02 Pump Device Service Manual

山东科瑞机械制造有限公司
Shandong Kerui Machinery Manufacture Co.,Ltd.
12-P-160 Pump device

Service Manual
KR107.60.00SM
Version：2015-A
Dongying • China
12-P-160 Pump Device Service Manual
Shandong Kerui Machinery Manufacture Co.,ltd.
Preface
Thank you for choosing the 12-P-160 pump unit manufactured by Shandong Kerui
Machinery Manufacture Co., Ltd.
This service manual of 12-P-160 pump unit is written by our engineers and technicians
according to the product designing and manufacturing and experience in oilfield service, and
divided according to the function mudules, provide the corresponding guidelines to the
structure of products、use and maintenance, etc. correct usages of this rotary table independent
drive device, good maintaining measures not only keep the equipment working in a good
condition, improve working efficiency, reduce breakdown lose, but also can prolong its
service life to the limit.
Because the product involves wide content, and this service manual only provide parts of
main contents. The equipments that are not mentioned or only provide a brief introduction can
be found in the respective technical document.
If products described in the manual are different from material object because technical
agreement changed temporary and related technical improvement, please in kind prevail.
I
 Special tips：
 Use the service manual personnel has the certain knowledge of drilling equipment
and drilling technology、the personnel familiarize professional technical、operators
and technicians, etc.
 Some equipment instructions from the manufacturer manual. if the manufacturers

have updated the user manual, unless otherwise specified, the manufacturer’
manual prior to the instruction manuals.
 All the information contain in this manual base on published in the latest product
information, the company reserves the right to abolished (or modify) at any time
without notice, also not take any responsibility and obligation
 Without the authorization of our company, prohibited to provide the set of

information to third parties in any way, otherwise the consequences, our company
will investigate its legal liability.
 The service manual although after a detailed review, but don’t rule out there are
still not satisfactory, please users put forward valuable opinion, convenient we
timely correction, make our products better service for you.
II
Important Safety statement
Any operation, management, maintenance and repair personnel of the products must
know very well of the relative content of the instruction and abide by the regulation related
to operation, management, maintenance and repair, especially for the content such as safety
warning and notes prompted by the instruction and national law, regulation, industrial
regulation and common-sense safety regulation and matters needed attention in and to
prevent the human injury and damage of the equipment.
The instruction could not list all safety warning information in detail, so when select a
method to operate, it must affirm the method neither can endanger the human safety nor
damage the equipment.
Correct maintenance is the key factor for the safety and reliable operation of the product.
The maintenance person should maintain the equipment to the method instruction
introduced.
The correct repair of the products and replacement of the components original factory
manufactured is the key factor for safe and reliable operation of the equipment. The user
must maintain and replace the component within the range manufacture authorized.
Please read carefully when the instruction uses the following title and mark!
Warning: Used for the condition which can cause human injury or dead if does not
abide by the operation procedure and method;
Attention: Used for the condition which can cause the damage or destruction of the
equipment if does not watch the operation procedure and method carefully.
Note: Used for attention or individual explanation.
III
catalogue
Preface ......................................................................................................................................... I
Important Safety statement....................................................................................................... III
Chapter 1 safety rules ................................................................................................................. 1
1.1 Personnel ....................................................................................................................... 1
1.1.1 Qualification requirements of operators .................................................................... 1
1.1.2 Protection requirements of operators ........................................................................ 1
1.1.3 Unauthorized personnel............................................................................................. 1
1.2 Other safety considerations ........................................................................................... 1
1.2.1 Equipment operation ................................................................................................. 1
1.2.2 Correct use of common tools .................................................................................... 2
1.2.3 Prevent falling objects accidents ............................................................................... 2
1.3 Safety habit ....................................................................................................................... 2
Chapter two Product descriptions .............................................................................................. 3
2.1 Summary .......................................................................................................................... 3
2.2 Technical parameter ......................................................................................................... 4
2.2.1 Mud pump ................................................................................................................. 4
2.2.2 DC motor ................................................................................................................... 4
2.2.3 Belt drive（input from pump two ends）................................................................. 5
2.2.4 Weight of pump ......................................................................................................... 5
Chapter three Installation of new pump ..................................................................................... 6
3.1 Pump installation on well site .......................................................................................... 6
3.2 Installation of pump base and mud pump ........................................................................ 6
3.3 The installation of transmission device ............................................................................ 6
3.4 Adjustment of belt pulley pre-tightening ......................................................................... 7
3.5 Check the centering of belt pulley.................................................................................... 7
3.6 Fixing of connecting bolts ................................................................................................ 7
3.7 Other attachment .............................................................................................................. 7
IV
Chapter 4 Belt changing ............................................................................................................. 8
Chapter five pump start and daily maintenance ....................................................................... 12
5.1 Preparation work before start ......................................................................................... 12
5.1.1 Lube ......................................................................................................................... 12
5.1.2 Dampener ................................................................................................................ 13
5.1.3 Safety valve ............................................................................................................. 14
5.1.4 Cooling .................................................................................................................... 14
5.1.5 Hydraulic end .......................................................................................................... 14
5.2 Start ................................................................................................................................ 15
5.3 Stop the pump................................................................................................................. 15
5.4 Mending ......................................................................................................................... 15
Chapter six Pump maintenance period and content .............................................................. 16
6.1 Daily maintenance .......................................................................................................... 16
6.2 Weekly maintenance ....................................................................................................... 17
6.3 Monthly maintenance ..................................................................................................... 17
6.4 Annually maintenance .................................................................................................... 18
6.5 Storge.............................................................................................................................. 18
6.6 The start after storing ..................................................................................................... 18
Chapter 7 pump unit common faults diagnosis and elimination .............................................. 20
7.1 Reason for shock of hydrailic end .................................................................................. 20
7.2 Reason for chock of power end ...................................................................................... 21
7.3 Reason for shock of pump unit ...................................................................................... 21
7.4 Reason and solutions of piston and cylinder sleeve wear .............................................. 21
7.5 Reason and solutions of the cylinder sleeve can not installed in the cylinder sleeve seat
.................................................................................................................................................. 22
Chapter 8 spare parts list .......................................................................................................... 23
V
Chapter 1 safety rules
In order to avoid and prevent the casualties, environment pollution, equipment damage and
property loss, and other accidents which may happen in installation, production, maintenance
and service process of the drilling rig, according to the relevant industrial standard specification,
we draw up the criterion.
1.1 Personnel
1.1.1 Qualification requirements of operators

The users of this service manual must have knowledge of drilling equipments and drilling
process. The users must be technical personnel, operators and technicians familiar with the
professional. Only authorized qualified personnel can operate and maintain the equipment.
1.1.2 Protection requirements of operators

Operation and maintenance personnel must wear helmet, protective clothing, safety shoes
and other protective equipments. Wear safety belts during aerial working. In the process of
drilling, in case of toxic gas escape, operating construction personnel must wear gas protective
equipment in the process of operation.
1.1.3 Unauthorized personnel

Unauthorized personnel refers to enthetic personnel or the personnel who is not in charge of
this position. Without the permission of the drilling crew related leaders, can not do any
operation to any parts of equipment. When operate, maintain and run this equipment, the
unauthorized personnel should keep safe distance with the equipment.
1.2 Other safety considerations
1.2.1 Equipment operation

To ensure that the equipment can run safely, reliably, stably, the operator should read the
documents belongs to this equipment carefully before using this equipment, understand the
operation requirements and special matters of the related equipments. All parts are not allowed
illegal disassembly or maintenance, espically illegal operation. When operate moving parts,
1
ensure that hands, cloth, tooles keep safe distance with moving parts.
1.2.2 Correct use of common tools

For the convenience of regular maintenance and operation of equipments, this set of
equipment is attached with a variety of common tools for maintenance and operation. Correct
use of these tools is very convenient for maintenance and operation.
1.2.3 Prevent falling objects accidents

When lift or remove the equipment, fully consider the ability of the lifting equipment and
the weight of the equipment. Ensure that there is no parts which is not fixed or easy to fall on the
lifting equipments. All personnel should keep safe distance with the equipment. In any case,
people are not allowed to stay under the euqipment.
1.3 Safety habit

