3 11 LGF3101-05.22.19.03.00 Piston 5-1/2″and
rubber 3
12 LGF3101-05.22.19.02.00 Piston 5″and rubber 3 13 LGF3101-05.21 Piston rod 3 14 LGF3101-04.09 Pony rod 3 15 LGF3101-05.18.00 Piston nut 6 16 LGF3101-05.04 Liner seals 12 17 LGF3101-05.09 Valve pot cover seals 6 18 LGF3101-05.20 Piston seals 6 For piston 19 LGF3101-04.18 Double-lip oil seal
4.5″×5.5″×0.5″ 6 For pony rod
20 LGF3101-27.03.00 Air bladder 1 For KB-75 air dampener
21 LGF3101-28.11 Shear pin 12 For shear pin safety valve
22 LGF3101-28.03.00 Piston assembly 2 For shear pin safety valve
Note: For every set of LGF-1000 mud pump delivered, 3 sets of 6-1/2″ liners and
pistons are provided.
13. List of LGF-1000 Drilling Pump Drawings Provided
No. Drawing No. Descriptions Copies Page Notes
1 LGF3101-00 LGF-1000 drilling pump
1 4 Assembly chart
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2 LGF3101-05.00 Fluid end assembly 1 2 Assembly chart
3 LGF3101-27.00 KB-75 pulsation dampener
1 1 Assembly chart
4 LGF3101-28.00 JA-3 shear pin safety valve
1 1 Assembly chart
14. List of Spare Parts
No. Part No. Descriptions Qty. Unit weight
Total weight
1 GB/T3452.1-1992 O seal ring Ф175×Ф3.55
3
2 GB/T3452.1-1992 O seal ring Ф140×Ф7
3
3 GB/T3452.1-1992 O seal ring Ф97.5×Ф3.55
3
4 GB/T3452.1-1992 O seal ring Ф185×Ф7
3
5 GB/T3452.1-1992 O seal ring Ф345×Ф7
3
6 GB/T3452.1-1992 O seal ring Ф115×Ф5.3
3
7 GB/T3452.1-1992 O seal ring Ф165×Ф7.0
1
8 LGF3101-03.08 Oil seal 8.5″×10.5″×0.625″
2 0.6 1.2
9 LGF3101-04.06 Oil seal ring 3 0.1 0.3 10 LGF3101-04.18 Double-lip oil seal
4.5″×5.5″×0. 5″ 6 0.1 0.6
11 LGF3101-05.04 Liner seals 6 0.32 1.92 12 LGF3101-05.09 Valve pot cover
seals 3 0.1 0.3
13 LGF3101-05.17.05 Valve rubber (API 6#)
6 0.25 1.5
14 LGF3101-05.19.06.02.00 Piston rubber 6-1/2″
3 1 3
15 LGF3101-05.20 Piston seals 3 0.001 0.003 16 LGF3101-05.29.01 Air bladder
(suction ) 1 4 4
17 LGF3101-09 Seal gasket (back cover watch hole)
2 0.15 0.3
18 LGF3101-22.06 Gasket ring R27 2 0.45 0.9 19 LGF3101-23 Gasket ring R44 3 0.8 2.4
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20 LGF3101-27.01 Gasket ring R39 1 0.65 0.65 21 LGF3101-27.03.00 Air bladder
(discharge) 1 11 11
22 LGF3101-28.03.00 Piston assembly 1 0.057 0.057 23 LGF3101-28.06 Cushion gasket 1 0.1 0.1 24 LGF3101-28.11 Shear pin 10 0.022 0.22
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