剪切泵说明书(中英文)

1、剪切泵Shear Pump安装使用说明书Diections For InstaI I at ion And Operat ion成都西部石油装备有限公司Chengdu Weast Petro Ieum Equ i pment Co.,LTD目录1 .作用12 .原理13 .型号说明34 .性能表35 .结构图56 .安装、使用、维护指南7引言 7强调说明 7安装 8使用11维护12DERECTORY1. I ntroduct ion152. Principle of operat i on 153. Explanation of mode I 174. Performance tab Ie 1

2、75. StructuraI drawing 186. Guidle to i nstaI I at i on, operat ion and ma i ntenance 206. 1 Foreword206. 2 Emphases 206. 3 I nsta I I at ion20246.4 Operat i on6.5 Ma i ntenance 25WJQ5" 6 J-10剪切泵使用说明书1 .作用WJQ5 6 J-10 剪切泵是一种专门用于剪切聚合物和粘土 并已被现场使用和理论证实有效的机械。在钻井液系统中，聚合物（或粘土）应提前充分地剪切以后， 再进入钻井液系统，才能充分

3、发挥其效用，改善钻井液性能，如 果没有充分剪切，聚合物在第一次循环中就可能堵塞振动筛网， 损失大量的聚合物，增加钻井成本，并且还可能使钻井液中的大 尺寸的固相颗粒变硬而难以除掉；在完井液中，由于没有充分剪 切，聚合物会产生许多“鱼眼”。这些“鱼眼”会伤害地层，使地 层渗透率降低，油气层减产。经过事实证明WJQ5 6 J-10 剪切泵具有优良的性能，它能为高分子聚合物（也能为粘土）迅 速水合提供高度的剪切，解决聚合物（或粘土）在钻井液中或完 井液中因水合不好而存在的突出问题。同时，使用 WJQ5 6 J-10 剪切泵能使聚合物用量减少15%以上，膨润土 用量减少30%以上，并且改善了泥饼和液流损

4、失，降低钻井液剪 切比速率，提高凝胶强度，达到了国外同类产品的先进水平，其 轴封结构更可靠，使用维护更方便。2 .原理WJQ5 6 JC-10剪切泵密封采用了非常可靠的机械密 封，保证无泄漏。泵内部配有一个300mm不锈钢涡轮（其上有 导叶、叶轮、44个喷嘴、4个收集室），及一个剪切板，能够 产生超过s的小端剪切（液体剪切），当液流通过剪切泵时， 有一半（50%）的液体在涡轮收集室的强力推进下将被剪切两 次。该涡轮剪切泵安装在一专用底座上，并用皮带轮、窄V 带和55KW/75kw防爆电动机驱动，与剪切泵配套使用的还有一 个尺寸适合的ZHP150混合漏斗，这样组成了一个完善的剪切 及水合作用系统

5、。由于该泵轴封的改进，使其寿命大大提高。如遵循该泵安装及特殊条件应用的规则，将进一步提高其 性能。本公司将对在油田及工业应用中有利于提高该泵性能的一 般及特殊建议进行处理。注意：该泵不能用于活性泥浆系统，因为系统中的钻井固 体及重晶石，它们在受到剪切时将很快损坏该泵。原理如图一:图一 WJQ5 6 JC-10 剪切泵原理图聚合物流体从V流道进入，并以平行与剪切板P的方向抽 送，收集室内液流量的50%通过44个喷嘴N射出，并以高速 冲击剪切板P,然后在M处90 方向进入泵的蜗壳收集室。总 流V及射流N沿着剪切板流动到达剪切盘的尖端T,在尖端有 许多牙齿，高速旋转的牙齿使聚合物（或粘土）再一次被剪

6、切。 这样就完成了聚合物（或粘土）高度剪切而迅速水合。3 .型号说明WJQ 5"6 J-10涡轮名义直径（英寸）密封形式泵进口直径（英寸）泵出口直径（英寸）涡轮剪切泵4,性能表（表1）型号流量扬转速效汽蚀功率（kw）(m3/ h)程(m)(r/mi n)率(%)余量(m)功轴率配套功 率WJQ5 6 J-101553222802834655WJQ56 J-101553222802834675H|mlE|%lQUZOf 1 J.Z-Z Qr 1/ r- 一 _ .H-»i66Z (;L II一一_6 m4 vNt60C A二 ncROAftz O IIO.PalKwl二 n

