Shanghai B.O.P. Control System FKQ1280-10 Parts

1

YTK-02 Pressure switch

Housing: 304 Stainless Steel; Sensing Element: 316L Stainless Steel Diaphragm; Internal Components: Brass Alloy (Nickel-Plated); Seals: FKM/Viton Rubber

1. Diaphragm wear and deformation due to long-term high-pressure cycling; 2. Contact oxidation and poor conductivity caused by high humidity and corrosive gas (H₂S) in well sites; 3. Inaccuracy from contamination of pressure sensing channels by drilling fluid residues

1. Calibrate pressure switch every 3 months using a precision pressure gauge (traceable to national standards); 2. Install a gas dehydration device in the control cabinet to maintain relative humidity ≤60% and use anti-corrosion coatings for exposed parts; 3. Regularly flush pressure sensing channels with clean hydraulic oil (ISO VG 32) to remove residues, and inspect for blockages

2

3-position and 4-way Connecting Rotary Valve

Valve Body: 304 Stainless Steel; Spool: 42CrMo Alloy Steel (Quenched & Tempered); Seals: FKM/Viton Rubber; Valve Seat: Polytetrafluoroethylene (PTFE) Reinforced with Glass Fiber

1. Spool wear and jamming due to contamination by solid particles in hydraulic oil; 2. Seal degradation from high-temperature operation (exceeding 80°C) and exposure to drilling fluid additives; 3. Valve seat leakage caused by improper torque during installation

1. Use hydraulic oil with cleanliness grade NAS 7 and replace oil filters every 500 operating hours; 2. Monitor control system temperature and ensure cooling systems operate to keep temperature ≤60°C; verify compatibility of drilling fluid additives with FKM seals; 3. Tighten connecting bolts to the torque specified by the FKQ1280-10 system manual (typically 25-30 N·m) using a torque wrench, and conduct leak tests with nitrogen (0.8MPa) after installation

1

Crankshaft Plunger Pumps JYS21-25

Crankshaft: 40CrNiMoA Alloy Steel (Forged & Nitrided); Plunger: 316L Stainless Steel (Hard Chrome Plated); Pump Body: Gray Cast Iron HT250 (Anti-Corrosion Coated); Connecting Rod: 42CrMo Alloy Steel

1. Plunger surface wear and chrome plating peeling due to contamination by solid particles in hydraulic oil; 2. Crankshaft fatigue cracking from long-term high-speed rotation (typically 1450rpm) and cyclic loads; 3. Connecting rod bushing wear caused by insufficient lubrication

1. Install a high-precision filter (2μm) at the pump inlet and replace hydraulic oil every 1000 operating hours; inspect plunger surface for scratches monthly and re-plate chrome if wear depth exceeds 0.1mm; 2. Conduct ultrasonic flaw detection (UT) on the crankshaft every 6 months to detect hidden fatigue cracks; avoid overloading the pump (limit maximum output pressure to 10MPa, per FKQ1280-10 specs); 3. Use high-temperature resistant lubricating grease (NLGI Grade 2) for connecting rod bushings and replenish every 200 operating hours; check bushing clearance monthly (maximum allowable clearance ≤0.05mm)

2

Crankshaft Plunger Pumps JYSQ21-25

Crankshaft: 40CrNiMoA Alloy Steel (Forged & Nitrided); Plunger: 316L Stainless Steel (Ceramic Coated); Pump Body: Ductile Iron QT450-10 (Anti-Corrosion Coated); Connecting Rod: 42CrMo Alloy Steel (Shot-Peened)

1. Ceramic coating peeling on plunger surface due to improper hydraulic oil viscosity (too low/high); 2. Crankshaft bearing wear from high-temperature operation; 3. Pump body corrosion from exposure to seawater in offshore drilling scenarios

1. Use hydraulic oil with viscosity ISO VG 32-46 (temperature range 10-60°C) and avoid mixing different types of oil; inspect plunger coating for peeling monthly and replace plunger if damaged; 2. Monitor pump bearing temperature (normal range ≤70°C) and replace bearings if temperature exceeds 80°C; use bearing lubricants with anti-high-temperature additives; 3. For offshore applications, apply marine-grade anti-corrosion coating (epoxy resin) to the pump body every 6 months and install a waterproof cover to prevent seawater splashing

3

Pneumatic Pump 34ZL21-25

Pump Body: 304 Stainless Steel; Air Cylinder: 6061 Aluminum Alloy (Anodized); Pistons: NBR Rubber (Reinforced with Nylon); Valves: PTFE

