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Petroleum and Natural Gas Industry Standard of the People's Republic of China $Y/T 5050—93
Operation and maintenance of beam pumping units
Published on September 9, 1993
China National Petroleum Corporation
Implementation on March 1, 1994
1 Main content and scope of application
Petroleum and Natural Gas Industry Standard of the People's Republic of China Operation and maintenance of beam pumping units
This standard specifies the requirements and methods for the operation and maintenance of beam pumping units.
SY/T5050—93
Synchronize SYS050-—84
This standard applies to the operation and maintenance of beam pumping units (hereinafter referred to as pseudo-pumping units). Other types of pumping units can also refer to the 2 reference standards
GB6903 Medium load industrial gear oil
SY1172 Industrial gear oil
SY403B7407 gear grease
SY 1677
Wire rope surface grease
GB7324
General lithium-based grease
SY/T5044 Beam pumping unit
3 Use of pumping unit
3.1 Principles for selecting working parameters of pumping unit
3.1.1 According to different pumping conditions, reasonably select the working parameters of the pumping unit. In deep well heavy oil pumping, long stroke (>4.2m) and low frequency (≤6/mim) should be used as much as possible. For shallow and low viscosity oil pumping, short stroke and high frequency should be used. 3.1.2. The pumping unit is not allowed to operate under the condition of over-rated suspension load and over-rated torque of reducer. 3.2 Starting and stopping the pumping unit
3.2.1 When starting the unit, first check whether the power supply system is normal, then remove the brake safety lock block, release the brake, and then start the motor. If it cannot start at one time, multiple starting methods should be used. In winter in cold regions, the machine should be turned first, and then the motor should be started. 3.2.2 When stopping the unit, the power supply should be cut off first, and then the brake should be applied. When braking, the operation should be smooth and avoid sudden braking. 3.3 Balance of the pumping unit
The pumping unit should be operated under good balance conditions, and the balance of the pumping unit operating under unbalanced conditions should be adjusted in time. The balance of the pumping unit can be adjusted by the "balanced current method" or the "average power method". When adjusting the balance by the "balanced current method", the maximum current difference between the upper and lower strokes should be less than 15% of the maximum current. The maximum current value should not exceed the rated current value of the motor. See Appendix A (Supplement) for balance calculation.
3.4 Pumping unit troubleshooting
When the pumping unit is in use, if abnormal noise, bearing overheating or other faults are found, the unit should be stopped immediately for inspection and troubleshooting. See Appendix B (reference) for the troubleshooting methods. 3.5 Pumping unit lubrication
3.5. Selection of reducer lubricant
3.5.1.1 The reducer lubricant should be industrial gear oil, medium-load industrial gear oil or grease of similar nature with high load-bearing capacity and sufficient viscosity.
Approved by China National Petroleum Corporation on September 9, 1993 and implemented on March 1, 1994
SY/T 5050--93
3.5.t.2 Lubricants with appropriate viscosity should be selected. When the temperature is high, select a lubricant with a relatively high viscosity index. When the temperature is low, select a lubricant with good fluidity at low temperatures to ensure that the lubricant can flow freely into the lubricating oil tank of the reducer. 3.5.1.3 The minimum operating temperature of the lubricating oil used in the reducer should be 5 to 10°C lower than the minimum temperature in the area; the maximum operating temperature should be 12 to 15°C higher than the maximum temperature in the area. The lubricating oil used in the reducer is specified in Table 1. The performance of the grease used should not be lower than the quality indicators specified in SY4036.
Industrial gear oil (SY1172)
Medium load industrial gear oil (GB5903)
3.5.2 Lubricating grease for other parts of the pumping unit
70:120:150:2001250
N68;N100;N150:N220;N320,N460 and the replacement time of the grease shall be as specified in Table 2. The replacement interval shall be calculated based on the accumulated operating time. Table
Lubricating parts
Wire rope
Bracket bearing seat
Beam bearing seat
Crank pin bearing seat
Connecting rod pin
Motor bearing
4 Pumping unit maintenance and care
Number of lubrication points
Grease name
Wire rope surface grease
(s1577
General lithium-based grease
(GB 7324)
General lithium-based grease
(GB 7324)
Replacement time, h
4.1 Maintenance and care work of the on-duty workers4.1.1 Check whether the foundation of the oil pump is firm, whether it has sunk or shifted, and whether the fastening screws of the base bolts, central bearing seat, and walking beam bearing seat are loose.