7、/. |l IIJ uE-u一一.一r Jill -_.-一1,一一 -'.op一.'一力:LP3-1L DN (I- 。n，IIZu-1ZL 7II/131?1 二/QI)11I/II/ /, 1111 匕 81?飞？II 八 /B 5/ 36 ill 口“5/ S6 60 5 O|l/S|图二WJQ5 6 J-10 剪切泵特性曲线5.结构图图三WJQ5 6 J-10 剪切泵结构图WJQ5" X6nJ-10n剪切泵零件明细表(表2)序数 量零部件名称序数 量零部件明称11泵壳274螺母21叶轮组件284垫圈31剪切板291压板组件41加强板3010型密封圈55X51

8、护板311填料61填料箱321销71右端盖331轴套82油封X X12341机械密封92轴承 2313 (GB/T281-94)351加强套101油孔盖361盖型螺母111泵座371方螺母121轴承座381垫圈1310型密封圈140X391前护板142轴承 7311ACM/DB (GB/T292-94)1510型密封圈125X161油杯 GB1152-89172圆螺母GB812-88182锁紧垫圈 GB858-88191左端盖201油封X X10211轴221油标A12231丝堵ZG1/2241挡泥环251堵头ZG3/4264调节螺栓6. WJQ5" X6"J"1

9、0n剪切泵安装、使用、维护指南引言本指南仅就WJQ5 X6"J-10"剪切泵的安装、使用、维护 中的一般性问题作了介绍，供参考，本指南不能解决的问题， 请与本公司售后服务部门联系，将会及时地给你答复。强调说明该泵只能在设计范围内使用。该泵主密封是机械密封,填料密封为辅密封，当机封失效后, 方可压紧填料密封,否则造成密封不必要损坏。该泵空转不能超过5秒，必须注满液体泥浆方可运转,否则会 造成机封损坏。安装图四WJQ5 6 J-10 剪切泵安装系统流程图剪切泵系统由剪切泵、混合漏斗、管线及聚合物（或粘土） 水合罐组成。为便于安装和运输，聚合物（或粘土）水合罐由 井场泥浆罐的一个

10、隔仓组成。图五WJQ56 J-10剪切泵外形图法兰尺寸（单位：inch）泵法兰盘DNDdb (mm)rrd出口法兰510872268-7/8进口法兰6113/8972268-7/8注：DN法兰通径，D法兰外径，d连接螺纹孔中心距，b法兰厚 度，n-d连接螺栓孔数及孔径。WJQ5" X6“J-10”剪切泵总成明细表（表4）序号数量零部件名称序号数量零部件名称11底座116销轴21剪切泵126开口销38螺栓132螺柱48垫圈144螺母54螺母154窄V1561电机55KW/75KW161大皮带轮71键81帐套91小皮带轮101护罩泵安装泵的安装位置应尽可能靠近抽送源，以缩短吸入段的长度，

11、减 少吸入损失。泵安装基础应水平，牢固可靠，以避免振动。皮带轮的安装A.两皮带轮轴线必须平行，且端面误差不得超过2mm。B.皮带必须找正、绷紧。C.电机安装必须平稳、牢固。进口管路安装A.吸入管路截面积必须大于或等于泵流道断面积。B.吸入管路中不允许安装节流阀，但可以安装常开阀以减少液 流紊乱，该阀只能在拆泵进行检修时才能关闭。C.为避免吸入管路中产生汽泡，抽送源和泵之间应从高到低逐 渐过渡。如果用户需要泵在有吸程状况下使用，请采用真空泵或 底阀引水。D.泵入口处的管路必须平直，其长度至少为吸入管路直径的 二倍。E.当临时使用软管吸入管路时，必须保证软管不被压缩，这 是因为吸入段管内压力一般都

12、比大气压低，在大气压作用下，软 管被压缩，从而导致流量降低甚至断流。出口管路A.为便于泵的检修，出口管路中应该安装常开阀。B.所有管路（包括入口管路）必须有自己的支撑，绝不允许 由泵承受管路重量。C.当工作条件不明或不稳定时，出口管路中必须安装节流阀， 以保证泵在设计点运行。D.当泵出口与压力设备相接时，在节流阀和泵出口之间必须 安装止回阀，以防止液体回流，否则，回流液会导致泵发生“水 锤现象”而损坏。使用准备A.用手转动泵轴，必须保证运转灵活，各处不得有摩擦声。B.检查转向，必须确保与泵体所示转向一致。C.全开入口段的阀门。D.给泵体和入口段管路注满液体，以排出空气。运转操作A.准备工作全部

