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H160-173-86 Owner`s Manual - Tianjin Ring

1. Input Output Shafts center to center inches mm 31 9 810 mm 29 53 750 mm Gear Reducer Weight pounds 5 584 Ibs Motor Rated Power Hp kW 24 8 Hp 18 5 kw Speed revolutions per minute 970 H160 173 86 Number of V belts C type and length inches mm Motor Sheave diameter options inches Page 6 of 44 2 V belts 177 4 500 mm 6 9 11 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd On this pump unit conventional crank balance weights are used together with a beam balance weight This mid range size pump combines the advantages of the two balance types for a very efficient and reliable pump unit Variations of this design include gear reducers rated at 114 160 and 228 thousand pound inches An optional feature not part of this design is the use of a phase angle between the crank pin center line and the centerline of the crank weights This causes movement of the crank shaft out of phase with the torque produced by load creating a flatter net torque curve reducing the peak reducer torque Somewhat less energy is consumed and component life is increased by the use of phased cranks Some of the advantages of a phased crank can also be obtained with the practice of staggering the position of crank weights on the crank arm H160 173 86 Page 7 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd 5 Structure
2. Tel 86 22 88823659 Fax 86 22 88823327 www tjringtop com info tjringtop com H160 173 86 Page 4 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 3 Safety Rules Walking beam pumps have large moving parts under heavy stress making them dangerous to operators and any others that may come near For safe use installers and operators must have a high level of skill knowledge and experience Fencing and guards must be specified and installed appropriate to the possible proximity of people and animals Please contact us for suggestions on training and educational programs available to the industry ATTENTION For safe and successful operation the contents of A A A this manual must be studied carefully You will find safety notices and technical notes throughout Some of the key points are 3 1 Ensure that personnel are properly equipped for this dangerous work Plan and prepare for safe operations Keep everyone away from activated components For any continuous operation check that all guards are in place 3 2 Cut off power to from the motor engine before braking Brake slowly to stop the unit in the position desired After stopping the unit the crank still has the potential to rotate 3 3 After braking set the brake stop pawl For work where crank movement could lead to danger chain the brake drum and otherwise secure the pump against rotation and movement 3 4 Before starting the motor r
3. H160 173 86 Pump Unit Owner s Manual Install Operate Adjust Maintain aig Ring Top Hybrid crank and beam balance pump unit WARNING A Read this manual closely for advice on avoiding serious injury to personnel damage to equipment and risks to property Tianjin Ring Top Petroleum Manufacturing Co Ltd dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd Contents Page 1 About our Company essessssssseeecoossssesssssecccosssesssseseecoossssesssseecocosssssssssseeeos 3 2 Letter to USerTS seseseosssoseesoesoosseoseeooeesooeseossesosseoosseooeseoosseoeseooeesooseeoseesoees 4 3 Safety Pe rasa wears suse asian cls ae eE EEEE ESA EESE AEE 5 4 Specifications sssisscssiscescssssiescesesssesssrisiesisiiaisuisiiiieisesiaeeiseriatediesiaseiisa iatea i st 6 5 Structure Summary ssesssesssssossesssossesssossesssosecsseossesssossssssossesssossosseosseseeoo 8 5 1 Horsehead Wireline and Carrier Baf ss ssseessseesseesssessseessressseessreesseessseessressee 8 5 2 Beam Beam Weight and Center Bearing e esseeseseesreresreresrererereresreresreresresesee 9 5 3 Base Reducer Platform and Samson Post ssessessssssseseseseserersesesesesesrseseseseses 9 5 4 Ladder and Service Platforms csssccssssssssssssscssssssssssssessessssssesssessessessssacees 9 5 5 Gear Reducer Cranks and Crank Pins esseessseesseesssessseessressseessseessressseessressee 9 5 6 Crank WCU EG ic se
4. dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd 5 2 Beam Beam Weight and Center Bearing At the end of the beam opposite the horsehead the beam balance weight is attached Midway along the walking beam the center bearing assembly is bolted on The center bearing is attached to the top of samson post The center bearing assembly has two sets of roller bearings The center bearings are properly filled with lubricating grease at our factory 5 3 Base Reducer Platform and Samson Post The base is supplied with the reducer platform attached welded The prime mover electric motor mounting structure is supplied separately to be attached by the user The samson post has two front legs and one rear leg double beam as part of the truss structure The samson post is fixed to the base by screw bolts the front legs connected to the pump unit base and the rear leg connected to the reducer platform 5 4 Ladder and Service Platforms A service platform is installed at the top of samson post A ladder is positioned between the front legs of samson post to provide operator access to the platform Another service platform is attached to the beam for worker access to the horsehead safety harness attachment points are included 5 5 Gear Reducer Cranks and Crank Pins A double reduction gear reducer is fixed to the reducer platform of the base by screw bolts The output shaft is toward the wellhead and the input shaft is away from w