4.1.2 Check whether the reducer bearing cover and shaft head seal, the speed reducer joint surface, and the oil drain hole plug are leaking oil. Check whether the crank pin lock nut is loose or disengaged. 4.1.3
Check whether the wire rope is broken or the rope cap is loose. 4.1.4
4.1.5 Keep the environment of the oil pump clean.
4,2 Strong maintenance of the oil pump
4.2.1 Maintenance
4.2.1.1 Perform maintenance once every 2000h of cumulative operation time. 4.2.1.2 Perform inspection and maintenance according to the contents of 4.1.1, 4.1.2, 4.1.3 and 4.1.4. 4.2.1.3 Check the reliability of the brake mechanism. The brake should be able to brake reliably at any position of the crank. The brake operating force should not exceed 0.15kN (measured by a spring dynamometer). After releasing the brake handle, there should be no contact between the brake hub and the remaining belt (brake block), and the minimum clearance is 1.62
～2mm (mesh).
sY/r 5050-—93
4.2.1.4 Check each lubrication point and add lubricant. 4.2.1.5 Check whether the tension of the tape is appropriate. Use one hand to apply 0.15~0.20kN force at the midpoint of the tape, and the tape should sag 30~50mm appropriately. The V-shaped tape should ensure that the motor belt pulley and the input shaft belt pulley end face are not coplanar by more than 1mm (self-test with a pull line). 4,2,2 Second maintenance
4.2.2.1 Perform once after the cumulative running time is 4500h. 4.2.2.2 According to 4,2,1.3, 4.2.1.4, 4.2.1. 5 items of inspection and maintenance. 4.2.2.3 Check the noise of the whole machine. When the pump is running, measure its noise. The measuring points are distributed at both ends of the reducer output shaft, 1m away from the shaft end face and 1.5m high from the bottom of the pump. The arithmetic mean value measured by the sound level meter A sound level (slow gear) should meet the requirements of Table 3. Cut 3
Reducer torque, kN·m
Sound, dB(A)
4.2.2.4 Check the reducer bearing temperature. The maximum bearing temperature shall not exceed 70G. 4.2.2.5 Detect the reducer oil pool temperature. The maximum oil pool temperature shall not exceed 70C. 4.2.2.6 Check the reducer oil leakage and lubricant quality. If the following conditions occur, the lubricant should be updated immediately. a: Is there any sediment on the internal surfaces of the reducer? b: Is the oil contaminated by sand, metal particles and other impurities! c. Is the oil emulsified?
4.2,2.7 Check the gear contact spots for scratches, pitting or cracks. 4.2.2.8 Check the wheel width and wheel rim for cracks. 4.2.2.9 Check the suspension rope for broken wire strands or loose rope caps. 4.2.3 Three Guarantees
4.2.3.1 Perform once every 9000 hours of cumulative operation time. ≥37
4,2.3,2 Perform maintenance according to 4.2.2.3, 4.2,2,4, 4.2,2,5, 4.2.2.6, 4,2.2.7, 4,2,2,8 and 4.2,2.9. 4.2.3.3 Check all welded parts of the pumping unit for permanent deformation, cracking and fatigue cracks in the welds. 4.2.3.4 Check the wear of the reducer tooth surface. Measure whether the gear side clearance exceeds the standard. 4.2.3.5 Check the projection of the pumping unit suspension point and the scissor difference. The measurement requirements are shown in SY/T5044. 4.2.3.6 Check the stability of the foundation. The amplitude index of the bracket shall not exceed the requirements of Table 4. 4.2.3.7
Replace the worn parts that affect the performance of the pumping unit. 3
Pumping unit specification code
3—1.2-6.5
3—1.5—6.5
4—1.5—g
3—2. 1-13
42.5—13
5--1.8—13
8—2.1—18
4—3—18
5—3-26
6—2.5—26
8—2,1—18
8-2.5—26||tt| |10—3—37
10—3-53
12—3.6—53
14—3.6—73
10—4.2—53
12-4, 2-73
12—4.8-73
14—4.8—73
16-~5.4—105
16-—6—105
18—6—105
SY/T5050—93
Amplitude at the top of the bracket
Allowable longitudinal amplitude
.4.2.3.8 Check the insulation of electrical appliances and maintain the motor. Transverse allowable amplitude
Testing methods and regulations
Measured by theodolite during full load operation
A1 Balance calculation of oil pump
SY/T5050—93
Appendix A
Balance calculation of oil pump
(Supplement)
