Plunger Pump Research Articles

Ensuring Reliable Operation of Machine Parts with a New System of Variable Tolerances

Introduction. The article describes an algorithm for determining the system of tolerances for ensuring reliable operation of parts on the section. The block diagram of the program for determining the variable tolerances is demonstrated. There determined blocks of initial information − broken and smooth curves of the controlled parameter, histogram and graph of resource distribution and definition of active area of control, and blocks of building graphs of “marginal fan curves of wear” and systems of admissions for objects of study of two types: for universal fuel pump (UTN-5) and four-section small-sized fuel pump with mechanical regulator. Two ways of determining the system of tolerances are suggested. Variant 1 is a graphical way through constructing “limit fan curves of wear” and determining tolerances by the value of ordinates in the control points. Variant 2 is an analytical way. There is created a formula to replace the graphical method for determining system tolerances. Materials and Methods. Two models of high-pressure pump were selected as objects of the study. Nominal and limit values of parameters were known for the pumps. Schedules for checking and equation of wear curves are determined. Dependencies describing the pump plunger pair wear curves are determined. A histogram and graph for determining pump life cycles are drawn. The active area of control is determined with a given failure probability coefficient. Results. As a result of the study the values for the tolerances system of two types of high pressure fuel pumps are obtained. Reliability values for one pump type are determined. Graphic and analytical algorithms for determining the system of tolerances by the formula are developed. Discussion and Conclusion. The study approves the possibility of using the variable tolerance as a basis for determining the system of tolerances and reliability indicators of the diagnostic object.

PRODUCTION OF EXTRACTS FROM VEGETABLE RAW MATERIALS BY CARBON DIOXIDE

The unique properties of supercritical carbon dioxide as a solvent are widely used for extraction. In supercritical media, the dissolution of molecules of various chemical nature is possible. The purpose of this investigation was to study the extraction process and obtain extracts from valuable regional plant materials by applying CO2 extraction under pre- and supercritical conditions. The objects of research were: ground seeds of melon, pumpkin and licorice roots, as well as mint leaves, mulberry and jida flowers. For extraction, a laboratory setup was used that allows extraction when the CO2 is supplied by a high-pressure plunger pump in the sub- and supercritical state using a heat pump. The pressure range is 3-15 MPa, temperatures 295–330 K, and the volumetric flow rate above the critical CO2 is 800–900 g. Experiments with ground seeds of melon and pumpkin showed that as a result of 4 sequentially performed extraction cycles on a single load with supercritical CO2 parameters ( 315–330 K; 3–7.5 MPa) the decrease in the mass of melon seeds was 90 g (pumpkins 80 g). During the total extraction time (2.5 hours), 20 kg of CO2 were pumped through the reactor (25 l at 290 K and 6.8 MPa), while the average oil content in the extract was 4 g per 1 kg of CO2 (3.0 g per 1 l of SС-CO2) In experiments with jida flowers, the maximum amount of solid extractable substance (2% by weight of the raw material) was obtained at a temperature in the extractor of 308 K and a pressure of 7.5 MPa. Upon extraction under critical conditions in collection 2, the liquid phase was absent; only a yellow-green paste was released in it. According to the results of experiments with mint leaves, the maximum yield of a greenish liquid was observed at T = 315 K and P = 4 MPa., Mulberry - at T = 306 K and P = 6.0 MPa. The results of the extraction of oils and extracts from ground seeds of melon, pumpkin and licorice roots, as well as mint leaves, mulberries and jida flowers confirm that the maximum yield of the extracted substance is achieved with supercritical CO2 parameters in the extractor (310 K, 7.5 MPa). When liquid CO2 is extracted (300 K and 6-8 MPa), up to 2% of a yellow substance is extracted, which does not differ in appearance from a supercritical extract.

Investigating the System Behaviors of a 10 kW Organic Rankine Cycle (ORC) Prototype Using Plunger Pump and Centrifugal Pump

Based on a 10-kW organic Rankine cycle (ORC) experimental prototype, the system behaviors using a plunger pump and centrifugal pump have been investigated. The heat input is in the range of 45 kW to 82 kW. The temperature utilization rate is defined to appraise heat source utilization. The detailed components’ behaviors with the varying heat input are discussed, while the system generating efficiency is examined. The exergy destruction for the four components is addressed finally. Results indicated that the centrifugal pump owns a relatively higher mass flow rate and pump isentropic efficiency, but more power consumption than the plunger pump. The evaporator pressure drops are in the range of 0.45–0.65 bar, demonstrating that the pressure drop should be considered for the ORC simulation. The electrical power has a small difference using a plunger pump and a centrifugal pump, indicating that the electric power is insensitive on the pump types. The system generating efficiency for the plunger pump is approximately 3.63%, which is 12.51% higher than that of the centrifugal pump. The exergy destruction for the evaporator, expander, and condenser is almost 30%, indicating that enhancing the temperature matching between the system and the heat (cold) source is a way to improve the system performance.