5. is over 140 F irregular noise Motor overheating burning smell irregular noise Oil leaking from bearing cap case seam or gear box Brake will not stop unit engages when not desired or makes irregular noise Irregular noise or movement at horsehead wearing of steel rope against side plate of horse head Badly worn or pitted internal components Faulty foundation integrity Loose connection between base and anchor bolts Loose connection between base and samson post Misalignment of horsehead and wellhead Polished rod overload Pump unit imbalance Lock nuts coming loose 2 Dirt in the crank pin bores 3 Worn taper surface of crank pin Gear oil level is too low or high 2 Wrong or bad quality gear oil Friction at seals or bearing cap 2 Failed bearing Wear of gear tooth surfaces gear spacing is too large Loose key way of helical gear Unbalanced unit operation and or overload Improper rotation direction Inadequate oil in motor Faulty motor bearing Too much oil in gear box Bad connection of case seam Loose plugs in check bores Improper adjustment of brake shoes 2 Worn brake shoes 3 Worn brake drum Dirty brake shoes drum or other brake components Inadequate steel rope lubrication Pump unit is not balanced Center bearing out of alignment Improper position of horsehead Partially worn steel rope Overloaded gear reducer 2 Pu
6. Summary a So O N A Horsehead LC Walking Beam L gt Center Bearing Beam EEES E an SAN L i f Weight r p Equalizer gt Equalizer E Pitman Bearing ie i i Service Crank Pin Bearing Platforms Crank Samson Post Gear Redue Carrier Bar Brake Ladder Belt Guard ank my Weights Prime Mover Reducer Platform Beam Pump Unit Structure The walking beam horsehead samson post equalizer pitmans reducer platform and base are formed from welded steel plate with a Q235B Chinese specification For cold applications below 5 F Q345B 0 16 C 1 2 to 1 6 Mn specification steel can be supplied 5 1 Horsehead Wireline and Carrier Bar The top of the horsehead has a semi circular seat to loop the wireline wire rope over There is a steel terminal lug fixed on each end of the wireline The carrier bar rests on the terminals A polished rod is passed through the carrier bar with a polished rod clamp installed above the carrier bar A bolted cover plate at the top of horse head prevents the wireline from coming off The horsehead connects to the walking beam with two horizontal shafts the upper shaft engaging a notched support on the walking beam and the lower shaft pivoting against the end of the walking beam Safety pins and adjustment bolts secure the horsehead in position on the walking beam H160 173 86 Page 8 of 44 Owner s Manual
7. a justifiable expense The viscosity of synthetic gear oil is less sensitive to temperature changes When adding grease to the center and equalizer bearing remote lubricating lines allow this work to be done from ground level Add grease until excess starts to ooze out of a weep hole on the opposite side of the bearings Add grease slowly to avoid damaging bearing seals Do not confuse the grease coming out of the weep holes with leaking bearing seals In addition to points to on the lubrication card screws on carrier bar a pitman pin b brake stop pawl c brake handle axle d etc should be regularly coated with lubricant in order to prevent rust and corrosion Every six months should be adequate H160 173 86 Page 28 of 44 Owner s Manual dig i Tianjin Ring Top Petroleum Manufacturing Co Ltd Remote lubrication lines for center and equalizer bearings Lubrication Card Inspect Points to Ambient add lube as__ Replace or Lubricate Temperature Lubricant Specification needed Add Replace ee ISO 15 to ISO 100 Monthly visual 6 mos Wire L 10 F to ae Center 200 For NLGI GC LB 2 Lithium grease Monthly check 6 mos ii Bearing for seal leakage Add 40 F to 150 F NLGI GC LB 0 Lithium grease Equalizer 10 F to 200 F NLGI GC LB 2 Lithium grease Monthly check 6 mos Bearing 40 F to 150 F_ NLGI GC LB 0 Lithium grease for seal leakage Add Crank Pin 10 F to 200 F NL
8. foundation type the foundation bolts of the pump unit must be properly tightened Please see the following diagram with dimensions mm H160 173 86 Page 12 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd Mounting points of two front Samson Post legs Mark below Center Bearing Mark between bottom of two front Samson Post legs The foundation must be accurately level front to back and side to side Further metal spacing shims should be used as needed to ensure the pump unit base is level the shims should be tack welded into place after final level is confirmed After adjusting level fix the base on the foundation by loosely tightening foundation bolts full torque will be applied after final adjustment of unit position with respect to the well head 6 3 Assemble Pump Unit 6 3 1 Prime mover support Attach motor support frame to base Then attach the brake handle and brake actuating linkage to the motor support frame Properly torque all connecting bolts 6 3 2 Samson post First assemble the structure and then lift with a sling from the top of the samson post The assembly will hang in a near vertical position for attachment to the base Install the attaching bolts from the bottom so that the nuts will be on the top side Tighten the bolts by hand only with final torque to be applied after the center bearing plate is leveled H160 173 86 Page 13 of 44 Owner s Manual AG Tianjin Ring Top Pet
