F-2200HL HP Drilling Mud Pump Spare Parts-2

1

AH100101-09B1

Crankshaft Gear

Alloy steel 42CrMo4 (EN 10083-3) with carburizing and quenching treatment; surface hardness HRC 58-62; gear teeth precision ground to DIN 3962 Class 6; nitrided surface for enhanced wear and corrosion resistance

1. Tooth surface abrasion due to contamination of lubricating oil with hard drilling mud particles; 2. Fatigue pitting on tooth roots caused by long-term cyclic loading and torque fluctuations

1. Maintain lubricating oil cleanliness at NAS 8 grade and replace oil filters (10 μm precision) every 500 operating hours; 2. Conduct magnetic particle inspection (MPI) on gear teeth every 2,000 hours to detect hidden cracks

2

AH220201-2100

Drive Shaft

Forged alloy steel 35CrMoA;调质 heat treatment (quenching + tempering); surface hardness HRC 28-32; journal surface ground to Ra ≤ 0.8 μm; keyway with induction hardening for torque resistance

1. Journal wear due to misalignment between shaft and bearing, leading to uneven load distribution; 2. Stress corrosion cracking at keyway corners caused by exposure to H₂S-containing drilling mud vapors

1. Check shaft alignment (radial runout ≤ 0.02 mm/m) during installation and adjust with precision shims; 2. Use H₂S-resistant lubricants and monitor H₂S concentration (maintain ≤ 10 ppm) in drilling environments

3

AH220201-09B2

Countershaft

Stainless steel 17-4PH (UNS S17400); solution heat treated and aged; surface polished to Ra ≤ 0.4 μm; integrated gear teeth with tungsten carbide overlay for extreme wear resistance

1. Overlay peeling due to impact loads during pump startup; 2. Corrosion on non-overlay surfaces caused by water-based drilling mud with high chloride content

1. Implement gradual startup procedures (pressure buildup ≤ 500 psi per minute) to reduce impact; 2. Apply anti-corrosion coating (epoxy-polyurethane) on non-overlay surfaces and touch up every 6 months

1

AK755201-00

Lubricating Oil Filter Element

Glass fiber filter media with 5 μm filtration precision; galvanized steel support frame; nitrile rubber (NBR) seal ring; maximum operating pressure: 100 psi; flow rate: 30 gpm; compliant with ISO 3724

1. Clogging due to excessive metal particles from worn transmission components; 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 (set pressure: 110 psi) upstream to protect the filter from surges

2

AH220201-22

Mechanical Seal Assembly

Stationary ring: tungsten carbide (WC-Co); rotating ring: silicon carbide (SiC); bellows: Hastelloy C-276; spring: Inconel 718; designed for dry-running resistance; maximum pressure: 7,500 psi; temperature range: -20°C to 200°C

1. Seal face wear due to entrapment of hard drilling mud particles; 2. Bellows corrosion caused by acidic drilling mud (pH ≤ 5)

1. Ensure effective operation of the mud screen (mesh size ≤ 100 μm) to remove large particles; 2. Monitor mud pH (maintain 8-10) and add pH adjusters if necessary; inspect seal for leakage weekly

3

AH220201-23

Oil Seal

Viton® (FKM) seal lip; carbon steel case with zinc plating; spring-loaded design for constant sealing pressure; inner diameter 70 mm; outer diameter 95 mm; width 12 mm; resistant to oil, fuel, and most drilling chemicals

1. Lip hardening and cracking due to prolonged exposure to high temperatures (exceeding 200°C); 2. Lip abrasion caused by contaminated oil with mud fines

1. Ensure cooling system efficiency to maintain oil temperature ≤ 65°C; 2. Use high-quality lubricating oil (meets API GL-4 standard) and replace oil every 1,000 operating hours

1

AH000006-1000

Cotter Pin

Stainless steel 304 (UNS S30400); diameter 3 mm; length 30 mm; hairpin design; surface passivated for corrosion resistance; compliant with DIN 94