13、结束后，开动电机。润滑A.轴承润滑a.轴承采用30号机油润滑，泗滑油应加至油标的中线， 不要加过多油，否则将导致轴承振动和过热。每90天 或1000小时换油一次。b.在特殊情况下，轴承可用与润滑油相容的洞滑脂润滑。B.填料腔润滑a.填料腔必须经常润滑，以防止填料过热而损坏，一般要 求每天至少一次。b.注入润滑脂时必须旋转泵轴，以使其充分进入填料腔， 直到填料压盖端有油脂渗出为止。维护（参照图三及零件明细表2）A.拆卸：a.拆下皮带轮组件。b.拆下填料压板组件（26）。c.卸下泵壳（1 ）od.拆除叶轮组件（2）、剪切板（3）、加强板（4）：先拆下 螺母（33、34）（螺母为反扣）及垫圈（35）

14、,注意如无 叶轮扳手，则用木制垫块和木榔头敲击涡轮背部辐筋， 退出叶轮组件（2）（拆出时应先在皮带轮端卡住轴，以防转动）。e.拆除加强套（32）和机封动环组件（31）。f.拆除护板（5）和填料箱（6）og.退出轴套（30）,如果轴套过紧，可用楔形块敲击其尾 部（轴肩处）使其松动。h.退出挡泥环（24）O1 .拆下左、右端盖（7、19）oj.从轴承托架内退出轴承总成。k.松掉锁紧垫圈，拆出锁紧螺母（17）和锁紧垫圈（18）o1 .拆下轴承托架，退出轴承（14）（用垫块垫上，敲击轴 中心）。m.退出轴承（9）（用3英寸套筒对准轴承内圈，敲击套筒 使内轴承退出）。B.检查a.叶轮：严重汽蚀（特别是主

15、叶片）、过度腐蚀、磨损、 破损时，要求更换叶轮。b.轴：径向跳动超过，轴承座及油封位置严重擦伤，轴上 螺纹、沟槽、台肩及其它表面有损伤时，要求修整轴， 无法修整时，则更换轴。c.轴套：表面粗糙及损伤严重时，更换轴套。d.经过拆卸的油封必须更换。e.滚动轴承：对过度磨损，运转时过紧、过松或有噪声的 轴承必须更换（新轴承只有在更换时才能开封，所换轴 承必须和泵原用轴承型号、尺寸一致）。f.。型密封圈：一般经过拆卸的。型密封圈应更换，对其 它密封垫片等，只要没有破损，也可以再用。C.装配（参照图三及零件明细表2）a.装配前所有零件必须清洗，特别是0型圈密封槽，螺纹、 轴承及轴承润滑部位，要仔细清洗，

16、对一些粗糙部位还应用细纱布打磨。b.装轴承(14)时，两轴承应背对背安装，旋进锁紧螺母 后要扣住锁紧垫片，锁紧螺母紧固力矩：346牛米。c.在装轴套(30)时，在轴上涂一薄层减摩剂。d.叶轮背面和护板之间的间隙为。e.填料压盖不能拧得过紧，否则泵运转时可能导致填料烧 坏。f.装配顺序按拆卸逆方向进行，装配好后，转动轴应灵活, 各部位不得有阻卡。如有阻卡，调节螺栓(26)和螺母 (27)O上紧螺栓(26)是将泵轴及轴上的零件向右移 动，松动螺栓(26)是将轴及轴上的零件向左移动。注意：无论是将轴左调或右调，调整完毕后，一定要将螺 栓(26)上紧,螺母(27)并紧，以防止轴运转时轴向窜 动。D.