When install, operate, disassembleand maintain this set of equipemt, good safety habit must
be kept. When operate this set of equipment, keep the related working area clean, no obstacles,
tools and other objects which effect operation.
2
Chapter two Product descriptions
2.1 Summary
12-P-160 pump is using high pressure to transfer the high viscosity、high proportion and
high sand content drilling liquid to well bottom during the drilling or workover process, it is used
for cooling the bit、washing the well bottom、broken the rock and take debris from the well
bottom, and it’s one of the most important equipment of drilling or workover rigs.
12-P-160 pump meet the design standard of《API 7K-2010 drilling and wellhead operation
equipment specification》and《SY/T5138-92 three cylinder one way drilling pump》.This pump
use module design and structure compact, it’s easy to maintenance and transport. It can used for
developing the petroleum and natural gas, and it’s a perfect equipment for mud circulation.
12-P-160 pump is combined with mud pump、AC motor、motor skid、big skid. Two sets of
AC motor separately fixed on the individual skid, and wholly fixed on the big skid of 12-P-160
pump，the power of motor through belt transfer into mud pump and drive it. Electrical lube pump
is used for lubricating the gear、bearing and crosshead，and spray pump is used for cooling the
piston and liner of power end, to confirm the power end can run reliable. Substructure as fig 2-1:
Belt Lamp frame Cable frame

Motor
12-P-160Mud Lube system
Spray system
Ladder
Control cabin frame
Release manifold
Fig 2-1 12-P-160 Mud Pump
3
2.2 Technical parameter
2.2.1 Mud pump

Rated power： 1600HP
Times of stroke： 120spm
Rated stroke： 12″/305mm
Max pump pressure： 5000psi/ 34.5MPa
Max liner diameter： 7-1/4″
Valve ： API7#
Gear ratio： 3.439
Table 2-1 12-P-160 Pump parameter
Liner diameter/in 7-1/4 7 6-1/2 6 5-1/2 5
Working pressure/MPa 22 23.6 27.4 32.2 34.5 34.5
Motor Stroke
Input
speed qty Exhaust volume GPM
power HP
rpm spm
1069 1600 120 772 720 621 529 444 367
891 1333 100 643 600 517 441 370 306
713 1067 80 515 480 414 353 296 245
534 800 60 388 360 310 264 222 184
356 533 40 257 240 207 176 148 122
Mechanical efficiency η=90%,volumn efficiency 100%
2.2.2 DC motor
Model ： 5GE752ARB2
Rated speed： 965rpm
Rated power： 1085HP
Rated voltage/currency： 750V/1150A
4
2.2.3 Belt drive（input from pump two ends）

Model： Gates 8V3350
Belt ratio： 2.34
2.2.4 Weight of pump

Weight of pump： 50000Kg
5
Chapter three Installation of new pump
3.1 Pump installation on well site

The position and direction of drilling pump, filling pump and the suction and discharge
pipeline route must be arranged well according to the wellsite arrangement plan, in order to
avoid reworking after installation and unnecessary cost.
The pump base has high flexural behavior but distortion resistance performance is poor. So,
the support infrastructure of pump must be horizontal, and the whole support of pump base is
even and with enough strength, in order to support the pump weight and vibratory force caused
during operating.
Put the pump on cement concrete horizontal infrastructure, which is good for the correct
grease distribution on power ends, to avoid the power ends rack become distorted or skewed and
affect the normal work of the pump.
If for ground installation, the support infrastructure must be 300mm wider than the pump
base beam. If for wet or marshes, the infrastructure should be more stable.
3.2 Installation of pump base and mud pump

The installation of pump base and mud pump must be carried out in flat board, and the board
surface flatness should not be more than 3 mm. Put the mud pump on the pump base plate when
the bolts are not tightened. Use bolts to fix the mud pump and base to avoid the power ends
rack become distorted or skewed.
3.3 The installation of transmission device

The transmission assembly pump and motor driven by V-belt, be careful when during
installation, in order to make sure the reliability of the transmission and avoid shut down caused
by transmission failure.
When install big belt, use light lubrication oil or anti adhesion of oil to grease the
transmission shaft spindle nose. And install the hub on the big belt pulley. When install hub,
because the tighten force piled into cone face, so it will increase number of times. If the tighten
force is too big, which would make big distend force and cause the hub and belt pulley broken.
6
So when tighten the hub bolts should alternately and step by step.
Connect the motor and pump base by motor base, and hang up the narrow V-belt and
pre-tighten (tighten a little, because some parts will be removed when adjust, the relevant bolts
need to tighten or disassemble.)
3.4 Adjustment of belt pulley pre-tightening

Move the center distance belt pulley by adjusting the screw rod, to adjust belt tension, until
no sagging happens in the tension side and the loose belt is tensioned. Then add a certain center
distance, generally increase 0.5%, such as the center distance of this pump unit is 2935.5mm, in
that way, the adjusted center distance should add 14mm.
Don’t lift the pump end to get belt tension, and not to put the pump penetrate into the earth
and use the pump weight to tighten belt.
3.5 Check the centering of belt pulley

The belts should be aligned after installation, the aligning method is to is to tension the two
strings (fishing line, piano wire is better) along one side of two belts to check the centering
condition. One line is over the center line, the other is under. Then move the small pulley (means
to move the motor) until the string touch the four points in the edge of the pulley, it means that
the transmission center line is paralleled, and its end surface is perpendicular to its axis. Tension
the belt pulley, and fasten the bolts. Follow the above method to check the coplanarity, if it the
change is too big, and then adjust again until up to grade. Finally, fasten all the bolts.
3.6 Fixing of connecting bolts

All bolts should be fixed after adjustment. And should use torque wrench not the normal
one, and the torque should in the range of 2214-2952 N.m
Note: The adjusting screw only used for belt’s extension force, can’t bear the huge
pull force of the working big belt，so all bolts must be fastened well, and should be often
checked.
3.7 Other attachment

cover，supporter and frame should install and fix according to drawing
7
Chapter 4 Belt changing

The belt driving device of 12-P-160 conclude motor、belt cover、big wheel、small wheel、
belt etc，as fig 4-1. The transmission parts of Pump and motor use V belt to drive, when
dismantle and install should be careful to guarantee the reliable and avoid machine stop because
of fault.
Big wheel Belt Belt cover Motor Small wheel
Fig 4-1 Pump driving device

When the belt worn or damage should change immediately, now should according to below
steps to dismantle and install:
(1) Remove the guard board inside cover

After removing the guard board
Remove 4 guard board
8
(2) Remove the fixing bolt on the bottom of cover Total remove 8 bolts
(3) Remove cover
Cover
9
(4) Remove the old belt
a. Remove the cable frame
c. Move skid for 100mm d. Remove old belt

b. Total 8 loosen bolts
(5) Check the belt and installation

Check the old belt and carefully check the belt before installation, confirm the belt will not
bring the problem of pump working not steadily and damage. Especially should check below
items：
a. Belt set difference not exceed 25mm；
b. New and old belt can’t mix using；
c. Different type of belts can’t mix using.
(6) Tension the belt and alignment the belt wheel，according to chapter three 3.4~3.6 Instillation
and adjust belt.
a.Tension blet c.8 loosen bolts b. Alignment 2 belt wheel
10
(7) Install cover
Install 8 fixing bolts
(1) Install inside guard plate and cable tray
Install guard cover
Install cable tray
11
Chapter five pump start and daily maintenance
Below content is the operation for the first time start，if not can’t execute all the operation.
5.1 Preparation work before start
5.1.1 Lube
Check the frame pitch of mud pump power end clean or not. Take out the mud pump pipe
plug to release and wash. Inject the proper extreme gear oil in power end, to guarantee the pump
can get lube immediately.
Mud pump lube system must start with pump together or previous start, in case damage the
parts friction surface
Table 5-1 Recommend lube oil in Power end
Environment temperature Oil spec
AGMA MILD EP #7 or ASTM/ISO - VG460 grade

0°F~ 155°F(+10℃~+68℃)
（viscosity 2214- 2719SSU.When 100°F）
AGMA MILD EP #6 or ASTM/ISO–VG320 grade

20°F~ 100°F(-7℃~+38℃)
（viscosity 1533– 1881SSU.When 100°F）
AGMA MILD EP #2 or ASTM/ISO–VG68 grade

-20°F~ 60°F(-29℃~+16℃)
（viscosity 318– 389SSU.When 100°F）
Oil volume：about 130 us gal（492L）
Note：according to table 5-1 to inject lube oil，position as fig 5-1.
12
Fig 5-1 Oil inlet position
5.1.2 Dampener
Inject the nitrogen into dampener, and air pressure is 2.8～4.5MPa。
Fig 5-2 Dampener
Warning！Forbidden to inject hydrogen、oxygen etc combustible gas into

dampener
13
5.1.3 Safety valve

The safety valve is spring reset type，working pressure is 1500～5000psi.
Note！The operation of safety valve should obey《Operation and maintenance manual》。
Fig 5-3 Safety valve
5.1.4 Cooling
Fill the cooling liquid in water cooling tank to guarantee the cooling liquid fill the spray
pump，and check the connector of pipeline leakage or not！
Cooling liquid can use the mixture of emulsified oil and water or use water to add cleaning
agent, but if use water as basic liquid, must add some antiseptic to protect parts not corrosion！
Spray system must start with pump together or previously start to prevent the liner and
piston being damaged！
Note！The cooling of liner and piston is only under the circumstances of the cooling
liquid is colder than drilling liquid. Under the special situation should take other measures
to cooling the liquid.
5.1.5 Hydraulic end