1. Air cylinder wear and air leakage due to contamination by dust and moisture in compressed air; 2. Piston seal degradation from high-pressure air (up to 1.0MPa) and temperature fluctuations; 3. Valve jamming caused by oil residue accumulation in compressed air

1. Install an air filter-regulator-lubricator (FRL) unit at the pump inlet to remove dust (particle size ≤5μm) and moisture (dew point ≤-20°C); drain the FRL moisture trap daily; 2. Inspect piston seals monthly for cracks and replace with OEM-compatible NBR seals if damaged; avoid operating the pump at air pressure exceeding 1.0MPa; 3. Use food-grade mineral oil for the FRL lubricator (1-2 drops per minute) to ensure valve lubrication, and flush the air circuit with clean compressed air every 3 months to remove oil residues

1

Relief Bleed Valves JYSQM21-25

Valve Body: 304 Stainless Steel; Valve Core: 42CrMo Alloy Steel (Hardened); Seals: FKM/Viton Rubber; Spring: 60Si2Mn Alloy Steel (Heat-Treated)

1. Valve core wear and seat leakage due to solid particle contamination in hydraulic oil; 2. Spring fatigue and deformation from long-term high-pressure compression; 3. Seal degradation from exposure to H₂S and CO₂ in sour gas wells

1. Use hydraulic oil with cleanliness grade NAS 7 and replace oil filters every 500 operating hours; inspect valve core and seat for wear monthly and lapping if necessary; 2. Calibrate the relief pressure every 3 months (set pressure per FKQ1280-10 specs: 10MPa) and replace the spring if pressure deviation exceeds ±0.3MPa; 3. For sour gas well applications, use H₂S-resistant FKM seals (rated for H₂S concentration ≤1500ppm) and apply anti-corrosion coating to the valve body; conduct leak tests with nitrogen (1.0MPa) after maintenance

2

Relief Bleed Valve QYB 40-120L

Valve Body: Ductile Iron QT450-10 (Anti-Corrosion Coated); Valve Core: 316L Stainless Steel; Seals: EPDM Rubber (for Low-Temperature Applications); Spring: 50CrVA Alloy Steel

1. Valve body corrosion from exposure to rainwater and drilling fluid splashes; 2. Valve core jamming due to ice formation in low-temperature environments (≤-10°C); 3. Seat leakage caused by improper installation torque

1. Install a protective cover to prevent direct exposure to rainwater and drilling fluid; clean the valve body monthly and touch up anti-corrosion coating if scratched; 2. For low-temperature drilling environments (≤-10°C), use EPDM seals (temperature range -40°C to 120°C) and install a trace heating device around the valve to maintain temperature ≥0°C; 3. Tighten the valve bonnet bolts to the specified torque (20-25 N·m) using a torque wrench and conduct a pressure holding test (10MPa for 30 minutes) to ensure no leakage

3

QB21-60

Valve Body: 304 Stainless Steel; Valve Core: 42CrMo Alloy Steel (Induction-Hardened); Seals: FKM/Viton Rubber; Valve Stem: 316L Stainless Steel (Polished)

1. Valve stem wear and seal leakage due to friction with contaminated hydraulic oil; 2. Valve core sticking caused by foreign matter accumulation in the valve cavity; 3. Corrosion of external components from high humidity in offshore drilling

1. Regularly flush the valve cavity with clean hydraulic oil (ISO VG 32) to remove foreign matter; inspect the valve stem surface for scratches monthly and polish if necessary; 2. Operate the valve manually 2-3 times per week to prevent sticking; disassemble and clean the valve every 6 months; 3. For offshore applications, apply marine-grade anti-corrosion coating to external components and inspect for rust monthly

4

QB21-80

Valve Body: 316L Stainless Steel; Valve Core: 40CrNiMoA Alloy Steel; Seals: FKM/Viton Rubber (High-Pressure Rated); Valve Seat: PTFE Reinforced with Carbon Fiber

1. Valve seat wear due to high-velocity fluid flow (exceeding 10m/s); 2. Seal degradation from high-temperature operation (exceeding 90°C); 3. Valve core fatigue from long-term high-pressure cycling

1. Optimize the pipeline layout to reduce fluid velocity at the valve inlet to ≤8m/s; inspect the valve seat for wear every 3 months and replace if wear depth exceeds 0.2mm; 2. Monitor system temperature and ensure cooling systems operate to keep temperature ≤70°C; avoid operating the valve at temperatures exceeding 80°C; 3. Conduct ultrasonic flaw detection (UT) on the valve core every 6 months to detect fatigue cracks; avoid frequent overpressure cycling (limit pressure fluctuations to ≤1MPa)