17、故障及排除a.填料密封泄漏严重，填料严重磨损，轴套表面磨损。拆下填料，用一细铁丝弯曲90 ,在轴套壁上移动， 如果检查到有过深的沟槽则更换轴套，填料压盖压得过 紧导致填料磨损严重。b.聚胺脂油封(20)磨损严重导致泄漏。排出：更换聚胺脂油封(20)。一般情况，当泵运转3-6个月后，应更换一次轴封处的 聚胺脂油封和轴套。c.填料烧坏。原因：填料压盖压得过紧，引起发热。排出：更换填料，压盖不能压得过紧。d.叶轮或副叶轮转动不正常。原因：叶轮背面和护板间隙过小，或副叶轮与护板和 填料盒之间间隙过小。排出：用螺栓(26)和螺母(27)调节间隙。调节完 后用手转动轴，各部位不得有阻卡、摩擦声，转动灵活。

18、e. WJQ5 6 J-10 剪切泵一般故障及排除一览表5。WJQ5" 6 J-10 剪切泵故障及排除（表5）序故障原因排除方法1轴功率过 大1、叶轮与泵壳端面 或叶轮与衬套发 生摩擦或副叶轮 发生摩擦。2、泵在比设计点扬 程低得多的条件 下运行。3、填料压盖压得太 紧。4、皮带打滑。1、调整叶轮与泵壳端面 及叶轮与衬套的间隙， 或副叶轮的间隙，消除 摩擦。2、检查所配工作机是否 符合要求，并关小排出 阀门，使泵在设计点工 作。3、重新调整压盖紧固力。4、张紧皮带（检查两皮带 轮安装位置是否合 适）。2扬程下降1、大块颗粒堵塞吸1、清除堵塞物。流量下降入管和叶轮流道。2、泵转速下降。

19、3、叶轮磨损。4、叶轮与泵壳端面 间隙过大，泄漏增 大。5、进口阀门开度太 小。2、使泵在额定转速下运 行。3、更换叶轮。4、调整叶轮与泵壳端面 的间隙。5、开大进口阀门。3轴承过热1、润滑油太多或太 少。2、油中有杂质。3、轴承磨损。1、使油面保持在油标规 定位置。2、更换润滑油。3、更换轴承。4泵运行产 生振动和 异常噪声1、叶轮磨损不平衡。2、轴承磨损。3、联接松动。1、更换叶轮。2、更换轴承。3、紧固各松动部位。4、泵产生汽蚀。4、改善吸入条件，防止空 气进入泵内。1、机封损坏。1、更换机封。2、轴套磨损严重。2、更换轴套。3、密封填料磨损过3、装填新的盘根环。5密封泄漏 严重大。4、

20、盘根环斜卷。5、杂质、异物进入盘4、重新组装盘根环。5、清除杂质、异物，清洗 密封件。根环。6、盘根环斜口 一致。6、重新按要求错位装填 盘根环。1. Introduct i onThe WJQ5” 6 J-10 shear pump generation is uniquelydesigned pump for shear i ng polymers and cI ays.To improve the drill fluid properties, the poIymers or clays shouId be highly sheared before adding them to the

21、 drill fluid system. If not sheared, the poIymers maybe jam the strainer and wi I I resu11 in losing amount of poIymer and increasing drilling costs, and the large-size solids in the drill fluid wi I I harden and difficult to c I ear away as well. The WJQ5 "6 J-10 shear pump has proven best for

22、applying the high shear necessary to hydrate poIymers and clays and to thei r best propert i es. Us i ng the WJQ5 "6 J-10 shear pump reduces the bentonite c I ay needed by 33% or more and po I ymer needed by 15% or more. 11 a I so improve fluid Ioss and f iI ter cake, bu iIds geI strength, and

23、Iow shear rate viscosity to better ho I d up so I ids. With re I i ab I e shaft sea I structure and more convenient i n operation and maintenance, it comes up to advanced wor Id standards in the same products.2. Principle of operationThe WJQ5 "6 J-10 shear pump adopts a set ofmechanica I sea I

24、for no I eakage at stuffing box. Inside pump i s a 300 ser i es sta i nI ess steeI turb i ne containing 44 nozzIes, four scoops and shear pI ate. Fifty percent of the fluid is sheared twice each time through the pump. This turb i ne shear pump i s mounted on a spec i a I base with be I ts and sheave

25、s to dr i ve pump, OSHA type belt guard and a 75HP/102(55kw/75kw) 1480 RPM EXPLOSION PROOF U/L approved electr ic motor, 460 volts, 3 phase 60 eye Ie. IncIuded i s a specia I hopper(ZHP150) with nozzIe s ized for this app I i cat i on and one mud kit as a package i n order to build a comp lete shear