(1) Confirm the liner and piston etc are correctly installation，clamp、valve cover etc are all
tightened；
(2) Open all the valves on suction and exhaust pipeline，and confirm charge pump and mud
pump start at the same time or start before mud pump. Forbidden the mud pump start before
charge pump，because this may cause the mud pump cavitation or suction not sufficient；
14
(3) Pump cavitation：Before the mud pump start with pressure，must fill the drilling liquid in
cylinder. For the pump which has cavitation should open the air pipeline, start running the
pump till the air exhaust.
5.2 Start
(1) Dot start mud pump
Before start the mud pump motor, should first start the electric liner、lube pump and charge
pump, or can start at the same time to avoid the damage of equipment
Check the direction of each motor and stipulated is same or not, and if the voice is abnormal,
if no can open the two motors at the same time
(2) Low speed to rotor the mud pump
Check the hydraulic end leakage or not、lube system and spray system abnormal or not，if no
abnormal can speed up and drilling.
5.3 Stop the pump

If want to stop the pump should first stop the main motor, then should stop the lube system、
spray system motor and charge pump motor at the same time.
5.4 Mending
Mending work should after the pump stop；
If need to check the hydraulic end，should first close the butterfly valve of suction pipe，after
mending then open.
position“1”
position“0”
Warning！Before checking the pump must put the switch of main motor to position“1”！
15
Chapter six Pump maintenance period and content
6.1 Daily maintenance

(1) Power end：Pump off, check the oil level of the power end, also check whether there is
working oil leakage once per shift.
(2) Piston and liner：Observe the situation of liner and piston, some liquid leakage from some
“by pass” doesn’t mean the liner or piston is worn. The liner is worn averagely means the
piston also worn averagely. But they can still work till the leakage from “by pass” is
obviously and seriously every stroke, then can change.
(3) Clean the cylinder sleeve cabin：According to the necessary to clean the liner cabin, the
drilling liquid leakage from “by pass” will be sediment in cylinder sleeve cabin. When the
cooling liquid is contaminated should change the cooling liquid and clean the cooling water
tank.
(4) Lube for cylinder sleeve：Daily check the cylinder sleeve cooling liquid and add according
to necessary, when dirty should change in time. Before add the cooling liquid, should
remove the two pipe plug on the side of cooling tank and should use water to clean.
Note！The contaminated cooling liquid will increase the worn of liner pump and
shorten the pump life
(5) Spray pipeline or piston rod：Daily check the nozzle of cylinder sleeve to avoid its clogging,
ensure the full cylinder and piston have enough supply of cooling and lubricating fluid once
per day.
(6) Piston rod and cylinder sleeve clamp：After pump first time running several hours should
tighten the liner and piston clamp once. This can prevent the pump initial assembly, messy
go inside and hinder the connection and let the pump running under loosen situation.
(7) Valve cover：After the pump running several hours, tighten valve cover once again.
(8) Suction dampener：Checked whether the working of Suction dampener is properly, and
confirm the pump has proper charge under the running condition.
(9) Rod seal device：Daily use lithium grease lube the rod seal device
16
6.2 Weekly maintenance

(1) Valve thread：Every two weeks check once. Clean the messy on valve thread and flange
thread，using the drill collar grease clean all the thread. Forbidden to use “thread lube” that
the normal tools used because they lack the connection protect ability.
(2) Taper lock wedge block and valve lock bolt: ( For the valve cover installed “taper lock” )，
Thoroughly clean the two sides of taper lock block. Use the grease same as the drill collar to
lube these parts.
Note！Valve cover should put on the cleaned valve chamber
(3) Valve cover and seal ring：Clean the top of valve cover and using above thread grease to lube.
Before install the valve cover，should check the seal ring，and carefully clean and lube the
circular bead. To prevent valve cover cock and guarantee the cover and metal overall contact,
this is necessary.
(4) Valve rod guide sleeve：Check the rubber valve stem guide sleeve, replace it if it is worn
clearly. Losing the correct guiding of valve rod, un-round or oval guide sleeve will
accelerate the wear of the valve. The old sleeve can cut off and new can use jaw vice to press
into sleeve seat
(5) Valve and valve seat：Check the wear situation of valves and valve seats, replace the worn or
stabbed valve, valve rubber and valve seat. Check the valve spring, replace the broken or
elasticity loosen valve spring.
(6) Seal for piston bushing：This is a compress seal，installed on the piston bushing flange
surface and the radius of piston rod circular bead. Can’t use other seals for replace, after
damage should change in time, should confirm the seal ring properly installed in the piston
bushing round channel.
(7) Piston locking nut：If the piston locking nut has been damaged, abrasion or lock nut nylon
have lost their locking capacity, replace it. Any bolt which has been used for three times, can
not be used any more.
6.3 Monthly maintenance

(1) Filter：Demolition and clean the exhaust filter and filter pipe every month.
(2) Lube for power end：Drain and clean the power end oil case and oil pool under crosshead
every 6 month，re-add the proper extreme pressure gear oil.
17
(3) Stud and nut：Check all the cylinder stud and nut loose or not, including the valve bolt、
cylinder and stud connect with cover、stud connect liner seat and cylinder 、exhaust &
suction stud.
(4) Seal washer and gasket：Check the leakage seal washer and loosen bolt on power end,
change according to requirement.
(5) Lube system magnet：When change the lube oil every time should clean the magnet on top
oil channel.
(6) Lube system oil channel fasten parts：Check the loose situation of fixing bolt and the
position for gear board.
6.4 Annually maintenance

(1) Recommend to check the pump every 2 to 3 years, check the connecting rod、small gear
shaft、crosshead pin shaft and crosshead guide plate loose or not. If loose should take
measures to maintenance thoroughly.
(2) Check the tighten degree of bolts on mud pump fixing plate.
6.5 Storge
(1) long time for storage or stop, lift and block up hydraulic end to make up decline to power
end, then, empty oil groove and setting pond, clean them for long storage. Remove the fuel
tank plug，then install a 90°elbow，and cover a wire entanglement. This can let the air
circulate and prevent the steam congeal. For all the bearing on power end should coat the
anti-rust oil on all the inside surface.
(2) Power end：Discharge the valves, piston, piston rod liner of hydraulic cylinder, clear out
inner hydraulic cylinder and all components. Coat anti-rust oil on whole hydraulic valves
and components, clean liner spray system and liner chamber. Inject some lubricating oil into
liner spray system for anti-rust.
(3) Check the storing up equipment once a month and drive gear once. Re-coat anti-rust oil if
necessary.
6.6 The start after storing

(1) Power end：Remove all the cover of power end, clean and check all the parts machining face.
Check all the bearings and confirm they are clean, put the proper and clean extreme pressure
18
gear oil in hydraulic end，confirm the oil channel and crosshead oil pitch all have oil, and
can enter all the bearing.
(2) Hydraulic end：valve、piston、liner and all the hydraulic end parts are at the correct position，
tighten all the bolts、nuts、studs and joints carefully， use the clean cooling liquid inject into
the spray system.
Note！Any mud pump after storing, no matter used by oilfield or deliver out of
factory should confirm it has no damage, even though all the parts on correct position
should check again
19
Chapter 7 pump unit common faults diagnosis and elimination
7.1 Reason for shock of hydrailic end

(1) Misoperation of discharge air chamber and suction air chamber: ensure that the discharge
air chamber is charged with nitrogen to the pressure is 2.8~4.5 Mpa. Check out whether the
level position is suitable.
(2) The valve is loose, valve shell or valve seat is wearing, valve is cocking in the valve seat:
use pipe wrench, quickly pull the valve seat from the valve seat base, check out whether it is
loose. Check out whether the valve is wearing uneven, fluid washout, snap ring and valve
palte loosen.
(3) Piston core loose: check out whether the piston nut is normal.
(4) Output of charging pump is too low: when mud pump is working, the charging pressure of
suction manifold is 0.14~0.35 Mpa.
(5) Charging pump packing loosen or wear, make the air into the suction pipe: when start
charging pump and mud pump, water the packing with hose, if the shock stops, then adjust
or change the packing.
(6) The suction pipeline is blocked or the suction pipeline filter is blocked.
(7) There is air or gas in the drilling fluid: check out whether there is too much bubble in the
mud pools, check out whether the end of mud return pipeline is lower than the level of mud,
check degasser equipments.
(8) Piston rod clamp loosen or wear: the surface of the two clamps can not contact metal to
metal. There should be no relative motion between the piston and clamp.
(9) Debris block the discharge bottom bracket filters, and hamper the normal working of
discharge air chamber: clean the filters.
(10) The expansion of the valve rod guide sleeve causes the bonding of valves: change valve
rod guide sleeve or valve.
Attention! Shock problems mostly associated with the hydraulic end. Before
check the power end, fully inspect the lydraulic end.
20
7.2 Reason for chock of power end