1. Fatigue failure due to repeated pump vibration; 2. Corrosion in saltwater offshore environments leading to breakage

1. Inspect cotter pins every 500 operating hours and replace if signs of bending or cracking are present; 2. For offshore use, apply anti-corrosion grease to the pin surface before installation

2

AH130101-1000

Hex Bolt

Alloy steel Grade 12.9 (EN ISO 898-1); zinc-nickel plating (thickness 8-12 μm) for corrosion resistance; thread size M24×2; length 100 mm; hexagonal head; torque capacity: 850 N·m

1. Thread stripping due to over-torquing during assembly; 2. Plating wear due to repeated assembly/disassembly and contact with drilling mud

1. Torque bolts using a calibrated torque wrench (specified torque: 780 N·m) per ASME PCC-1 guidelines; 2. Apply anti-seize compound (copper-based) on threads before assembly to reduce wear

3

AH100101-13

Nut

Alloy steel Grade 12 (EN ISO 898-2); zinc plating with clear passivation; thread size M24×2; self-locking design with nylon insert; hexagonal shape

1. Nylon insert degradation due to high-temperature exposure (exceeding 120°C); 2. Thread corrosion caused by moisture ingress

1. Avoid using self-locking nuts in high-temperature areas (e.g., near exhaust manifolds); use metal lock washers instead; 2. Store spare nuts in a dry, sealed container to prevent moisture buildup

4

380207302701611501

Washer

Stainless steel 316L; thickness 4 mm; outer diameter 50 mm; inner diameter 25 mm; flat washer design compliant with DIN 125A; surface polished to reduce friction and corrosion

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 dry immediately to remove chloride residues

5

AH130101-19

Locating Pin

Stainless steel 304; diameter 15 mm; length 60 mm; cylindrical shape with chamfered ends; precision ground to h6 tolerance; surface passivated for corrosion resistance

1. Wear on the pin surface due to rotational motion and mud contamination; 2. Bending deformation caused by improper installation with excessive force

1. Lubricate the pin surface with lithium-based grease before assembly; 2. Use a hydraulic press for installation to avoid applying excessive force; do not hammer the pin directly

1

AH220201-2400

Suction Valve

Valve disc: hardened alloy steel 4140 (HRC 55-60); valve body: carbon steel A106 Grade B with internal chrome plating; spring: chrome silicon steel (51CrV4); poppet-style design for low flow resistance

1. Valve disc wear due to high-velocity mud flow carrying abrasive particles; 2. Spring fatigue caused by frequent opening/closing cycles (≥ 120 cycles per minute)

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

2

AH220201-2500

Discharge Valve

Valve disc: tungsten carbide (WC-Co, 94% WC); valve body: alloy steel 42CrMo4 with nitrided surface; buffer: polyurethane; designed for bidirectional sealing; maximum pressure: 7,500 psi

1. Impact wear from high-pressure mud surges; 2. Corrosion pitting caused by H₂S in drilling mud

1. Install a surge suppressor downstream to mitigate pressure fluctuations; 2. Use H₂S scavengers if H₂S concentration exceeds 10 ppm; conduct ultrasonic testing on valve seats every 2,000 hours

3

AH220201-2600

Relief Valve

Valve core: stainless steel 316L; valve seat: Stellite 6 alloy; spring: Inconel 718; 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

1

T503-1007

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 160 mm; inner diameter 130 mm; length 350 mm

1. Inner surface abrasion due to piston reciprocation and abrasive mud particles; 2. Thermal deformation caused by uneven cooling

1. Maintain mud solid content ≤ 0.5% by optimizing shale shaker and desander operation; 2. Ensure uniform cooling water flow (≥ 20 L/min) and remove scale buildup from cooling channels quarterly

2

T507-2001

Valve Liner

Alumina ceramic (Al₂O₃, 99.5% purity); metal substrate: stainless steel 316L; vacuum brazed joint; inner diameter 50 mm; length 80 mm; extremely high wear and corrosion resistance