The balance of the oil pump can be adjusted according to one of the following three principles. a. Make the work done by the motor in the upper and lower strokes equal, b. Make the maximum net torque of the reducer crankshaft in the upper and lower strokes equal, c. Make the deviation between the instantaneous tangent of the reducer crankshaft and the average tangent force equal and the minimum. A1.2 When the oil pump is working in an unbalanced state, analyze it according to the measured oil and indicator diagram, and then make adjustment balance calculation. A1.2.1 Calculate according to the principle that the maximum net torque value of the reducer crankshaft in the upper and lower strokes is equal. When the maximum net torque M1m2\ of the upstroke is greater than the maximum net torque M1m2\ of the downstroke, the maximum torque M value of the rotating counterweight is increased, otherwise it is reduced. The maximum torque M value of the rotating counterweight can be calculated according to the torque curve as follows: IMwniI+IMwee
Ising,l+[singl
Wherein. M.rt-
Maximum torque of pure light rod load in upstroke, N·mMwraw
Maximum torque of pure light rod load in downstroke, N·m0, the crank angle at which the maximum torque of pure light rod load is generated in upstroke (") (A1)
8. The crank angle at which the maximum torque of pure light rod load is generated in downstroke, (°). A1.2.2 The appropriate maximum torque M value of the rotating counterweight can also be obtained according to other principles in A1.1. A1.2.3 After calculating the reasonable maximum torque M value of the rotating counterweight, use the following formula to calculate the reasonable placement position of the counterweight, S
Wherein: S-
the distance from the center of gravity of the balance block to the center of the crankshaft, m9-gravitational acceleration (g-day.81m/s)7
-maximum motion acceleration m/s\,
1stroke
downstroke
(A2)
SY/T5050-93
Q-balance block gravity, unit N.
According to SY/T5044, S, 9, a, Q can be found or converted in the pumping unit manual. A2 Calculation Example
A certain oil pump uses a CYJ6-2.5-26HB oil pump. The pumping unit rotates counterclockwise, with a stroke length of 2185m. The pumping unit has an unbalanced weight G=D (kN) and a measured dynamometer diagram as shown in Figure A1. A2.1 Take the point = 285° for calculation. From the table of the pumping unit torque factor and the rod position factor, it is found that when = 285, the torque factor TF = -1.10Sm. The rod position factor PR = 0.4451, At the scale 0,4451 on Figure A1, draw a vertical line that intersects the stroke load curve on the dynamometer upwards. The ordinate of the intersection is 0.033mm. The force ratio coefficient of the dynamometer is 1320kN/m. The light rod load at this point is W=0.033x1320=43.56kN.
Torque generated by pure light rod load
M.-TF(WG)
——1,103×43,56
- 48,06kN-m
Pure light rod load torque
- 20 +
33 (0 36 0 27 )
26 type reducer limit torque
crank auxiliary net torque
240210
15012090603070 degrees
upstroke
rotating counterweight torque
downstroke
A2.2 The maximum torque M of the rotating counterweight is calculated from the maximum counterweight torque table provided by the manufacturer (or found in the chart) according to the measured distance S between the center of gravity of the counterweight and the center of the crank. If there is no such table, the balance rod effect of the crank at 90 and 270 is calculated by measuring the balance rod effect of the crank at 90 by the dynamometer. The balance rod effect of the crank at 270\ is 37kN, and the balance effect of the crank at 270\ is 36.66kN. The torque factor TF at -90 is 1.084m, and the torque factor TF at 270' is -1.081m. Then the maximum torque of the rotating counterweight when the crank is at 90 is M=TF(WG)=1.064X37=89.37kN·m. The maximum torque of the rotating counterweight when the crank is at 270 is M---1.081 X36,66=39.83kN-m
The maximum torque of the rotating counterweight
M=($9,37+39.es）+2-39.50kN·m. The net torsion shortening of the crankshaft at 6=285 is;
Mw-TF(WG)-Msing
=48 06-39,60×sin286
-9.89kN·m
When drawing the torque diagram, because the pumping unit rotates counterclockwise, the positive and negative signs of M are reversed, and the net torque of the crankshaft when measuring 6-285 is written as M.=9.89kN-m
Using the same method as above, the crank angle? Starting from o°, the values of W, M, M, M, for a total of 24 points every 15\ can be calculated. According to the obtained 6
SY/T 5050-93