Experience with Sucker-Rod Plunger Pumps and the Latest Technology for Repair of such Pumps

A technological process for renovation and repair of plunger pumps is developed. Technical specifications and technical conditions for repairs and the equipment for conducting the repairs and inspection of repaired pumps are prepared. The effectiveness of the proposed technology, by means of which the service life of the pumps may be increased, is demonstrated.

Исследование совместной работы струйного и плунжерного насосов с балансирным кривошипно-шатунным приводом

Исследование совместной работы струйного и плунжерного насосов с балансирным кривошипно-шатунным приводом

Lubrication system of a roller cone bit

For drilling roller bits that work with face purging, a device for a circulating lubrication system is proposed through the use of a plunger pump. A constant circulation of the lubricant is realized with a performance proportional to the speed of the bit. The relationship between the parameters of the lubrication system and the purge air pressure with the maximum depth of the well is established. The obtained equations allow us to determine the parameters of the bit journal lubrication system and exclude the penetration of drilling products into the bearing cavity, which will increase the bit life.

OSCILLATION DAMPER CALCULATION BASED ON THE ELECTRO HYDRAULIC ANALOGY

The method of the synthesis and the pressure fluctuations damping calculation based on the electro-hydraulic analogy is proposed. The mathematical model describing the processes of unsteady fluid flow through the device is developed. Using the composed transfer function and its approximation, the oscillation damper parameters identification to reduce the outlet pressure pulsations in the triplex plunger pump is carried out.

Scientific and technical aspects of grouting of marginal rocks of mine workings

The goal of the paper is to justify ways to achieve maximum radius of extent of grouting mortar in a rock massif and to maximize filling of cavities and cracks with minimal openings. Filling of cavities and cracks directly influences a “massif – roadway – safety structure” system. Some scientific and technical aspects of grouting and injecting inorganic binders into marginal rocks are considered. Advantages of usage of triple plunger pumps in injecting units are determined. The influence of pulsation on a condition and process of grouting mortar extension is justified. It is established that under equal operating conditions, pulsations created by a triple plunger pump reduce mortar viscosity by 15 %, and a radius of extent of mortar based on grouting cements is increased by an average of 12 %, and with usage of very finely dispersed substances – up to 20 %. Suggested recommendations significantly improve the technology of grouting of marginal rocks and concrete structures.

Совершенствование технологии контроля параметров смазочной системы дизеля Д-245

А significant factor affecting the reliability of the internal combustion engine and its technical and Economic indicators is the efficiency of the lubrication system. When the standard oil supply is applied, semiliquid friction occurs between the contacting parts, in which the parts are not completely separated by a layer of oil. However, with this friction, the required durability of components and parts with heat removal is guaranteed. The performance of the engine lubrication system is determined by the state of its elements (coarse and fine filters, oil radiator and pump, valves), as well as the quality of oil, its level in the internal combustion engine crankcase and temperature. In domestic internal combustion engines, the minimum oil level in the crankcase is controlled, but in operation there are situations when the oil level exceeds its maximum permissible value. This situation occurs when coolant or fuel enters the lubrication system. Coolant can get into the oil if the cylinder head gaskets, sleeve o-rings, or cracks in the cylinder head and block are broken. Top-Livo can enter the oil through worn and damaged parts of the fuel equipment (gas pump diaphragm, fuel pump plunger pairs, etc.). These liquids sharply degrade the quality of the oil and increase the wear of internal combustion engine parts, and the standard singlelevel indicator will not give the driver operational information about the malfunction. In connection with the above, the purpose of this work is to improve the technology for monitoring the technical condition of the internal combustion engine lubrication system on the example of the d-245 diesel engine and its modifications, which are widely used in GAZ (GAZ-3309), ZIL (ZIL-5301), MAZ (MAZ Zubrenok), PAZ buses (PAZ-3205), MTZ tractors (MTZ — 100, 892, 1020), agricultural and construction equipment.by developing and implementing a built — in device for monitoring the minimum and maximum oil levels in the crankcase, as well as its temperature. The scientific novelty of the work is due to the use of new circuit and technical solutions, as well as the original algorithm of the sensor operation developed by the authors, based on the use of switching laws of reed switches with normally closed and normally open contacts, the operation of which is spaced over time and controlled oil levels. Block diagram of the proposed device comprises a multifunction sensor level and oil temperature, including sensors of the mi-minimum and increased levels of engine oil in the crankcase of the engine and its temperature, the operation mode switch signal cooling temperature-edusei fluid and engine oil, the first and second voltage сomparators, indicator lights, buzzer, switch power supply, voltage regulator and regular temperature sensor coolant. The use of the developed device significantly increases the reliability and convenience of monitoring one of the most important indicators of internal combustion engines-the oil level in the crankcase, which will avoid significant engine damage. As a result of further research, it is planned to develop the device design, conduct laboratory studies of the developed multifunctional sensor in order to determine the dependence of its resistance on the temperature at the normal level of engine oil in the measuring flask, as well as determine the actual values of the developed sensor response heights at the lower and upper levels.

