F-2200HL HP Drilling Mud Pump Spare Parts-1

1

AH220201-0500

Pump Crankshaft

Alloy steel 42CrMo4 (EN 10083-3) with quenching and tempering treatment; surface hardness HRC 28-32; precision ground journals with Ra ≤ 0.8 μm finish; nitrided surface for enhanced wear resistance

1. Fatigue wear on journal surfaces due to long-term cyclic loading and inadequate lubrication; 2. Stress corrosion cracking caused by exposure to corrosive drilling mud vapors

1. Maintain lubricating oil cleanliness (NAS 8 grade) and monitor oil temperature (≤ 65°C) regularly; 2. Conduct magnetic particle inspection every 2,000 operating hours to detect hidden cracks

2

AH220201-051500

Connecting Rod

Forged alloy steel 35CrMoA; precision machined big end and small end bores; bushing made of copper-lead alloy (CuPb24Sn4) for anti-friction performance; shot peened surface to improve fatigue strength

1. Bushing wear due to misalignment between crankshaft and crosshead, leading to uneven load distribution; 2. Bending deformation caused by sudden impact loads during pump startup

1. Check and adjust crankshaft-crankpin concentricity (tolerance ≤ 0.02 mm) before assembly; 2. Avoid rapid startup/shutdown; implement gradual pressure buildup (≤ 500 psi per minute)

3

AH220201-051000

Crosshead

Carbon steel 45# with carburizing treatment; surface hardness HRC 58-62; sliding surface with graphite impregnation for self-lubrication; guide rail contact surface ground to high precision

1. Sliding wear on guide rail surfaces due to contaminated lubricating oil containing drilling mud particles; 2. Thermal deformation caused by uneven heat distribution during prolonged high-load operation

1. Install high-efficiency oil filters (10 μm filtration precision) and replace filters every 500 operating hours; 2. Ensure adequate cooling system performance, maintain cooling water flow rate ≥ 15 L/min

4

AH220201-051700

Piston Rod

Stainless steel 17-4PH (UNS S17400); solution heat treated and aged; surface polished to Ra ≤ 0.4 μm; chrome plating (thickness 0.05-0.08 mm) on working surface for corrosion and wear resistance

1. Chrome plating peeling due to impact from hard particles in drilling mud; 2. Thread damage at the connecting end caused by improper torque during assembly

1. Ensure effective operation of the mud screen (mesh size ≤ 100 μm) to prevent hard particles from entering the pump chamber; 2. Tighten connecting nuts using a torque wrench (specified torque: 850 N·m) and use thread lock compound

5

AH220101-010500

Pump Shaft

Alloy steel 40CrNiMoA (EN 10083-1); precision forged and heat treated; keyway with induction hardening; surface coated with anti-corrosion primer and topcoat for outdoor storage protection

1. Keyway wear due to torsional vibration during pump operation; 2. Corrosion on uncoated surfaces during long-term storage in humid offshore environments

1. Inspect key and keyway fit every 1,500 operating hours; replace worn keys promptly; 2. For stored parts, use VCI (Volatile Corrosion Inhibitor) film wrapping and control storage humidity ≤ 60%

1

AH220201-052200B1

Piston Seal

High-performance polyurethane (PU) with Shore hardness 90A; reinforced with polyester fabric for dimensional stability; nitrile rubber (NBR) backup ring for high-pressure resistance (up to 7,500 psi)

1. Abrasive wear caused by solid particles in drilling mud; 2. Swelling and degradation due to incompatibility with oil-based mud additives (e.g., diesel, esters)

1. Maintain mud solid control efficiency (sand content ≤ 0.5%) by optimizing shale shaker and desander operation; 2. Select seal materials compatible with mud type (e.g., Viton® for oil-based muds) and inspect seal condition every 300 operating hours

2

AH220201-050600

Rod Seal Assembly

Dual-lip seal design with primary lip made of Viton® (FKM) and secondary lip of NBR; stainless steel 316L metal case; spring-loaded design for constant sealing pressure; integrated scraper to remove mud particles

1. Lip wear due to misalignment of the piston rod, causing uneven pressure distribution; 2. Scraper damage from large debris entering the seal area

1. Check piston rod straightness (tolerance ≤ 0.03 mm/m) and correct misalignment promptly; 2. Install a pre-scraper upstream to block large debris (particle size ≥ 2 mm) from reaching the rod seal