1. Ceramic cracking due to thermal shock from rapid temperature changes; 2. Brazed joint failure caused by vibration

1. Avoid rapid pump startup/shutdown; implement gradual temperature rise/fall (≤ 50°C per minute); 2. Install vibration dampers near the valve assembly to reduce vibration transmission

3

T508-6001

Wear Ring

Polyurethane (PU) with Shore hardness 95A; reinforced with polyester fabric; inner diameter 140 mm; outer diameter 160 mm; width 25 mm; resistant to abrasion and oil

1. Abrasive wear due to contact with drilling mud particles; 2. Swelling and degradation due to exposure to oil-based mud additives

1. Clean the wear ring surface regularly with water-based cleaners; 2. Select PU material compatible with mud type (e.g., oil-resistant PU for oil-based muds); replace every 1,500 operating hours

4

T503-1011

Piston Kit

Piston head: aluminum alloy 6061-T6; piston seal: Viton® FKM; piston rod: stainless steel 17-4PH; assembled with precision fasteners; designed for seamless compatibility with F-2200HL pumps

1. Seal wear due to abrasive mud particles; 2. Piston rod corrosion caused by moisture ingress

1. Ensure effective operation of the mud filter system to remove fine particles; 2. Store the piston kit in a dry environment with VCI (Volatile Corrosion Inhibitor) film before installation

5

T507-2005

Valve Seat Kit

Valve seat: Stellite 6 alloy; seal ring: NBR; retaining ring: stainless steel 316L; complete assembly with all necessary fasteners; precision machined for exact fit

1. Valve seat wear due to frequent valve disc impact; 2. Seal ring degradation due to high temperatures

1. Control pump operating frequency ≤ 120 cycles per minute to reduce impact load; 2. Monitor valve chamber temperature (≤ 150°C) and ensure cooling system effectiveness

6

T508-6002

Bushing Kit

Bushing: bronze alloy (CuSn8) with oil impregnation; outer sleeve: carbon steel 20#; lubricant: lithium-based grease; kit includes bushing, sleeve, and installation tool; designed for self-lubrication

1. Bushing wear due to contaminated lubricant with mud particles; 2. Sleeve corrosion caused by drilling mud contact

1. Replace lubricant every 1,000 operating hours and use high-efficiency oil filters; 2. Apply anti-corrosion grease to the sleeve outer surface before installation

7

T515-2005

Seal Kit

Included components: O-rings (Viton® FKM), gaskets (spiral wound with graphite filler), oil seals (NBR); all components meet API Spec 7K requirements; compatible with both oil-based and water-based muds

1. O-ring extrusion due to high pressure; 2. Gasket degradation due to chemical attack from mud additives

1. Ensure proper groove design (per ASME B16.24) to prevent O-ring extrusion; 2. Verify chemical compatibility of seal materials with mud additives before use

8

T515-2013

Gasket Kit

Gaskets: spiral wound (316L stainless steel winding + flexible graphite filler), flat gaskets (rubber-lined); compliant with ASME B16.20; temperature range: -50°C to 450°C; pressure range: 0-15,000 psi

1. Gasket compression set due to over-torquing; 2. Graphite filler degradation due to moisture

1. Torque bolts to specified values per ASME PCC-1; 2. Store gaskets in a dry environment (humidity ≤ 60%) and avoid reusing old gaskets

9

T508-6006

Thrust Washer

Steel-backed with PTFE coating; base material: carbon steel 10#; coating thickness 0.05-0.1 mm; outer diameter 90 mm; inner diameter 50 mm; low friction coefficient (≤ 0.08)

1. PTFE coating wear due to high thrust loads; 2. Steel base corrosion caused by lubricant contamination

1. Ensure thrust load does not exceed the washer's rated capacity (5,000 N); 2. Maintain lubricant cleanliness and replace oil filters regularly