(1) Crosshead pin loosen: demount the two bolts outside the pin pressing plate and knock on the
pins lightly. If the pins can move easily in the crosshead, tighten it again and add gaskets.
(2) The installation of crosshead guide plate is nor correct.
(3) The clearance between crosshead and connecting rod bearing is too large ( more than
0.46mm ).
(4) The clearance between crosshead and guide plate is too large.
(5) The main bearing do not rely on the bearing sleeve shoulder tightly, make the crankshaft
component float to on side, and the big gear touch oil scraper.
(6) The big gear or small gear is out of shape: check gear surface and file to any interference
parts.
(7) Main bearing bolts loosen, tighten one by one according to the mud pump service manual.
7.3 Reason for shock of pump unit

(1) The drive pullley is imbalanced.
(2) The drive belt loose.
(3) Pump unit support is unsuitable.
(4) The drive belt is composed by new and old two parts.
(5) The two DC drive motor is not synchronous: after checked, diamantle one side belt, use the
single motor drive, check out whether the shock is eliminated.
7.4 Reason and solutions of piston and cylinder sleeve wear

(1) The cooling fluid sprayed to the cylinder sleeve is not enough and cause overheating: check
out whether the nozzle of spray pipeline or piston rod hole is blocked.
(2) The cooling fluid is overheating, higher than 38℃: use a larger cooling fluid box or heat
exchanger connected with a uncirculated clean water system.
(3) The cooling fluid is polluted by sundry or drilling fluid.
(4) The quantity of sand, solid or carbide particles in the drilling fluid is very high: normally, it
will cause to form the strip mark in the cylinder sleeve. Inspect desander and sprayed mud
tank.
(5) If the oil aniline point is lower than 90℃, the oil-base drilling fluid can make the piston cup
and cover metamorphic.
(6) The corrosive fluid corrode the cylinder sleeve: the PH value should be greater than 8.5. the
21
corrosive fluid should use high quality cylinder sleeve.