3

AH220201-053000

Valve Seat Seal

Tungsten carbide (WC-Co, 94% WC) for wear resistance; metal substrate made of alloy steel 4140; vacuum brazed joint for high bonding strength; lapped sealing surface with Ra ≤ 0.2 μm

1. Impact wear from valve disc during frequent opening/closing cycles; 2. Corrosion pitting caused by acidic drilling mud (pH ≤ 5) and hydrogen sulfide (H₂S) presence

1. Control pump operating frequency (≤ 120 cycles per minute) to reduce impact load; 2. Monitor mud pH (maintain 8-10) and use H₂S scavengers if H₂S concentration exceeds 10 ppm

4

AH000005-0800

Gasket

Spiral wound gasket with 316L stainless steel winding and flexible graphite filler; inner and outer rings made of carbon steel A3; rated for temperature up to 450°C and pressure up to 15,000 psi; compliant with ASME B16.20

1. Compression set due to over-torquing during installation; 2. Graphite filler degradation due to exposure to high-temperature mud and chemical additives

1. Torque bolts according to ASME PCC-1 guidelines (specified torque: 450 N·m for M24 bolts); 2. Replace gaskets after each disassembly and avoid reusing old gaskets

5

AH220201-050100B4

O-Ring

Fluorocarbon rubber (Viton® FKM) with Shore hardness 75A; compliant with ASTM D2000 standard; resistant to oil, fuel, and most drilling mud chemicals; temperature range: -20°C to 200°C

1. Extrusion damage through gasket gaps under high pressure; 2. Hardening and cracking due to prolonged exposure to high temperatures (exceeding 200°C)

1. Ensure proper groove design (groove width and depth per ASME B16.24) to prevent extrusion; 2. Monitor pump temperature and ensure cooling system effectiveness to avoid overheating

1

AH220201-0200

Suction Valve

Valve disc made of hardened alloy steel 17-4PH; valve body of carbon steel 4140 with internal chrome plating; spring made of Inconel 718 for high-temperature resistance; poppet-style design for low flow resistance

1. Abrasive wear on valve disc seat due to high-velocity mud flow carrying solid particles; 2. Spring fatigue caused by frequent compression/extension cycles and high-temperature exposure

1. Maintain adequate suction line diameter (≥ 4 inches) to reduce flow velocity (≤ 2 m/s); 2. Inspect valve spring deflection every 1,000 operating hours and replace if deflection exceeds 5%

2

AH220201-0300

Discharge Valve

Tungsten carbide valve disc; valve body of alloy steel 42CrMo4 with nitrided surface; polyurethane buffer to reduce impact noise; designed for bidirectional sealing

1. Impact wear from high-pressure mud surges during pump operation; 2. Corrosion due to chemical reactions with drilling mud additives (e.g., corrosion inhibitors, viscosifiers)

1. Install a pressure relief valve downstream (set pressure: 110% of rated pressure) to mitigate surges; 2. Analyze mud chemical composition regularly and select compatible valve materials

3

AH220201-0400

Relief Valve

Valve core made of stainless steel 316L; valve seat of Stellite 6 alloy for wear resistance; spring-loaded pilot-operated design; pressure adjustment range: 5,000-7,500 psi; compliant with API Spec 16C

1. Seat wear due to frequent pressure relief cycles; 2. Valve sticking caused by mud particle accumulation in the pilot chamber

1. Test relief valve operation weekly by manual activation to ensure responsiveness; 2. Flush the pilot chamber with clean lubricating oil every 500 operating hours to remove debris

4

AH220201-0600B1

Throttle Valve

Brass alloy (CuZn37) valve body; stainless steel 304 valve stem; PTFE packing for sealing; handwheel with graduated scale for precise flow adjustment; maximum flow rate: 500 gpm

1. Valve stem wear due to rotational friction and mud particle abrasion; 2. Packing leakage caused by improper tightening and packing degradation

1. Lubricate valve stem with anti-seize compound (copper-based) every 300 operating hours; 2. Tighten packing glands uniformly (torque: 25-30 N·m) to avoid stem damage and ensure sealing

5

AH220201-060100

Check Valve

Swing-type design with valve disc made of cast iron ASTM A48 Class 30; valve seat of rubber-lined NBR; stainless steel 316 hinge pin; designed for low pressure drop and high flow capacity

1. Hinge pin wear due to swinging motion and mud contamination; 2. Rubber seat degradation from exposure to ozone and UV radiation in outdoor installations