24 net torque shortening M.The torque curve can be drawn (see Figure A2) based on the value. From the torque curve, it can be seen whether the net torque of the reducer is overloaded and whether the pumping unit is balanced (i.e. whether the maximum net torque of the upper and lower strokes is equal). When the pumping unit is unbalanced, the maximum torque M of the rotating counterweight can be calculated according to formula (A1) and formula (A2) for adjustment. Therefore, the base vibrates, the frame swings, the motor makes uneven noise, the crank pin is loose in the crank hole or the axis makes periodic noise when it moves in the opposite direction, the connecting rod rubs the crank or balance block, the crank and the reducer output auxiliary connection are damaged, the crank jumps violently, the brake fails or the brake is automatically braked, knocking sounds occur in the reducer, the reducer lubricant heats up, the reducer gears produce severe pitting wear or abrasion under good lubrication conditions, the gear bearings wear faster, the lubricant in the box foams and the lubricant fails. SY/T 5050--93
Attached beam B
Common faults of oil pumping units and troubleshooting methods (reference)
Foundation sinking, displacement, foundation making does not meet design requirements
The base and foundation are not in good contact, the bottom plate of the bracket and the base are not in firm contact
The oil pump is not aligned with the center of the parallel port
The oil catcher is unbalanced
The drip machine is overloaded
The donkey head is overloaded, impacted Too high
Continuous hitting and crank reverse connection
The matching surface between the crank pin and the pin hole is dirty, and the crank pin and the shaft sleeve hole are not tightly matched
The beam installation is skewed
The differential bolt of the crank is loose
The keyway or wedge key on the auxiliary is squeezed
The clearance between the brake hub and the brake band (brake block) is incorrect. The brake band (brake block) is worn or contaminated by oil
The oil beater is unbalanced
The fit between the gear and the shaft is loose, resulting in
excessive wear or breakage of the gear
wear or damage of the bearing
excessive or insufficient lubricant
gear overload
lubricant is contaminated by impurities
improper lubricant selection or kerosene used for flushing contaminates the lubricant
return hole is blocked, baffle sealing ring is seriously worn. Troubleshooting methods
Correct the foundation according to the design requirements
tighten the connected anchor bolts, add metal gaskets between the bottom plate of the shelf and the base to adjust
align the top screw of the central bearing seat with the center of the parallel port to adjust the position of the crankshaft balance block
adjust the parameters
adjust the parameters
adjust the installation position of the connecting rod and the crank
clean the pin shaft and pin hole, tighten the locking nut of the purple pin, adjust the walking beam so that the longitudinal center of the walking beam is aligned with the longitudinal center of the reducer Realign to the center line
Tighten the differential bolts and nuts
Install new inserts in the new keyway on the shaft that is 90° away from the keyway
Adjustment room
Replace the brake band (brake block), clean the brake hub, brake band (brake block)
Adjust the balance block
Replace the reducer
Replace new bearings
Add or reduce lubricants according to the specified amount
Reduce the load||t t||Replace new lubricant
Replace new lubricant
Clear the oil return hole and replace the oil retaining seal
The lubricant is turbid
The gears produce continuous pitting wear or abrasionwwW.bzxz.Net
The wire rope tension of the rope hanger is inconsistent
The tape is loose and slipping
Additional instructions:
Oil emulsification
SY/T5050 --93
Continued Table B1
Breaker is blocked
Intermittent operation in a humid environment, lubricant deteriorates
Insufficient lubricant
Improper lubricant selection
The wire rope jumps and is stuck
The rubber side stretches
The tape of the motor pulley track is contaminated by oil, replace with new oil
Non-elimination method
Clean the respirator
Replace with new lubricant and add anti-pain agent
Lubricant should be added according to regulations
Replace with appropriate lubricant
Adjust the correct distance between the wire rope pulley and the donkey head lonely panel and the wire rope pressure plate
Adjust the center distance
Clean the tape and the tape wheel groove
This standard is proposed and managed by the Professional Standardization Committee of Petroleum and Natural Gas Exploration and Development Equipment and Materials. This standard was drafted by Jianghan Machinery Research Institute of China National Petroleum Corporation. The main drafters of this standard are Liu Shunzhen, Zhou Liren and Ma Xiaomao.
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