(7) If the drilling fluid containing hydrogen sulfide, it will corrode the piston cup.
7.5 Reason and solutions of the cylinder sleeve can not installed in the cylinder
sleeve seat
(1) The two guide diameter of cylinder sleeve coated with paint, eliminate paint with emery
cloth.
(2) Due to the incorrect tightening of screw, lead to the ovality of cylinder sleeve seat: the
wearproof gasket is 0.05mm protruding. Cross tighten the screw can make the cylinder
sleeve will not be out of shape because of the 0.05mm protruding.
(3) Burr of the guide diameter of cylinder sleeve: use sandpaper grind the burr gently. Can not
damage the surface.
(4) There is cuttings on the wear resistant mat: clean wear-resisting plate.
Attention! Before installation, apply drill collar thread oil on the guide
diameter of cylinder sleeve.
22
Chapter 8 spare parts list
Item Part Description Qty Requested Part number
1 Liner 6'' 30 05-466-600 NOV TS-0259-60HP TSC
2 Liner 6''1/2 50 05-466-650 NOV TS-0259-64HP TSC
4 Liner Gasket 6" 100 1540124 NOV G-261 TSC
5 Liner Gasket 6"1/2 100 1540151 NOV G-284 TSC
7 Piston Complet 6" 30 20-021-505 NOV 1-60-B15 TSC
8 Piston Complet 6"1/2 50 20-021-507 NOV I-64-L15 TSC
9 Piston Complet 7" 20 20-021-509 NOV I- 70-Ll5 TSC
10 Piston Rubber 6" 30 20-040-013 NOV TM-60-BR TSC
11 Piston Rubber 6"1/2 50 20-040-037 NOV TM-64-LR TSC
12 Piston Rubber 7" 30 20-040-041 NOV TM-70-LR TSC
13 Piston Rod 12 1292147 NOV TM-258A TSC
14 Extension Piston Rod 3 1292146 NOV TM-258B TSC
15 Piston Rod nut 3 6308241 NOV TM-NUT TSC
1292147/12921 TM-258A/TM-25
16 Cross head extension 6 46/1292085/129 NOV 8B/TM12P-01-06 TSC
2023 /TM12P-03-08
17 Liner Clamp 12 1292166 NOV TS-1292166 TSC
23
18 Valve Complete 100 1560985 NOV TS-0985M TSC
19 Valve Spring 20 1560702 NOV TS-1560702 TSC
20 Valve Cover Gasket 200 1540127 NOV TS-1540127 TSC
21 Upper guide bushing 20 1292165 NOV TS-1292165 TSC
22 Valve Cover 3 1292352 NOV TS-1292352 TSC
23 Valve Seat 100 1561440 NOV TS-1561440 TSC
24 Seal valve Retainer 60 1540127 NOV TS-1540127 TSC
25 Clamp Complete Rod 6 1292085 NOV TM12P-03-08 TSC
26 Disc Valve 12 1560557 NOV TS-7-MI TSC
27 Wear Plate 30 1292266 NOV TS-1292266 TSC
28 Wear Plate Gasket 100 1292257 NOV TS-1292257 TSC
29 Fluid End Assy (suction) 2 1292612 NOV TS-1292243 TSC
30 Fluid End Assy (discharge) 2 1292611 NOV TS-1292240 TSC
31 Fluid end seal 30 1540851 NOV TS-1540851 TSC
32 Ring threaded (flange) 1 1292351 NOV TS-1292351 TSC
33 Discharge adapter 2 1292253 NOV 1S-1292253 TSC
34 Discharge adapter seal 10 1292258 NOV TS-1292258 TSC
35 Discharge connector 1 1292252 NOV TS-1292252 TSC
36 Discharge con nector seal 1 4 2410031-437 NOV TS-2410031-437 TSC
24
38 Liner bushing 1 1292165 NOV TS-1292165 TSC
39 Liner bushing screw 1 24008028 NOV TS-2408028 TSC
40 Lubrification electric pump 1 7815926 NOV
41 Oil filter 6 781507 NOV
42 V belt 2sets 8V3350 gates
25
Shandong Kerui Machinery Manufacture Co.,Ltd.
12-P-160 泵装置
使用说明书
Service Manual
KR107.60.00SM
版本：2015-A
中国•东营
12-P-160 泵装置使用说明书
前言
感谢您选用山东科瑞机械制造有限公司制造生产的 12-P-160 泵装置。
12-P-160 泵装置使用说明书是由我公司工程技术人员根据产品设计制造和油田服
务经验，按照功能模块的划分进行编写而成，对产品的安装、使用及操作等提供了相应
的指南。正确的使用方法、良好的维护保养措施不仅可以保证设备在工作中处于完好状
态、提高生产效率、减少停机损失，还能够最大限度的延长设备使用寿命。
因为产品涉及内容宽泛，本使用说明书仅提供了部分主要内容，未提及或仅作简要
介绍的设备详见各自技术文件。
本说明书所描述的产品，由于技术协议的临时变化或相关技术改进等原因，可能会
存在与实物不相符的地方，请以实物为准！
特别提示：
 本套使用说明书使用的对象是对钻井设备及钻采工艺具有一定知识、熟悉的专
业技术人员、操作人员和技工等；
 部分设备的说明取自各制造厂商的使用手册。如该制造商更新了使用手册，除
非另有说明，该制造商的使用手册优先于本套使用说明书给定的资料；
 所有本说明书中包含的信息是基于出版时所具备的最新产品信息，本公司保留
在任何时间废止（或修改）而无需通知的权利，也不负任何责任和义务；
 未经本公司授权，严禁以任何方式，把本套资料提供给第三方，否则对产生的
后果，本公司有权追究其法律责任；
 本说明书旨在对本套设备实际操作维护的指导及要求，如有不当之处，恳请用
户提出宝贵意见，以便再版时补充修正，让我们的产品更好的为您服务。
 为了更加直观表达产品，本说明所涉及的设备及流程的图片颜色仅供参考，具
体颜色以实物为准。
I
重要安全声明
产品的任何使用、管理、操作、维护保养及维修人员必须熟知本手册的相
关内容，并遵循本手册的有关使用、管理、操作、维护保养及维修的规范程序，
并特别注意本手册所提示的安全警示、注意等内容，以及国家法律法规、行业
规定及一般常识性的安全条规及注意事项，以避免导致人身事故和设备的损坏。
本手册可能无法详尽列出所有的安全警示信息，因此在选用任何一种方法
进行操作时，必须首先确认该方法既不会危害人身安全，也不会损坏设备。
正确的维护保养是产品安全可靠运行的重要因素，维护保养人员应按照本
手册介绍的方法进行维护保养。
产品正确的维修、更换原厂的零部件是设备安全可靠运行的重要因素，使
用者必须根据厂方的授权范围进行维修和更换零部件。
本手册使用以下标题、标志时，请认真阅读！
警告！用于如果不正确遵守操作步骤、方法等，可导致人身伤
亡的情况。
注意！用于如果不严密观察操作步骤、方法等，可能导致损伤
或破坏设备的情况。
注释！用于注意或单独解释说明的情况。
II
目录
前言 ......................................................................................................................................... I
重要安全声明 ........................................................................................................................... II
第一章安全准则 ...................................................................................................................... 1
1.1 人员 ............................................................................................................................. 1
1.1.1 操作人员的资质要求 ...................................................................................... 1
1.1.2 操作人员安全防护要求 .................................................................................. 1
1.1.3 未被授权人员 .................................................................................................. 1
1.2 其它安全事项 ............................................................................................................. 1
1.2.1 设备的操作 ...................................................................................................... 1
1.2.2 常用工具的正确使用 ...................................................................................... 1
1.2.3 预防落物事故 .................................................................................................. 1
1.3 安全习惯 ..................................................................................................................... 2
第二章产品概述 ...................................................................................................................... 3
2.1 概述 ............................................................................................................................. 3
2.2 技术参数 ..................................................................................................................... 4
2.2.1 泥浆泵 .............................................................................................................. 4
2.2.2 直流电机 .......................................................................................................... 4
2.2.3 皮带传动（由泵两端输入） .......................................................................... 4
2.2.4 泵装置总质量 .................................................................................................. 4
第三章新泵的安装 .................................................................................................................. 5
3.1 泵装置的井场安装 ..................................................................................................... 5
3.2 泵装置底座与泥浆泵的安装 ..................................................................................... 5
3.3 传动装置的安装 ......................................................................................................... 5
3.4 皮带预紧力的调整 ..................................................................................................... 5
3.5 检查皮带轮的对中性 ................................................................................................. 6
3.6 连接螺栓的紧固 ......................................................................................................... 6
III
3.7 其他附件 ..................................................................................................................... 6
第四章皮带更换 ...................................................................................................................... 7
第五章泵装置的启动及日常操作 ........................................................................................ 11
5.1 启动前的准备工作 .................................................................................................... 11
5.1.1 润滑 ................................................................................................................ 11
5.1.2 空气包 ............................................................................................................ 12
5.1.3 安全阀 ............................................................................................................ 13
5.1.4 冷却 ................................................................................................................ 13
5.1.5 液力端 ............................................................................................................ 13
5.2 启动 ............................................................................................................................ 14
5.3 停泵 ............................................................................................................................ 14
5.4 检修 ............................................................................................................................ 14
第六章泵装置维护周期与日常保养内容 .......................................................................... 15
6.1 日保养 ........................................................................................................................ 15
6.2 周保养 ........................................................................................................................ 15
6.3 月保养 ........................................................................................................................ 16
6.4 年度保养 .................................................................................................................... 17
6.5 泵的贮存 .................................................................................................................... 17
6.6 贮存后的启动 ............................................................................................................ 17
第七章泵装置常见故障的诊断与排除 .............................................................................. 18
7.1 液力端的震击的原因 ................................................................................................ 18
7.2 动力端的震击的原因 ................................................................................................ 18
7.3 泵装置震动原因 ........................................................................................................ 19
7.4 活塞和缸套加速磨损的原因及解决方法 ................................................................ 19
7.5 缸套难以装入缸套座的原因及解决方法 ................................................................ 19
第八章推荐备件清单 .......................................................................................................... 20
IV
第一章安全准则
为避免和防止产品在安装、调试、生产、维护和检修过程中可能出现的人员伤亡、环
境污染、设备损坏及财产损失等事故，根据相关行业标准规范，特制定本准则。
1.1 人员
1.1.1 操作人员的资质要求
本套使用说明书使用的对象是对钻井设备及钻采工艺具有一定知识、熟悉的专业技术
人员、操作人员和技工等，只有被授权的合格人员才能操作和维护该套设备。
1.1.2 操作人员安全防护要求
操作和设备维护人员都必须穿戴安全帽、防护衣、防护鞋及其他防护设备等，高空作
业时必须系安全带；在钻井过程中，如遇有毒气体逸出，操作施工人员在作业过程中还必
须穿戴防毒装备。
1.1.3 未被授权人员
指外来人员或非本岗位工作人员，在没有征得井队相关领导的许可下，不得对钻机的
任何部件设备进行任何操作。当操作、维护或运行设备时，未被授权的人员应与设备保持
安全距离。
1.2 其它安全事项
1.2.1 设备的操作
为保证您的产品安全可靠、稳定运行，操作者在使用设备前请认真阅读本套设备的随
机资料内容，了解相关设备的操作要求和特别注意事项。所有部件不允许有任何违章的拆
卸及维护，甚至违章操作。尤其操作运转部件时，须确保手、衣服、工具等远离运转部件。
1.2.2 常用工具的正确使用
为方便设备的正常维护及操作，该套设备附带有用于维护及操作的多种常用随机工具，
正确使用该套设备的随机工具，对设备的维护及操作是十分方便有利的。
1.2.3 预防落物事故
提升或移动设备时，应充分考虑提升设备的能力和被提升设备的重量，应确保被提升
1
设备上无未固定、易坠落的零部件及操作工具等。人员应当保持与被提升设备的安全距离，
在任何情况下，人员都不得处于被提升设备的下方。
1.3 安全习惯
安装、操作、拆卸及维护该套设备时，必须随时保持良好而全面的安全习惯。在操作
该套设备时，要保持相关的工作区域清洁、干净，不得有障碍物、工具及其他影响操作的
物体。
2
第二章产品概述
2.1 概述
12-P-160 泵装置是在钻井或修井过程中以高压向井底输送高粘度、大比重、含沙量较
高的钻井液，用以冷却钻头、冲洗井底、破碎岩石，从井底返回时携带出岩屑，是石油钻
井或修井作业中最重要的设备之一。
12-P-160 泵装置符合《API 7K-2010 钻井和井口操作设备规范》和《SY/T5138-92 三缸
单作用钻井泵》的设计制造标准。该泵装置采用模块化设计，结构紧凑，维护保养简单，
运输方便。可用于石油天然气的勘探开发，是泥浆循环的理想设备。
12-P-160 泵装置由泥浆泵、直流电动机、电机底座、大底座等组成。两台直流电动机
分别固定于各自的独立橇座之上，并整体固定于 12-P-160 泵后部的大底座之上，电动机动
力通过皮带从输入轴两端传给泥浆泵，带动泥浆泵工作。配套电动润滑油泵用以对齿轮、
轴承、十字头等的润滑，配套电动喷淋泵用以冷却液力端活塞、缸套，确保液力端部件运
转可靠。结构如图 2-1 所示：
皮带传动装置灯架电缆架电机
12-P-160 泥浆泵外置润滑系统
外置喷淋系统
操作梯
控制箱支架
小踏台
泄压管汇
图 2-1 12-P-160 泵装置
3
2.2 技术参数
2.2.1 泥浆泵
额定功率： 1600HP
额定冲次： 120spm
额定冲程： 12″/305mm
最大泵压： 5000psi/ 34.5MPa
最大缸套直径： 7-1/4″
阀腔： API7#
齿轮传动比： 3.439
表 2-1 12-P-160 泵装置性能参数表
缸套直径/in 7-1/4 7 6-1/2 6 5-1/2 5