1. Clean the valve interior regularly to remove mud deposits; 2. For outdoor installations, use UV-protective covers and inspect rubber seats every 6 months for cracking

1

AH100101-061400

Hex Bolt

Alloy steel Grade 12.9 (EN ISO 898-1); zinc-nickel plating (thickness 8-12 μm) for corrosion resistance; thread size M20×1.5; length 80 mm; compliant with DIN 931

1. Thread wear due to repeated assembly/disassembly and cross-threading; 2. Corrosion in saltwater offshore environments leading to bolt failure

1. Use proper-sized socket wrenches to avoid cross-threading; apply anti-seize compound on threads before assembly; 2. For offshore applications, inspect bolts monthly and replace if corrosion is detected (≥ 5% surface area)

2

AH050101-060200B1

Nut

Alloy steel Grade 12 (EN ISO 898-2); zinc plating with clear passivation; thread size M20×1.5; hexagonal shape; self-locking design with nylon insert

1. Nylon insert degradation due to high-temperature exposure (exceeding 120°C); 2. Thread stripping caused by over-torquing

1. Avoid using self-locking nuts in high-temperature areas (e.g., near exhaust manifolds); use metal lock washers instead; 2. Torque nuts to specified values (420 N·m for M20 nuts) using a calibrated torque wrench

3

AH220201-0800B2

Washer

Stainless steel 316L; thickness 3 mm; outer diameter 40 mm; inner diameter 21 mm; flat washer design compliant with DIN 125A; surface polished to reduce friction

1. Deformation due to uneven load distribution and over-torquing; 2. Pitting corrosion caused by chloride ions in drilling mud

1. Ensure washer is properly seated (flat side against the component surface) before torquing; 2. Clean washers thoroughly after use and store in a dry environment to prevent chloride buildup

4

AH160201-0200B1

Bushing

Bronze alloy (CuSn8); oil-impregnated for self-lubrication; inner diameter 30 mm; outer diameter 45 mm; length 50 mm; precision machined to H7 tolerance

1. Abrasive wear due to contamination of lubricating oil with mud particles; 2. Seizure caused by insufficient lubrication and high operating temperatures

1. Maintain oil cleanliness and replace lubricating oil every 1,000 operating hours; 2. Monitor bushing temperature (≤ 80°C) and stop operation immediately if overheating is detected

5

AH160201-020200B1

Sleeve

Carbon steel 20# with galvanizing; inner diameter 50 mm; outer diameter 60 mm; length 100 mm; surface coated with anti-corrosion paint for additional protection; chamfered ends for easy assembly

1. Galvanizing wear due to friction during assembly and vibration during operation; 2. Corrosion from contact with water-based drilling mud

1. Use a hydraulic press for assembly to avoid damaging the galvanized surface; 2. Apply a thin layer of anti-corrosion grease on the sleeve surface before installation to protect against mud contact

6

AH160201-020400B1

Spacer

Aluminum alloy 6061-T6; anodized surface (thickness 10-15 μm) for corrosion resistance; outer diameter 80 mm; inner diameter 40 mm; length 25 mm; lightweight design for reduced component weight

1. Anodization wear due to repeated contact with other metal components; 2. Bending deformation caused by improper assembly and uneven load distribution

1. Install a rubber gasket between the spacer and metal components to reduce friction; 2. Check spacer alignment during assembly to ensure even load distribution and avoid bending

7

AH000006-1000

Pin

Stainless steel 304 (UNS S30400); diameter 12 mm; length 60 mm; cylindrical shape with cotter pin hole; precision ground to h6 tolerance; surface passivated for corrosion resistance

1. Wear on the pin surface due to rotational or sliding motion; 2. Cotter pin hole damage caused by improper cotter pin installation/removal

1. Lubricate the pin surface with lithium-based grease before assembly; 2. Use pliers to install/remove cotter pins gently, avoiding excessive force that may deform the hole

8

AH000006-0300

Cotter Pin

Carbon steel A286; zinc plating; diameter 2 mm; length 25 mm; hairpin design; compliant with DIN 94

1. Fatigue failure due to repeated vibration during pump operation; 2. Corrosion leading to pin breakage in humid environments

1. Inspect cotter pins every 500 operating hours and replace if signs of fatigue (e.g., bending, cracking) are present; 2. Store spare cotter pins in a dry, sealed container to prevent corrosion