26、 and hydration system. The pump is designed to gi ve Ionger serv ice I ife through the improved shaft sea I.There are many principles of proper pump instaI I at ion and appI icat ion as we I I as spec i a I considerations for the pump design which, if foI I owed, wi I I further enhance the performan

27、ce of your WJQ5" 6 J-10 turbine shear pump.Thi s document wi I I dea I with both genera I and specific recommendat ions for improved WJQ5 "6 J"10 turbineshear pump performance i n both oi Ifield and industr ia I appIi cat i ons.Warning! This pump can not be used on active mud system s

28、ince it wi 11 shear drill solids and barite. These solids wi11 also damage pump very quickly.The pr inciple sees figure 1.T TX Y L、MFigure 1 Principle diagram of WJQ5" 6 J-10 shear pumpFluid enters at "V" and is pumped para I IeI to the shear “P” . The chambers scoops 50% of the voIum

29、e being pumped and jets that fluid through 44 nozzIes "N” and impacts the shear p I ate "P" at very high velocity at “ M'' 90 degrees to the fluid enter i ng the pump. The tota I fluid "V” and "N" trave I s down the shear p I ate to “T" where the fluid is f

30、urther sheared due to the shape and speed of the pI ate t i p.3. Explanation of mode IWJQ 5"6 J-10Turb i ne nomi naI d i a. (Inches)Sea I formPump inlet di a. (Inches)Pump out let di a. (Inches)Turb i ne shear pump4. Performance Tab Ie(Table1)ModelCapac ity(m3/h)Hea d(m)Speed(r/mi n)Eff i c i e

31、ncy(%)NPS H(m)Power (kw)Sha ft pow erMoto r powe rWJQ5 6 JC-101553222802834655WJQ5 6 JC-101553222802834675HlrrilEl%l 7ft一7268 6«'« ，Z hOUJ J5U r-H-口3 DAll一 一_-35 2 II> Il36)2OB? C IIZ 、L /, 一MlnE-Q32?B1 s1 _.一 “ 1n-l之(12n14ii J2l|/219/一8 11 n/II/ / r0j 812 120 24a s2 341 4B 12 56 51

32、1 6。O|L SIPerformance curve:WJQ56 JC-1O5. StructuraI drawingFig. 3 WJQ5,TX6nJC-10f, Shear pump parts I ist(Table 2)Ite m No.Qty Part NameI te m No.Qty Part name11Pump Case274Nut21ImpeI I er assembIy284Washer31Shear PI ate291PresspI ateassembIy41Strengthening board3010-R i ng (55 X51Protecting board3

33、11Stuffing61Stuffi ng Box321Pin71Right cover331Shaft sIeeve820i I X X12341Machine sea I92Bear i ng (2313)351Re i nforce sIeeve1010 iI ho Ie cover361Cap Nut111Pump seat371Nut231P i pe pIug ZG1/2241Mud throwing r ing251Pipe pIug ZG3/4264Bolt6. Guide to instaI I at ion, operat ion and maintenance of th

34、e WJQ5" X6"JC-10" shear pump.ForewordThe genera I problems to installation, operation and maintenance of the WJQ5" Xshear pump areintroduced in the guide(for your information only), pI ease contact our company for insolvabIe prob Iems i n this guide and wiI I be rep I i ed i n t

35、ime.EmphasesOperate the pump on I y i n the performance range and service for which it was designed.Thi s pump emp I oys mechan i a I sea I as i ts pr imary sea I and packing sea I as its secondary sea I. Packing sea I can be compacted on I y when mechanical sea I i s d i sab Ied. Otherwi se, the se

36、a I may be damaged.No-load running time of the pump cannot exceed 5s. The pump must run under the condition of being filled with I iquid sIurry. Otherwise, the mechanicaI sea I may be damaged.InstaI I at ionFlow diagram of WJQ5 X6“J-10”shear pump i nstaI I at i on systemThe shear pump system is form

37、ed by shear pump, mixing hopper, p i peIi ne and poIymer/cI ay hydrator. For instalI at ion and transportat i on, the poIymer/cI ay hydrator i s formed by a separate compartment.(Table 3)FlangeDNDdb (mm)n-dDischarge Flange51081/2268-7/ 8Suet i on Flange6117891/2268-7bNote: DN-FI ange inside dia. , D