工作压力/MPa 22 23.6 27.4 32.2 34.5 34.5
电机转速输入功率冲次
排量 GPM
rpm HP spm
1069 1600 120 772 720 621 529 444 367
891 1333 100 643 600 517 441 370 306
713 1067 80 515 480 414 353 296 245
534 800 60 388 360 310 264 222 184
356 533 40 257 240 207 176 148 122
取机械效率 η=90%,容积效率 100%
2.2.2 直流电机
型号： 5GE752ARB2
额定转速： 965rpm
额定功率： 1085HP
额定电压/电流： 750V/1150A
2.2.3 皮带传动（由泵两端输入）
型号： Gates 8V3350
皮带传动比： 2.34
2.2.4 泵装置总质量
泵装置总质量： 50000Kg
4
第三章新泵的安装
3.1 泵装置的井场安装
泵装置安装根据井场的布置方案，把泵装置的位置方向，吸入和排出管线的走向都规
划好，以免装完之后返工，造成不必要的浪费。
泵装置的泵底座具有很高的抗弯性能，但抗扭曲性能是较差的。因此，泵装置的支撑
基础必须是水平的，且泵底座的全长支撑均匀，并有足够的强度，以便能够支持泵的自重
和运转时产生的振动力。
应尽量将泵装置放在水泥混凝土的水平基础上，以利于动力端润滑油的正确分布，防
止动力端机架可能的扭曲或歪斜，影响泵的正常工作。
如果进行地面安装时，支撑基础必须比泵底座梁的主体宽 300mm 以上，潮湿或沼泽
地带，需要更稳固的基础。
3.2 泵装置底座与泥浆泵的安装
泵装置底座与泥浆泵的安装必须在平台进行，且平台的平面度不得大于 3mm,泥浆泵
在螺栓不拧紧的情况下坚实的坐落在泵装置底座的垫板上，用螺栓将泥浆泵与底座固定，
防止泵动力端机架可能的扭曲或歪斜。
3.3 传动装置的安装
泵和电动机的传动组件采用联组窄 V 带传动，安装时应十分小心，以保证传动的可靠
性并可避免由于传动故障造成的停机。
大皮带轮安装时，用轻质润滑油或防粘合油涂抹泵传动轴轴头，并将皮带轮毂装上，
安装大皮带轮，上紧轮毂螺栓。在安装轮毂时，紧固螺栓的力由于挤入锥形面的作用将增
大数倍，如果紧固螺栓的力过大，会产生很大的胀开力，引起轮毂和皮带轮破裂，因此上
紧轮毂螺栓时要交替紧固并逐步地进行。
将电动机通过电机底座与泵底座相连接，挂上联组 V 带并进行预紧（略加紧固即可，
因为再找正时还要对某些部分加以移动，对应的螺栓要松动或拆卸）。
3.4 皮带预紧力的调整
用调节丝杠移动皮带轮中心距，以调整皮带张力，直到皮带的张紧侧没有下垂，松弛
侧皮带也张紧，然后再增加一定的中心距，一般增加 0.5%，即如本套泵装置中心距为
5
2935.5mm，则在调整好中心距以后约再增加 14mm。
不要用垫起泵的端部的办法获得皮带张力，也不要把泵的端部降低到地面以下用泵的
自重来张紧皮带。
3.5 检查皮带轮的对中性
安装完成后对皮带轮进行调正，调正方法为张紧两条弦线（钓鱼线，最好是钢琴线）
沿两个皮带轮一侧边来检查对中情况。一根弦线在中心线之上，一根在下。然后移动小皮
带轮（即移动电机）的位置直到弦线接触到皮带轮轮缘上的四个点，这样就肯定了带轮的
传动中心线是平行的，并且其端面是垂直于其轴线的。将皮带轮涨紧，再紧固螺栓。按上
述方法再检测大小皮带轮的共面度，如果变动太大，需再次调正直至合格，最后对所有螺
栓做一次性紧固。
3.6 连接螺栓的紧固
完成调整工作后电机与电机底座、电机底座与大底座之间螺栓必须紧固。螺栓紧固时
必须使用扭矩扳手，不可使用普通扳手，并且拧紧力矩要在 2214-2952 N.m 的范围内。
注意！调节丝杠只做调正皮带的涨紧力用，不能承受皮带轮在
工作时产生的巨大拉力，因此所有的固定螺栓必须彻底紧固，
而且以后要经常检查。
3.7 其他附件
护罩，支架和吊架等按随机图纸所示位置安装并紧固即可。
6
第四章皮带更换
12-P-160 的皮带传动装置由电机、皮带护罩、大带轮、小带轮、皮带等组成，如图 4-1

所示。泵和电动机的传动组件采用联组窄 V 带传动，拆卸与安装时应十分小心，以保证传
动的可靠性并可避免由于传动故障造成的停机。
大带轮皮带皮带护罩电机小带轮
图 4-1 泵装置皮带传动装置
皮带磨损失效或损坏时应及时进行更换，此时应按以下步骤拆卸与安装皮带传动装置：
（1)拆掉护罩内侧的护板
拆掉四个护板护板拆除后
7
（2）拆掉护罩底部的固定螺栓
共计拆掉 8 个螺栓
（3）移除护罩
护罩
8
（4）拆除旧皮带
a. 拆掉电缆架
b.旋松螺栓共 8 个 c.利用张紧装置推动电 d.拆掉旧皮带

机底座移动 100mm。
（5）检查皮带并安装
检查拆除掉的旧皮带，在进行安装之前要对皮带进行认真仔细的检查，确保不会因皮
带问题带来泵的工作不平稳及对泵装置的损坏。尤其要对以下几点进行认真的核实：
a.皮带配组差不超过 25mm；
b.新旧皮带不可混用；
c.不同种类皮带不可混用。
（6）张紧皮带并找正皮带轮，按照第三章 3.4~3.6 安装调整皮带。
a.张紧皮带 c.旋紧螺栓共 8 个 b.找正大小两个皮带轮
9
（7）安装护罩
安装固定螺栓共 8 个
（8）安装内侧护板及电缆架
安装护板
安装电缆架
10
第五章泵装置的启动及日常操作
以下内容为初次启动时需要进行的操作，如非初次启动可无需执行全部操作。
5.1 启动前的准备工作
5.1.1 润滑
检查泥浆泵动力端机架油池是否清洁。取下泥浆泵的管塞进行放泄和冲洗。给动力端
加上适当牌号和数量的工业用极压齿轮油，把润滑油灌进小齿轮轴承油槽和十字头油池，
并盘车数圈使内部各储油部位都充满油，以保证启动泵时立即得到润滑。
泥浆泵润滑系统必须和泵同时启动或提前启动，以避免损伤零部件摩擦面。
表 5-1 动力端推荐润滑油
环境温度油品规格
AGMA MILD EP #7或ASTM/ISO - VG460级（粘度