9

AK755201-00

Filter Element

Cellulose filter media with 10 μm filtration precision; metal frame made of galvanized steel; rubber seal ring (NBR); maximum operating pressure: 100 psi; flow rate: 20 gpm

1. Clogging due to high solid content in drilling mud; 2. Filter media damage caused by pressure surges in the lubrication system

1. Replace filter elements every 250 operating hours or when pressure drop exceeds 15 psi; 2. Install a pressure relief valve upstream to protect the filter from surges (set pressure: 110 psi)

10

512605520020600000

Mounting Bracket

Mild steel S235JR with powder coating (thickness 60-80 μm); welded construction per AWS D1.1; designed for bolt-on installation; load capacity: 500 kg; corrosion resistance rating: C5-M (ISO 12944-2)

1. Weld joint fatigue due to pump vibration; 2. Powder coating damage from impact during transportation and installation

1. Install vibration dampers between the bracket and pump base to reduce vibration transmission; 2. Use protective packaging during transportation and inspect coating before installation; touch up damaged areas with matching powder coat paint

1

AH220201-0100

Pump Housing Cover

Alloy steel 4140 with heat treatment; surface painted with anti-corrosion epoxy paint; gasket groove designed for spiral wound gasket; bolt holes with thread inserts (stainless steel 316L)

1. Warpage due to uneven heating during welding repairs; 2. Corrosion on painted surface from exposure to drilling mud and chemicals

1. Avoid welding repairs on the housing cover; replace with new components if damaged; 2. Clean the surface regularly and touch up paint every 6 months to maintain corrosion protection

2

AH220201-0700

Oil Seal

Nitrile rubber (NBR) seal lip; carbon steel case; spring-loaded design for constant sealing pressure; inner diameter 60 mm; outer diameter 85 mm; width 12 mm; temperature range: -30°C to 120°C

1. Lip wear due to contaminated oil with mud particles; 2. Hardening and cracking caused by prolonged exposure to high temperatures

1. Ensure oil cleanliness and replace oil filters regularly; 2. Monitor oil temperature and ensure cooling system is functioning properly to prevent overheating

3

AH220201-09B1

Piston Liner

Cast iron with pearlitic structure; inner surface honed to Ra ≤ 0.2 μm; chrome plating (thickness 0.1-0.15 mm) for wear resistance; outer diameter 150 mm; inner diameter 120 mm; length 300 mm

1. Inner surface wear due to piston reciprocation and abrasive mud particles; 2. Cylinder deformation caused by uneven thermal expansion

1. Maintain mud solid control to reduce abrasive particles; 2. Ensure uniform cooling of the liner by checking cooling water flow and removing scale buildup

4

AH220201-10B2

Valve Guide

Stainless steel 316L; precision machined inner bore (H7 tolerance); outer surface with knurling for secure press-fit; length 80 mm; inner diameter 25 mm

1. Inner bore wear due to valve stem reciprocation and mud contamination; 2. Loosening of press-fit due to thermal cycling

1. Lubricate the valve stem with high-temperature grease before assembly; 2. Ensure proper press-fit interference (0.02-0.04 mm) during installation to prevent loosening

5

AH220201-11

Spring

Chrome silicon steel (51CrV4); heat treated for fatigue resistance; wire diameter 5 mm; outer diameter 40 mm; free length 100 mm; number of coils: 12; surface shot peened

1. Fatigue failure due to prolonged cyclic loading and high-temperature exposure; 2. Corrosion caused by moisture and drilling mud vapors

1. Avoid operating the pump beyond the recommended pressure range to reduce spring load; 2. Store spare springs in a dry environment and apply anti-corrosion oil before installation

6

AH220201-12

Retaining Ring

Stainless steel 304; circlip design; inner diameter 50 mm; thickness 2 mm; compliant with DIN 471; surface passivated for corrosion resistance

1. Deformation due to improper installation with pliers; 2. Corrosion in acidic drilling mud environments

1. Use specialized circlip pliers for installation/removal to avoid deformation; 2. Inspect retaining rings for corrosion every 300 operating hours and replace if necessary

7

AH220201-1300

Drive Shaft Coupling

Alloy steel 42CrMo4; jaw-type design; rubber spider (urethane) for vibration damping; bolt holes with stainless steel inserts; torque capacity: 2,500 N·m

1. Rubber spider wear due to misalignment and vibration; 2. Jaw wear caused by impact loads during pump startup

1. Check coupling alignment (radial runout ≤ 0.1 mm, axial runout ≤ 0.05 mm) every 1,000 operating hours; 2. Avoid rapid startup and ensure gradual load application