38、-FI ange outs ide di a., bolt circle, b-FIange thickness, n-dNo. & size of bo 11 ho I es.WJQ5" X6"JC_10MShear pump assembIy I ist(Table 4)I ternQty Part NameI te mQty.Part Name11Base-pI ate116Clevis Pin with Head21Shear Pump126Split Pin38Bolt132Stud48Washer144Nut54Nut154NarrowV-belt(15

39、)61E lectr i c Motor (55kw/75KW)161DrivingPul ley71Key81Expanding Sleeve91Dr i ve Pul ley101HoodPump instalI at ionThe pump shou Id be Iocated near the I iquid source so that the suction I ine can be short and reduce losses. The foundation shou I d be sufficiently rigid and substant i a I to absorb

40、any vibration and support the base pI ate at a I I points. The base p I ate shou Id be i nsta I I ed in a I eve I position.Pul ley i nstaI I at i onA. The axes of two pu I I eys must be para I I e I to each other and the end surface error can not exceed 2mm.B. The belts shouId be a I i gned and t i

41、ghtened.C. The eIectr i c motor must be mounted stab Iy.Connect i on of suet i on p i pesA. The suet ion I ine shouId be equa I to or larger than the pump suet i on.B. The capacity of a centr ifugaI pump shouId never be adjusted by throttIing the suetion line, but a positive shut-off va I ve of a ty

42、pe to cause minimal turbu I ence shou I d be instaI Ied in the suetion Iine to permit the closing of the I i ne for remova I of the pump for i nspect i on andma i ntenance.C. The suet i on Ii ne shouId be des i gned to eIimi nate any a i r pockets. The pipes shouId graduaI Iy slope downwards to the

43、supply source to eI imi nate a i r pockets. PI ease use a vacuum pump or foot vaIve for priming if you operate the pump the pump under the condition of suetion lift.D. The suetion I ine shouId have a straight section into the pump of a length equ i va I ent to at I east two times its diameter.E. For

44、 temporary hook-up when flexible hose i s used, a non-coI lapsi ng hose i s essent ia I s i nee the suet ion I i ne pressure i s often be Iow atmospher ic pressure. A co I Iapsed suet i on I i ne wi I I result i n be Iow average or complete Ioss of f I ow.Discharge pipesA. A positive shut-off vaIve

45、shouId be Iocated in the discharge pipe to permit the closing the Iine for removaI of the pump for i nspect i on and ma i ntenance.B . Al I pipes (including suction p i pes) should be i ndependentIy supported and accurate Iy aligned. The pump must not support the we i ght of p i pe or compensate for

46、 misaI ignment.C. If operating conditions are not known with sufficient accuracy, it wi I I be necessary to provide a throttIe vaIve i n the d i scharge I i ne to ensure that the pump operates at the design point.D. If the pump is connected to a pressur ized system, it is important to instaI I a che

47、ck vaIve between the discharge and the thrott I ing vaI ve. The check vaI ve wi I I prevent back flow through the pump. Back f I ow may cause the impe I I er to become loose on the shaft. A I oose impe I I er wi I I I i ke I y I ead to mechanic damaged and fluid Ieakage beneath the shaft sleeve.Oper

48、ationPreparationA. Pump rotates free Iy by hand.B. Check the pump rotate di rect ion, the correct di rect ion can be found by an arrow on the casing.C. Open the suction vaIve fuI Iy.D. Pump and suet ion line full of fluid for vent i ng a i r.Operation for runningStart the motor after finishing al I

49、the preparat i ons.Lubr icat ionC. Bear i ngs lubr icat ionc. Add a good grade of 10w30 weight motor oi I unti I the middle I eve I of d i pst i ck. Do not overf i I I the oi I High I eve I s nay cause churning and overheating of the bearings. 0i I shouId be changed every 90 days or 1000 hours.d. Un

50、der the special condition, you may seIect a grease which can dissolve with the motor oi I for Iubr icat ion.D. Stuffing box lubricationc. The stuffing box may be re-lubr icated with grease as often as necessary to prevent the packing form overheating. It shou Id be I ubr icated at least once a day.de On fi