0°F~ 155°F(+10℃~ +68℃)
2214- 2719SSU。当100°F 时）
AGMA MILD EP #6或ASTM/ISO–VG320级（粘度

20°F~ 100°F(-7℃~ +38℃)
1533– 1881SSU。当100°F 时）
AGMA MILD EP #2或ASTM/ISO–VG68 级（粘度

-20°F~ 60°F(-29℃~ +16℃)
318– 389SSU。当100°F 时）
加油量：约 130 us gal（492 升）
注释：按表 5-1 所示加注润滑油，注油口位置如图 5-1 所示。
11
图 5-1 注油口位置
5.1.2 空气包
空气包内充入氮气，充气气压为 2.8～4.5MPa。
图 5-2 空气包
警告！空气包内严禁充入氢气、氧气等易燃易爆的气体。
12
5.1.3 安全阀
安全阀为弹簧复位式，工作压力范围 1500～5000psi，应使用高于正在使用缸套相应的
最高额定压力的 10%来设定安全阀的压力。
注意！安全阀的操作应遵循其《操作与维护手册》
。
图 5-3 安全阀
5.1.4 冷却
向冷却水箱内加满干净的冷却液，保证冷却液灌满喷淋泵，并检查管线接头处是否漏
水！
冷却液可使用乳化油和水的混合物或水加净化剂，但是若以水为基本液体，则必须加
某些型号的防腐剂以保护零件不受腐蚀！
喷淋系统必须和泵同时启动或提前启动，以免损伤缸套活塞！
注意！缸套和活塞的有效冷却仅仅是在冷却液温度低于钻井液
温度的情况下才能完成。在特殊情况下，需要采取另外的方法给冷
却液散热。
5.1.5 液力端
（1）确保缸套、活塞等均已正确安装，卡箍、阀盖等均已拧紧；
13
（2）打开所有吸入管线、排出管线上的阀门，并确保灌注泵和泥浆泵同时启动或先
于泥浆泵启动。禁止泥浆泵先于灌注泵启动，因为这样会造成泥浆泵气蚀或吸入不足；
（3）泵的气穴现象：泥浆泵在带压启动前，必须向液缸里灌满钻井液。已发生气穴
的泵，应打开放空管线，开泵运转直到空气被排除。
5.2 启动
（1）点启动泥浆泵
启动泥浆泵主电机前，必须先启动电动喷淋泵、电动润滑泵和电动灌注泵，或同时启
动，避免设备的损坏。
分别检查各电机的旋转方向与规定的方向是否相同，有无异常响声，无异常后才能同
时开双电机。
（2）低速运转泥浆泵
检查液力端有无渗漏、润滑系统和喷淋系统有无异常，无异常后方可提速进行正常钻
井作业。
5.3 停泵
停泵操作应先停主电机，再停润滑系统、喷淋系统电机和灌注泵电机或同时停止。
5.4 检修
检修作业应在泵装置完全停止后进行；
如需进行液力端检修，应先关闭吸入管蝶阀，检修完成后打开蝶阀。
“1”位
“0”位
警告！泵装置检修前必须把主电机的检修开关旋到“1”位！
14
第六章泵装置维护周期与日常保养内容
6.1 日保养
（1）动力端：每天检查泥浆泵动力端油面一次，检查时停泵。
（2）活塞和缸套：观察缸套和活塞的情况，某些“旁路”漏出来的钻井液并不表示
缸套或活塞已经磨损。缸套均匀的磨损，意味着活塞也均匀的磨损。但它们还可工作，直
到“旁路”漏失每冲程很明显或漏失过量，才需更换。
（3）清洗缸套室：按需要清洗缸套室，
“旁路”漏失的钻井液会在缸套室沉淀。当冷
却液被污染时应更换冷却液，并清洗冷却水箱。
（4）缸套润滑：每天检查缸套冷却液，按需要增加，脏了及时更换。在加冷却液之
前，卸去冷却液箱侧面两个管塞，用清洁水清洗冷却液箱。
注意！受污染的冷却液会增加喷淋泵的磨损和缩短泵的寿命。
（5）喷淋管线或活塞杆孔：每天检查一次缸套喷淋管线上的喷嘴和活塞杆上的孔，
假如堵塞，必须清洗疏通，以保证缸套和活塞的冷却剂和润滑剂的足够供应。
（6）活塞杆和缸套卡箍：泵第一次开始运转几小时后，要对缸套和活塞杆卡箍再拧
紧一次。这可防止泵的初始装配时，夹进去的杂物妨碍了连接的拧紧，使泵在松连接下的
情况下运转。
（7）阀盖：在泵第一次运转几小时后，要再一次拧紧阀盖。
（8）吸入空气包：每天检查一次吸入空气包，确保泵在运转条件下得到适当的灌注。
（9）介杆密封装置：每天用锂基润滑脂润滑介杆密封装置一次。
6.2 周保养
（1）阀盖螺纹：每两周拆卸阀盖一次。小心清洗阀盖螺纹和法兰螺纹上的异物，用
钻铤丝扣油润滑清洗过的所有螺纹。禁止使用普通连接工具用的“螺纹润滑剂”，因为它
们缺乏有效保护连接的能力。
（2）锥度锁紧楔块和阀盖锁紧螺钉：（对装有“锥度锁紧”的阀盖），彻底清洗锥度
锁紧楔块的两面。用与润滑阀盖螺纹同样的钻挺丝扣油润滑这些零件。楔块调节螺钉的锥
15
度部分和丝扣也要清洗干净并涂以丝扣油。
（3）阀盖和锥度锁紧楔块部件：（对装有“锥度锁紧”的阀盖）注意：在把阀盖螺纹
拧到液缸上之前，要先把锥度锁紧楔块和调节螺钉装到阀盖上去。使调节螺钉底部与楔块
底部齐平。使楔块部件松松地靠在阀盖上，这是很重要的。调节楔块、上阀盖，用手旋紧
螺母都是很容易的事。为了拆卸时松开调节螺钉要提供足够的空间也是很必要的。为了调
节螺钉能上紧并锁住楔块部件，螺钉要有足够的行程。用一根两英尺（0.6 米）长的棒穿
过压盖上的孔，用 16 磅的大锤狠狠地敲击 4 下即可上紧。然后用泵所带的 5-1/2 英尺（1.7
米）的加长搬手一个人的力量牢固地拧紧调节螺钉上的螺母。第一次开泵运转几小时后，
还要重新检查该螺母的上紧度。
注意！阀盖应拧在清洁的阀腔上。
（4）阀盖与密封圈：清洗阀盖的上部，用上述同样的丝扣油润滑。在装阀盖前，检
查密封圈，并小心清洗和润滑用于安装密封圈的液缸的台肩。为了防止阀盖翘起和保证压
盖与阀盖金属对金属全面接触，这样做是非常必要的。
（5）阀杆导向套：检查阀杆导向套衬套，如明显磨损应及时更换。衬套的磨损会增
加阀的磨损。旧衬套可以切除掉，新衬套可利用虎钳压入导向套的套座中。
（6）阀和阀座：检查阀和阀座的磨损，更换刺坏或磨损的阀和阀座。卡板如已松动
或磨损亦要更换。确保卡簧将卡板保持在适当的位置上，同时卡板的两半也各在它应在的
位置上。
（7）活塞芯密封：这是一个压缩密封，装在活塞芯法兰面及活塞杆台肩圆角半径处。
不可用其他密封圈替换，损坏后及时更换，应确保密封圈正确安装在活塞芯的环形槽中。
（8）活塞杆锁紧螺母：如果活塞杆锁紧螺母已经损坏或锈蚀、或锁紧尼龙圈已经失
去了有效锁紧能力就应及时更换。任何使用过三次的螺母都不可再次使用。
6.3 月保养
（1）过滤器：排出过滤器连同它的过滤管每月最少检查和清洗一次。
（2）动力端润滑：每六个月需要放掉和清洗动力端油箱和十字头下边的油池一次，
重新加入合适的极压齿轮油。
（3）螺柱和螺母：检查所有的液缸螺柱和螺母是否松动，包括法兰上的阀盖螺栓、
液缸和机壳连接的螺柱，缸套座和液缸连接的螺柱以及排出、吸入的螺柱。
16
（4）密封垫和密封圈：检查动力端泄漏的密封垫和松动螺钉，根据需要更换。
（5）润滑系统磁铁：每次更换润滑油时，要清洗上部油槽上的磁铁和放油丝堵处的
磁铁。
（6）润滑系统油槽坚固件：检查固定油槽螺钉的松紧度和齿轮刮油板应在的位置。
6.4 年度保养
（1）推荐每隔 2 至 3 年对泵检查一次，检查连杆、小齿轮轴、十字头销轴承以及十
字头导板等是否松动。假如发现松动，就要进行彻底的检查并采取进一步保养措施。
（2）检查泥浆泵固定压板螺柱的上紧度。
6.5 泵的贮存
（1）如停泵时间超过一星期，就要准备贮存，抬高液力端，使泵向动力端倾斜，然
后放掉油槽和油箱内的油，并清洗干净。拆去油箱丝堵，然后装上一个 90°弯头，头向下，
并盖上一个铁丝网。这样能使空气流通，防止水蒸气凝结。对动力端所有轴承，加工面和
全部内表面敷以防锈油。
（2）液力端：取出液缸中的所有阀、活塞、活塞杆和缸套。清洗液缸内部及所有零
件。对液缸全部阀和零件敷以防锈油。清洗内部喷漆系统及沉淀箱。对喷淋泵注入干净的
油以防生锈。对油箱和喷淋零件敷以防锈油。
（3）定期检查：每月检查一次泵和转动一个大齿轮，再敷一次防锈油。
6.6 贮存后的启动
（1）动力端：拆下所有动力端的盖子，清洗和检查所有零件的加工面。检查所有轴
承，确认它们是干净的并处于良好状态，用合适的、干净的极压齿轮油加入动力端，确保
分配油槽和十字头油池都有油，并进入所有轴承。
（2）液力端：阀、活塞、缸套以及所有液力端零件都完全安装就位并处于良好状态，
小心地拧紧所有的螺栓、螺母、螺柱和活动接头，用清洁的冷却液注入缸套喷淋系统。
注意！经过贮存的任何一台泥浆泵，不管是油田使用后还是出
厂装运后，无论如何保证它没有损坏，即使所有的零部件都各自在
它合适的位置上，都要检查。
17
第七章泵装置常见故障的诊断与排除
7.1 液力端的震击的原因
（1）排出空气包或吸入空气包预充气操作不当：应保证排出空气包预先充入氮气至
2.8～4.5MPa；检查吸入空气包液面位置是否合适。
（2）阀板松动、阀壳或阀座磨损、阀在阀座中翘起：用一开式钳口管钳，在阀座底
座上迅速拉起阀座，检查是否松动；检查阀是否磨损不均匀、流体冲蚀以及卡环和阀盘松
动。
（3）活塞芯松动：检查活塞螺母是否正常。
（4）灌注泵输出过低：泥浆泵工作时，吸入管汇灌注压力应为 0.14～0.35MPa。
（5）灌注泵盘根松动或磨损，使空气抽至吸入管中：开动灌注泵和泥浆泵时，用软
管向盘根浇水，若震击停止，则调节或更换盘根。
（6）吸入管线受阻或吸入管线过滤器堵塞。
（7）钻井液中有空气或瓦斯气：检查泥浆池是否有过多气泡、检查泥浆回流管线终
端是否低于泥浆面、检查除气设备。
（8）活塞杆卡箍松动或磨损：两个卡箍面决不能金属对金属的接触。活塞杆和卡箍
间不应有相对运动。
（9）岩屑堵塞排出五通过滤器，妨碍排出空气包正常工作：清洗过滤器。
（10）阀杆导向套的膨胀引起阀的粘结：更换阀杆导向套或阀。
注意！泵的震击问题多数与液力端有关，在检查动力端之前，
须对液力端进行全面检查。
7.2 动力端的震击的原因
（1）十字头销松动：卸下销子压板外面的两个螺钉并轻轻敲击销子。若销子在十字
头内活动容易，则重新拧紧并加垫片。
（2）十字头导板安装不正确。
（3）十字头或连杆轴承游隙过大（超过了 0.46mm）。
（4）十字头和导板之间间隙过大。
18
（5）主轴承没有靠紧轴承套台肩，使曲轴组件浮向一边，使大齿轮碰击刮油器。
（6）大齿轮或小齿轮轮齿变形：检查齿面并锉去任何干扰部分。
（7）主轴承座螺栓松动，按泥浆泵说明书规定要求依次拧紧。
7.3 泵装置震动原因
（1）驱动皮带轮不平衡。
（2）驱动皮带松弛。
（3）泵装置支承不当。
（4）驱动皮带由新旧两部分组成。
（5）两台直流驱动电机不同步：检查后拆下一侧的皮带脱开电机，用单电机驱动，
检验震动是否消除。
7.4 活塞和缸套加速磨损的原因及解决方法
（1）喷淋到缸套的冷却液不足而引起过热：检查喷淋管线喷嘴或活塞杆孔是否堵塞。
（2）冷却液过热，超过 38℃：使用较大的冷却液箱或热交换器接通至一非循环的净
水系统。
（3）冷却液被杂物或钻井液污染。
（4）钻井液中砂子、固体或碳化物微粒浓度很高：通常会导致在缸套孔内形成条纹
粒痕。检查除砂器和喷射泥浆罐。
（5）若油的苯胺点低于 90℃，则油基钻井液会使活塞皮碗和阀盖变质。
（6）腐蚀性钻井液腐蚀缸套：钻井液的 PH 值应大于 8.5，腐蚀性钻井液应使用优质
缸套。
（7）若钻井液中含有硫化氢会腐蚀活塞皮碗。
7.5 缸套难以装入缸套座的原因及解决方法
（1）在缸套的两个引向直径上涂有油漆，用金刚砂布除去油漆。
（2）由于螺柱拧紧不正确而引起的缸套座的椭圆度：使耐磨垫凸出 0.05mm，用交叉
拧紧的方法拧紧螺柱使缸套座不会由于凸出 0.05mm 而变形。
（3）缸套座内导向直径的毛刺：应用砂纸轻轻打磨去除毛刺，注意不得损伤表面。
(4) 耐磨垫上有岩屑：清理耐磨板。
注意！安装前要用钻铤丝扣油涂抹缸套的导向直径。
19
第八章推荐备件清单
Item Part Description Qty Requested Part number
2 Liner 6''1/2 50 05-466-650 NOV TS-0259-64HP TSC
5 Liner Gasket 6"1/2 100 1540151 NOV G-284 TSC
7 Piston Complet 6" 30 20-021-505 NOV 1-60-B15 TSC
8 Piston Complet 6"1/2 50 20-021-507 NOV I-64-L15 TSC
9 Piston Complet 7" 20 20-021-509 NOV I- 70-Ll5 TSC
10 Piston Rubber 6" 30 20-040-013 NOV TM-60-BR TSC
11 Piston Rubber 6"1/2 50 20-040-037 NOV TM-64-LR TSC
12 Piston Rubber 7" 30 20-040-041 NOV TM-70-LR TSC
13 Piston Rod 12 1292147 NOV TM-258A TSC
14 Extension Piston Rod 3 1292146 NOV TM-258B TSC
15 Piston Rod nut 3 6308241 NOV TM-NUT TSC
1292147/12921 TM-258A/TM-258
16 Cross head extension 6 46/1292085/12 NOV B/TM12P-01-06/T TSC
92023 M12P-03-08
20
17 Liner Clamp 12 1292166 NOV TS-1292166 TSC
18 Valve Complete 100 1560985 NOV TS-0985M TSC
19 Valve Spring 20 1560702 NOV TS-1560702 TSC
20 Valve Cover Gasket 200 1540127 NOV TS-1540127 TSC
21 Upper guide bushing 20 1292165 NOV TS-1292165 TSC
22 Valve Cover 3 1292352 NOV TS-1292352 TSC
23 Valve Seat 100 1561440 NOV TS-1561440 TSC
24 Seal valve Retainer 60 1540127 NOV TS-1540127 TSC
25 Clamp Complete Rod 6 1292085 NOV TM12P-03-08 TSC
26 Disc Valve 12 1560557 NOV TS-7-MI TSC
27 Wear Plate 30 1292266 NOV TS-1292266 TSC
28 Wear Plate Gasket 100 1292257 NOV TS-1292257 TSC
29 Fluid End Assy (suction) 2 1292612 NOV TS-1292243 TSC
30 Fluid End Assy (discharge) 2 1292611 NOV TS-1292240 TSC
31 Fluid end seal 30 1540851 NOV TS-1540851 TSC
32 Ring threaded (flange) 1 1292351 NOV TS-1292351 TSC
33 Discharge adapter 2 1292253 NOV 1S-1292253 TSC
34 Discharge adapter seal 10 1292258 NOV TS-1292258 TSC
35 Discharge connector 1 1292252 NOV TS-1292252 TSC
21
38 Liner bushing 1 1292165 NOV TS-1292165 TSC
39 Liner bushing screw 1 24008028 NOV TS-2408028 TSC
40 Lubrification electric pump 1 7815926 NOV
41 Oil filter 6 781507 NOV
42 V belt 2sets 8V3350 gates
22