1

420201011127120060

Hydraulic Hose

Inner tube: nitrile rubber (NBR); reinforcement: 4 layers of high-tensile steel wire; outer cover: polyurethane (PU); maximum working pressure: 5,000 psi; temperature range: -40°C to 120°C; compliant with SAE 100R12

1. Outer cover abrasion due to contact with sharp pump components and drilling debris; 2. Inner tube degradation caused by contaminated hydraulic fluid

1. Install protective sleeves on hoses near sharp edges; 2. Maintain hydraulic fluid cleanliness at ISO 4406 Class 18/15/12 and replace fluid every 2,000 operating hours

2

420503016271600000

Hydraulic Fitting

Stainless steel 316L; NPT 3/4" thread; compression-type design; working pressure: 6,000 psi; compatible with SAE 100R12 hoses; surface passivated for corrosion resistance

1. Thread wear due to over-torquing during assembly; 2. Corrosion in humid drilling environments

1. Torque fittings to specified values (55 N·m for NPT 3/4") using a torque wrench; 2. Apply anti-seize compound on threads before assembly and inspect for leakage after installation

3

420402016270400000

Hydraulic Filter

Filter element: glass fiber (5 μm precision); housing: aluminum alloy 6061-T6; bypass valve: stainless steel 304; maximum flow rate: 40 gpm; pressure drop: ≤ 10 psi at rated flow

1. Filter element clogging due to metal particles from worn hydraulic components; 2. Housing corrosion caused by environmental moisture

1. Replace filter elements every 500 operating hours or when bypass valve activates; 2. Clean the filter housing exterior regularly and apply anti-corrosion paint annually

4

420201011124115060

Pneumatic Tube

Polyurethane (PU) tube; inner diameter 8 mm; outer diameter 12 mm; working pressure: 1 MPa; temperature range: -20°C to 60°C; resistant to oil, water, and most chemicals

1. Tube cracking due to repeated bending and vibration; 2. Inner wall wear caused by contaminated compressed air with oil and water

1. Avoid bending the tube to a radius less than 80 mm; 2. Install an air dryer and oil separator in the pneumatic system to ensure clean, dry air

1

AH220201-0001

Pump Housing Cover

Carbon steel A36 with epoxy-polyurethane paint coating; thickness 15 mm; bolt holes with stainless steel inserts; gasket groove for spiral wound gasket; designed for easy access to internal components

1. Paint coating damage due to impact from tools and drilling debris; 2. Corrosion on uncoated surfaces caused by drilling mud splashes

1. Install a protective cover during drilling operations; 2. Clean the housing cover regularly and touch up paint on damaged areas immediately

2

170506010100243000

Lifting Eye Bolt

Alloy steel Grade 8 (EN ISO 898-1); lifting capacity: 5 tons; thread size M24×2; hexagonal head; surface zinc plated; compliant with DIN 580

1. Thread wear due to repeated use and contact with drilling mud; 2. Fatigue failure caused by overloading during lifting

1. Never exceed the rated lifting capacity; inspect the bolt for cracks before each use; 2. Clean the thread after use and apply anti-corrosion grease before storage

3

AH220201-0002

Access Cover

Aluminum alloy 5052-H32; thickness 8 mm; transparent polycarbonate window for visual inspection; rubber seal (NBR); quick-release fasteners for easy access

1. Polycarbonate window scratching due to contact with debris; 2. Rubber seal degradation due to UV exposure in outdoor installations

1. Clean the window with a soft cloth and mild detergent; avoid using abrasive cleaners; 2. Replace the rubber seal every 6 months and use UV-protective covers for outdoor storage

4

520209064050401502

Temperature Sensor Housing

Stainless steel 316L; NPT 1/2" thread; designed for insertion of a thermocouple sensor; temperature range: -50°C to 300°C; IP67 protection rating

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

1. Use thread seal tape (PTFE) during installation to protect threads; 2. Apply anti-corrosion coating to the housing exterior and inspect for corrosion quarterly