Расчет тягового усилия цилиндрического линейного вентильного двигателя для привода плунжерного насоса

Расчет тягового усилия цилиндрического линейного вентильного двигателя для привода плунжерного насоса

Development and Performance Research of New Small Displacement Pump with Solid Plunger and Non-coaxial Delivery Valve

Background: After the oilfield development coming into the middle and later periods, many oil wells only had liquid production less than 5m3 per day, therefore the present sucker-rod pumps didn’t satisfy the need for oilfield production. We revised all patents relating to small displacement pump and didn’t found any suitable pump for low production well. A new type of pump with small diameter was needed to design for solving the unbalance between the production and feed in lower production wells. Objective: o resolve the problems of supply and production imbalance of the low producing well, low pump efficiency and low system efficiency, a low displacement pump with non-coaxial delivery valve had been designed. Methods: This type pump adopted a solid plunger, and its delivery valve was not coaxial with the pump axial that would enhance its structural strength and been useful to reduce the partial flow loss of oil flowing through the static pump valve. At the down dead point of pump plunger, the delivery valve was located at the top of the pump chamber that was to the benefit of discharge of the gas and the oil from the pump chamber. The uneven distribution of the delivery hole was suitable for the wellhead diameter of the traditional oil wells. Results: The delivery valve was non-coaxial with the plunger that would decrease the flow loss through the passage and increase the pump efficiency. At the down-dead point, the plunger entered the extension nipple, and the delivery valve was located up the end of the solid plunger that promoted the remnant gas flowing out of the pump cylinder and decreased the effect of gas on the pump efficiency. Conclusion: As to this low displacement pump, we suggested: The suitable stroke was 2-3m; the stroke frequency was less than 3min-1. A reasonable range of submersible depth for low production well was 200-300m. It was used in the gas content well lower than 20%, else used the gas anchor firstly. The low displacement pump with non-coaxial delivery valve and solid plunger (NLDP) can improve the pump efficiency and reduce the polish rod load. At the same time, this NLDP provides new equipment for the production of the low oil well and improves the artificial lift design theory.

Microstructure and Properties of the Nitrided Layer of Nodular Cast Iron

Abstract The plunger pair is an important part of the plunger pump. It is required to have high wear resistance, self-lubrication, deformation resistance, and sufficient strength and rigidity because of the harsh application environment, thus ductile iron is a common material for large piston pumps because of its excellent overall performance. In order to improve the friction and wear performance of spheroidal graphite cast iron plungers, a nitride layer was prepared on the ductile iron QT600-3 by the ion nitriding technique. The morphology of the permeable layer was observed with a metallographic microscope, and its hardness, friction, and wear properties were analyzed using a Vickers hardness tester and a multifunctional material tester. The results of the article show that the hardness of the nitrided specimens is greatly improved, which is about twice the hardness of the matrix. The friction coefficient is found to be much lower than the friction coefficient of the matrix; the diameter of the wear scar is small, showing a moderate change compared with the matrix; and the performance is about four times. Therefore, the ion nitriding technique can significantly improve the friction and wear resistance of the pump plunger pair.

Research of plunger pump unit for the evaluation of operational parameters

The article describes the technique of laboratory research of the plunger pump. The aim of the research is to assess the technical condition of the pump unit and its compliance with technical documentation.