02 Pump Device Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

02 Pump Device Service Manual

Uploaded by

Copyright:

Available Formats

山东科瑞机械制造有限公司

Shandong Kerui Machinery Manufacture Co.,Ltd.

12-P-160 Pump device

Machinery Manufacture Co., Ltd.

service life to the limit.

be found in the respective technical document.

and technicians, etc.

 Some equipment instructions from the manufacturer manual. if the manufacturers

manual prior to the instruction manuals.

without notice, also not take any responsibility and obligation

 Without the authorization of our company, prohibited to provide the set of

will investigate its legal liability.

timely correction, make our products better service for you.

Important Safety statement

prevent the human injury and damage of the equipment.

damage the equipment.

abide by the operation procedure and method;

Note: Used for attention or individual explanation.

Important Safety statement....................................................................................................... III

Chapter 1 safety rules ................................................................................................................. 1

1.1 Personnel ....................................................................................................................... 1

1.1.1 Qualification requirements of operators .................................................................... 1

1.1.2 Protection requirements of operators ........................................................................ 1

1.1.3 Unauthorized personnel............................................................................................. 1

1.2 Other safety considerations ........................................................................................... 1

1.2.1 Equipment operation ................................................................................................. 1

1.2.2 Correct use of common tools .................................................................................... 2

1.2.3 Prevent falling objects accidents ............................................................................... 2

1.3 Safety habit ....................................................................................................................... 2

Chapter two Product descriptions .............................................................................................. 3

2.1 Summary .......................................................................................................................... 3

2.2 Technical parameter ......................................................................................................... 4

2.2.1 Mud pump ................................................................................................................. 4

2.2.2 DC motor ................................................................................................................... 4

2.2.3 Belt drive（input from pump two ends）................................................................. 5

2.2.4 Weight of pump ......................................................................................................... 5

Chapter three Installation of new pump ..................................................................................... 6

3.1 Pump installation on well site .......................................................................................... 6

3.2 Installation of pump base and mud pump ........................................................................ 6

3.3 The installation of transmission device ............................................................................ 6

3.4 Adjustment of belt pulley pre-tightening ......................................................................... 7

3.5 Check the centering of belt pulley.................................................................................... 7

3.6 Fixing of connecting bolts ................................................................................................ 7

3.7 Other attachment .............................................................................................................. 7

Chapter 4 Belt changing ............................................................................................................. 8

Chapter five pump start and daily maintenance ....................................................................... 12

5.1 Preparation work before start ......................................................................................... 12

5.1.1 Lube ......................................................................................................................... 12

5.1.2 Dampener ................................................................................................................ 13

5.1.3 Safety valve ............................................................................................................. 14

5.1.4 Cooling .................................................................................................................... 14

5.1.5 Hydraulic end .......................................................................................................... 14

5.2 Start ................................................................................................................................ 15

5.3 Stop the pump................................................................................................................. 15

5.4 Mending ......................................................................................................................... 15

Chapter six Pump maintenance period and content .............................................................. 16

6.1 Daily maintenance .......................................................................................................... 16

6.2 Weekly maintenance ....................................................................................................... 17

6.3 Monthly maintenance ..................................................................................................... 17

6.4 Annually maintenance .................................................................................................... 18

6.6 The start after storing ..................................................................................................... 18

Chapter 7 pump unit common faults diagnosis and elimination .............................................. 20

7.1 Reason for shock of hydrailic end .................................................................................. 20