8

AH220201-1400

Oil Pump Gear

Alloy steel 20CrMnTi with carburizing treatment; surface hardness HRC 58-62; precision ground teeth (class 6 per DIN 3962); module: 2.5; number of teeth: 20

1. Tooth wear due to contaminated oil with hard particles; 2. Gear tooth fatigue caused by overloading the oil pump

1. Maintain oil cleanliness and replace oil filters regularly; 2. Monitor oil pump pressure (normal range: 20-40 psi) and avoid overloading by ensuring proper oil flow

9

AH220201-15

Pressure Gauge Adapter

Stainless steel 316L; NPT 1/2" thread; designed for pressure gauge installation; maximum pressure rating: 10,000 psi; surface polished

1. Thread wear due to repeated gauge installation/removal; 2. Corrosion caused by exposure to corrosive drilling mud and chemicals

1. Use thread seal tape (PTFE) during installation to protect threads; avoid over-torquing; 2. Clean the adapter regularly and apply anti-corrosion grease to the thread area

10

AH220201-1600

Suction Manifold

Carbon steel A106 Grade B; welded construction; flanged ends (ASME B16.5 Class 150); internal surface coated with epoxy for corrosion resistance; diameter: 6 inches

1. Internal corrosion due to water-based drilling mud; 2. Weld joint wear caused by high-velocity mud flow

1. Monitor mud pH and add corrosion inhibitors if necessary; 2. Inspect weld joints every 2,000 operating hours using ultrasonic testing

11

AH220201-1700

Discharge Manifold

Alloy steel A694 Grade F65; flanged ends (ASME B16.5 Class 600); internal chrome plating; diameter: 4 inches; designed for high-pressure service (up to 7,500 psi)

1. Internal wear due to abrasive mud particles; 2. Stress corrosion cracking caused by H₂S in drilling mud

1. Use abrasion-resistant liners for high-solids mud applications; 2. Monitor H₂S concentration and use appropriate corrosion inhibitors

12

AH160201-0600B3

Bearing

Deep groove ball bearing (SKF 6312); chrome steel balls and raceways; cage made of brass; sealed design (2RS) for dust and moisture protection; rated speed: 6,000 rpm

1. Bearing failure due to contaminated lubrication and insufficient lubrication; 2. Overheating caused by misalignment and overloading

1. Maintain proper lubrication (fill with lithium-based grease to 30-40% of bearing volume); 2. Check bearing temperature (≤ 70°C) and vibration (≤ 4.5 mm/s) regularly

13

AH100101-16

Oil Sight Glass

Tempered glass (borosilicate); metal frame made of stainless steel 304; rubber gasket (NBR) for sealing; maximum temperature: 150°C; pressure rating: 50 psi

1. Glass breakage due to impact from tools or debris; 2. Glass fogging caused by moisture in the oil

1. Install a protective guard around the sight glass; 2. Monitor oil moisture content (≤ 0.1%) and replace oil if moisture exceeds limits

14

AH100101-1500

Drain Plug

Stainless steel 316L; NPT 3/4" thread; magnetic tip to capture metal particles; O-ring seal (Viton®); hexagonal head for wrench operation

1. Thread wear due to repeated removal/installation; 2. Magnetic tip degradation caused by high temperatures

1. Use a torque wrench to tighten the plug (torque: 35 N·m) to avoid thread damage; 2. Clean the magnetic tip during oil changes and replace the plug if magnetism is reduced

15

AH220201-1900

Thermometer Socket

Stainless steel 316L; NPT 1/2" thread; designed for insertion of a bimetallic thermometer; temperature range: -50°C to 300°C; welded connection

1. Weld joint corrosion due to exposure to drilling mud; 2. Thread damage caused by over-torquing during thermometer installation

1. Inspect the weld joint regularly for corrosion and cracks; 2. Torque the thermometer to specified values (15 N·m) to avoid thread damage

16

AH220201-20

Vent Plug

Brass alloy (CuZn37); NPT 1/4" thread; cap with rubber seal; designed to release air from the oil sump; corrosion-resistant plating

1. Rubber seal degradation due to oil exposure; 2. Thread wear caused by repeated opening/closing

1. Replace the rubber seal every 6 months; 2. Use a gentle hand torque when opening/closing the plug to avoid thread damage