Life Prediction of Lubricating Oil Based on GM Model

According to the method of testing the life of lubricating oil in the bench test of lubricating oil plunger pump, this paper puts forward the prediction method of lubricating oil life based on the combination prediction model of grey theory and GM model. The method carries out data processing on the original data through gray accumulation generating operation to enhance the regularity of the data; GM is used for prediction, and grey cumulative reduction is used to generate operation reduction data to obtain prediction results. The acid value change data of lubricating oil is selected as the life characteristic information of lubricating oil. The model is used to predict the life of lubricating oil, which solves the problems of less data information and uncertain prediction in one oil change cycle. The model is proved to have high prediction accuracy by posterior difference test.

Fatigue performance of hydraulic unit of high-pressure plunger pump

The present paper considers a hydraulic unit of high-pressure plunger pump that relates to the main types of equipment for oil-and-gas well drilling, completing or repairing. The problem of fatigue breakdowns of hydraulic units of high-pressure plunger pumps is posed in the paper. According to the leading pump manufacturers, the main source of stress concentration in a valve casing of a pump is the edgings of crossing of cylindrical surfaces of seating fits, valves or plunger bores. The value of stresses in the concentrator zone was assessed, and values of safety coefficients of fatigue strength depending on geometric parameters of stress concentrators were compared. To solve the problem set by the leading manufacturers of pumps, the full-scale model of hydraulic unit was elaborated, stress condition and its effect on fatigue parameters of valve casing of hydraulic unit of oilfield high-pressure plunger pump were analyzed. The obtained calculation results quantitatively clarify the pattern of stress distribution in zones of stress concentration in a valve casing of hydraulic unit of a high-pressure plunger pump. Certain conclusions were made on how the parameters under consideration affect the values of fatigue stresses and on priority research directions for the problem under study.

DYNAMICS OF FLOW RATE AND PRESSURE IN THE TUBING OF PLUNGER PUMPS WITH DOWNHOLE DRIVE

Background Significant progress has been achieved in improving the design of sucker rod pump units (SRPU), which have the highest efficiency in comparison with alternative methods of mechanized production during the operation of low flow rate production wells. Successful development of scientifically-based methods for selecting and optimizing the operation mode of sucker rod wells is being carried out, thanks to which efficient SRPU production of oil is achieved over a wide range of changes in production parameters. However, it should be noted that when operating wells with rod installations, there are significant limitations associated with the presence in the system of the pumping unit and the string of pump rods. Aims and Objectives Mathematical modeling of hydrodynamic processes in lift pipes and wells flow lines with the aim of calculating the pneumocompensators optimal geometric dimensions and technological parameters, predicting changes in their characteristics when changing the well operating mode. Results The mechanisms and features of the flow velocity and pressure in the lift pipes and flow lines of the wells equipped with plunger pump units with a linear drive are investigated. A mathematical model of the unsteady flow of a gas-liquid mixture is proposed. The analysis of the formation of the pressure field and the flow velocity in the cavity of the lift pipes during pumping of the produced products is presented. Simulation of the pumping out of high-viscosity oil and water-oil emulsion by the plunger pumps with a linear drive showed that with an increase in the viscosity of the fluid, the oscillation amplitude at the pump tip increases. At the mouth, with an increase in viscosity to 0.1 Paˑs, the amplitude of pressure fluctuations decreases, and with a further increase to 0.2 Paˑs, it increases. Calculations show that with an increase in the gas content of oil, the amplitude of the pressure fluctuations at the pump cradle and at the mouth decreases, which is associated with the damping properties of the gas due to its high compressibility, as well as a decrease in the viscosity of the gas-liquid mixture with increasing volume gas shares in well production. By modeling the pumping out of highly watered oil, it was shown that the pressure fluctuations formed during its flow are insignificant. In accordance with the simulation results, it was concluded that when pumping out highly viscous products (viscosity more than 0.05 Paˑs), the greatest effect due to equalization of the fluid flow rate in the pipes can be obtained when the well is equipped with deep pneumatic compensators, for example, placement of pneumatic compensators on the pump side and higher in depth.

