Installation, start-up, and operation of mud pumps for petroleum machinery

（1） Installation

1. Petroleum machinery should be kept level, with a horizontal deviation not exceeding 3 millimeters, in order to facilitate the normal supply of lubricating oil to the power end lubrication passage during operation and ensure the normal operation of the driving V-belt; The requirements for chain transmission are more stringent, requiring the size chain wheels of the pump to be installed on the same base, and rigid connections should be made when different bases are used.

2. The position of the pump should be lowered as much as possible, and the position of the mud tank should be raised as much as possible to facilitate suction.

3. It is best to use a flexible hose for the suction pipe of the pump, with a minimum diameter of 250mm. The length should be between 2.1 and 3.8 meters, straight and without sharp bends to reduce friction and inertia loss inside the suction pipe.

4. The connection between the suction pipe and the mud tank should not be located directly below when the mud returns to the tank, in order to prevent the suction of sediment at the bottom of the tank.

5. Firmly support all suction and discharge pipelines, preventing them from bearing additional external loads and reducing vibration. Under no circumstances should the pipeline be suspended from the pump due to insufficient support.

6. The suction system cannot tolerate any air leakage, which is a major issue related to the normal operation of the mud pump.

（2） Start up

1. To start a new pump or an old pump that has been out of service for a long time, it is necessary to first clean the power end oil pan, lubricating oil groove, oil passage, and the space around the crosshead. Add CKC320 or CKC220 medium load extreme pressure industrial gear oil, and open each inspection cover before starting. Add oil to the small gear, bearing, and crosshead oil groove to lubricate all friction surfaces of the pump before starting.

2. Check whether the spray pump, water tank, and spray pipeline are clean and normal. When forced to use tap water for cooling, the water pressure should be greater than 0.5Kg, and the cooling water volume per hour for each mud pump should not be less than 6 cubic meters. The higher the ambient temperature and pump pressure, the greater the amount of cooling water should be. The outer wall of the cylinder liner should be frequently touched by hand to monitor the heat dissipation of the liner. Generally, it is advisable to feel cool by hand. If circulating water is used, it should be precipitated, filtered, and naturally cooled. The inlet water temperature should generally not exceed 20 ℃.

3. Tighten the bolts of the crankshaft main shaft pressure cover on the power end and all fasteners on the valve box; There should be no leakage at the sealing parts of the corrugated pipe, pump rod, and positioning plate to prevent cooling water from entering the power end.

4. Check all valves on the mud pipeline to ensure they are in the correct operating state before starting.

5. Check if the inflation pressure of the pre pressurized air bag meets the requirements.

6. Check if the pump pressure gauge and safety valve (especially the safety pin) are functioning properly.

7. Open the valve cover and fill the suction valve box with clean water or mud to remove air.

8. Slowly increase the pump speed during start-up to avoid cavitation in the cylinder.

9. When the mud density is high, the gas content is high, and the viscosity is high, the pump should be operated at medium or low speed as much as possible to avoid poor suction.

10. Immediately conduct a patrol inspection of the drilling pump after startup. If any abnormal local temperature rise, abnormal noise, or air leakage in the suction pipe is found, stop the pump quickly, investigate the cause, and rectify it.

（3） Operation

1. The key to achieving excellent performance of a three cylinder single acting drilling pump during operation is to use the largest possible piston while meeting the pump pressure requirements; On the premise of meeting the displacement requirements, use the lowest possible pump speed (impulse/minute). That is to say, while meeting the requirements of drilling technology, within the allowable range of drilling pump technical performance, try to use large pistons and low pump speeds as much as possible.

2. Carefully observe whether the cylinder liner moves back and forth, and whether there is any noise from the piston rod clamp during reciprocating motion. If any abnormal conditions are found, promptly handle them. Timely check and tighten all fastening parts.

3. Check whether there is any leakage in the high-pressure sealing parts, and whether there is any leakage or abnormal impact sound in the pump valve. If any abnormal situation is found, it should be dealt with in a timely manner.

4. Pay close attention to changes in pump pressure. If the pump pressure fluctuates rapidly, suddenly increases or decreases, quickly identify the cause and handle it properly.

5. Pay attention to the lubrication, temperature rise, and cooling of the operating parts (especially the bearing parts), check whether the lubricating oil and cooling water have deteriorated. If any abnormal situation is found, identify the cause and take measures.

6. Pay attention to whether the sound of each operating part is normal.

7. It is strictly prohibited to use pistons with two different diameters in a three cylinder pump, or to use a three cylinder pump as a dual cylinder pump.

8. Overloading operation is strictly prohibited. The optimal operating state is when operating below 80% of the rated power and below 75% of the rated maximum pump pressure.

9. Avoid long-term operation below 50% of rated power and pump pressure below 100 atmospheres, as the mechanical efficiency of the drilling pump will sharply decrease, resulting in an uneconomical operating state.

When this series of drilling pumps operates according to the recommended operating parameters mentioned above, continuous operation is allowed, and its reliability and economy can be fully guaranteed.

10. The basic points for the normal operation of petroleum machinery drilling pumps are: three "medium", three "no", and two "normal".

Three 'medium': medium power, medium pump pressure, and medium speed operation;

Three 'no's': no looseness in fastening, no leakage in sealing, and no fluctuation in pump pressure;

Two 'normal': normal temperature and normal sound.