IMPROVEMENT OF A DESIGN OF A BOREHOLE PLUNGER PUMP FOR PRODUCING A LIQUID WITH SUSPENDED PARTICLES INCREASED CONCENTRATION

When a large amount of solid impurities (sand) is contained in the produced formation fluid, the operation of production wells is complicated. Their presence leads to an increase in hydroabrasive wear of parts and components of a downhole sucker rod pump and causes its plunger pair to be wedged. In addition, this leads to cork formation, which requires cleaning and flushing. To prevent this phenomenon, various types of sand filters and structural changes of plunger pairs of the rod pump are used. The analysis of the operation of sucker rod pumps for oil production at the Tuymazaneft NGDU fields of Bashneft-Dobycha LLC revealed the following main reasons for the failure of the underground part of well sucker rod pump units: blockage of suction and discharge valves (52.2 %), jamming of the plunger in the pump cylinder (36.5 %), gaps in valves (4.8 %), disconnection of the plunger from the rod (1.8 %), breakage of the rod string (1.7%), lack of tightness in the support of the plugin pump (1.1 %). As a result, the average operating time of the pump is reduced to failure and the presence of sand in the formation fluid can be considered the main problem. Based on the analysis of field data on the operation of the plunger pump under complicated conditions (increased concentration of suspended particles in the produced fluid), it is proposed to change its design. Improvement affected the pump plunger and its filter. The proposed developments have a detailed description of their design and principle of operation. Detailed field tests of the developed devices are presented, showing the effectiveness of its use. As a result of the use of pumps with shortened plungers (and the previous modes of operation of the wells did not change), good results were achieved in reducing the load in the TPS and increasing the pump coefficient, and the durability of the elements of the plunger pairs of sucker rod pumps. After examining the plungers, slight wear of the eccentric rings to center the plunger was detected. For the purpose of further use of shortened plungers, only the replacement of all rings is necessary. There is no need for expensive repair of plungers. In addition, there was no seizure of the plunger in the cylinder. Sand filters were installed in 2018 at the well Nos. 1246, 1356, 1623 NGDU Krasnokholmskneft LLC Bashneft-Dobycha. Before the filter was lowered into the wells, samples were taken that established the presence of mechanical impurities in the product. The concentration of suspended particles exceeded the norm by several dozen times, which can lead to premature failure of the pump. In addition, sludge traps were located between the filter and the shank to increase efficiency. The use of new developments together allows to increase the efficiency of the use of a sucker rod pump in difficult operating conditions.

Research on a Temperature Control Device for Seawater Hydraulic Systems Based on a Natural Gas Hydrate Core Sample Pressure-Retaining and Transfer Device

In the study of natural gas hydrates, the maintenance of the low-temperature and high-pressure state of the core sample under in situ conditions is highly important for cutting, transferring, and subsequent analysis. The pressure maintenance and temperature control device (PMTCD) for natural gas hydrate core samples described in this paper is a subsystem of the pressure-retaining and transfer device. The device consists of a water tank, seawater chillers, a plunger pump and a thermoelectrical refrigeration device. The device cools the seawater to 2 °C, and then pressurizes it to inject it into the sample cylinder. Due to the inevitable heat generated by the pressurization and heat exchange with environment, there is a thermoelectrical refrigeration device to compensate for temperature rise. Finally, the seawater temperature entering the sample cylinder is no higher than 3 °C, effectively preventing the decomposition and deterioration of the natural gas hydrate core in the sample cylinder. In this paper, the temperature increase of the device and its compensation capacity are analyzed in detail on the basis of calculation and simulation. On the basis of testing with the device, it is verified that even at the ambient temperature, the water temperature can still be maintained at 3 °C.

Tribology Performance of Surface Texturing Plunger.

Plunger pumps are widely used in oil pumping units around the world. The water content of the wellbore is increasing along with the development progress, so the lubricating capacity of the well fluids between the plunger and barrel is decreasing correspondingly. Commonly, the substrate material of the plunger and barrel are stainless steel, and the plunger surface is usually covered with nickel-based coating. Therefore, the performance of the plunger and barrel has been affected due to poor lubrication and eccentric wear. Non-smooth surfaces have been proven to improve the tribology performance in many cases. A surface texturing plunger covered with specific dimples has been prepared by using laser surface texturing technology. The morphology of the surface texturing plunger was characterized and analyzed. The tribology performance of surface texturing plunger samples was tested using standard friction and wear test machines with oil and water lubrication, respectively. The results indicated that surface texturing could effectively reduce the coefficient of friction, and the wear resistance of the surface textured samples has been improved to some extent.

Cylindrical Linear Induction Motor with Intermittent Phase Switching Used in the Borehole Plunger Pump Drive with Mechanical Energy Storage Elements

Cylindrical Linear Induction Motor with Intermittent Phase Switching Used in the Borehole Plunger Pump Drive with Mechanical Energy Storage Elements