9. gear reducer Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd Symptoms a The crank pin bearing is Repair replace crank pin bearing Pitman arm is The arm is Pan seized 2 Adjust the unit balance deformed or vibrating with Damage from too great a degree 3 Inspect and repair welds and broken abnormal noise of unbalance or other improper components operation Ensure proper pump size is being used Alignment Broken keys and or damaged Replace the keys or change the key way marks show key way on shaft location movement The connection bolts on crank at Tighten the tail cap at crank periodic the reducer output shaft is loose throbbing perhaps Connection between crank and gear reducer is damaged violently H160 173 86 Page 41 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd 12 Replacement Parts 12 1 Seals and V belts Described below are parts of beam pumps which will require periodic replacement by users perhaps every couple years We provide these parts to customers as needed at reasonable cost Crank Pin Center Equalizer Reducer Input Reducer Output bearing seal bearing seal bearing seal shaft seal shaft seal HG4 338 66 HG4 692 67 HG4 338 66 HG4 692 67 HG4 692 67 Type H160 173 86 C type 177 outer J type Seal Seal J type Seal Seal Seal 90x115x16 PD140x170x16 110x140x16 FB80x110x10 FB180x210x15 12 2 Bearings circumference W
10. no energy from the prime mover This value is indicates how good the pump balance counterbalance matches the polished rod load CB Eat 90 can be calculated as follows Teranks 2Rcg Waa 2RpinsWpin Teranks amp crank wts 7 nRewtsWewe F Teranks T CBE at 90 or sarts Bstruct at 90 Where n Number of crank weights Bstruct Unit structural imbalance pounds Section 4 Specifications Reg Radius of crank center of gravity Section 4 Specifications inches Rpin Radius of crank pin bore in use three options in Section 4 Specifications inches Rewts Radius of crank shaft to crank weights V point on crank weights inches Werank Weight of each crank Section 4 Specifications pounds Wewt Weight of each crank weight Section 4 Specifications pounds Wpin Weight of each crank pin Section 4 Specifications pounds Teranks Torque from the cranks and crank pins pound inches Tcranks amp cwts Porque from the cranks crank pins and crank weights pound inches Try different values of Rerang wts in the above formulae until a desired level of counterbalance effect CBE is obtained this is where spreadsheets are handy If crank weights are being used at more than one radius the second equation must be expanded duplicating the term NRewtsWewr for each different value used for Rerank wts H160 173 86 Page 35 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufac
11. provided for remotely adding grease to the equalizer bearing Part of the lubricating line for the equalizer bearing follows the walking beam and part follows a samson post front leg Install now the line section on the walking beam However before attaching to the equalizer bearing completely fill the lubrication line with grease Use a type of grease as specified in the Section 8 Lubrication WARNING Do not stand under any elevated and unsupported parts of the assembly during this work Sudden drops are always a possibility 6 3 12 Pitman equalizer walking beam assembly Lift the walking beam with a sling horizontally to gain access to the underside Clean well the center bearing seat which will rest on the top of the samson post Also clean the top plate of the samson post Lift the pitman equalizer walking beam assembly by crane keeping the walking beam horizontal Position the center bearing over the top of the samson post Bolt the samson post top plate to the center bearing hand tight These bolts will be torqued after pitman alignment is checked 6 3 13 Pitmans to crank pins Slowly lower the equalizer end of the walking beam until the pitmans can be swung to attach to the crank pins Ropes can guide the pitmans to avoid H160 173 86 Page 18 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd contact with any other parts of the pump Ensure connection surfaces are clean The pitman ends sho
12. the brake Lift the cranks enough to remove the polished rod load from the wireline and then reset the brake Disconnect the carrier bar from the polished rod WARNING Repositioning the crank pins presents many risks of injury Plan the work carefully and employ knowledgeable personnel who are properly trained and equipped Holding the carrier bar away from the polished rod with a rope or chain gradually release the brake and allow the cranks to move into the 4 o clock position Reapply the brake and engage the stop pawl Lockout Tagout power to the motor Also chain the brake drum against clockwise rotation Now use come a longs or ratchet boomers to restrain the walking beam against any movement after the crank pins are removed Also support the pitmans so that they will not swing violently when the crank pins are removed from the cranks the crank pins will remain attached to the pitmans Proceed to remove the crank pins from the cranks loosening both and checking for free movement before removing either one Note Done properly crank pin removable and reinstallation is rather demanding If you lack the required experience or tools please consult with us on this challenging procedure Swing the crank pins out and check the condition of pins and cranks bores Excessive wear or the presence or rust may mean pins were loose Keep the inside of the crank bores coated with good rust preventer Clean the crank pins and new bore posi
13. the steps of the quarterly inspection The six month inspection is especially important Part of the visual inspection is performed with the pump unit in motion and part of it is performed with the unit shut down and the brake lever set Look for smooth operation with no lateral motion from the pump unit centerline Check that the polished rod is moving vertically at all points in the pump stroke Check that spacing between the pitmans and the crank shaft is the same for each crank Add lubricating grease to the center equalizer upper pitman and crank pin bearings until a small amount is seen coming through the provided weep holes Pump the grease slowly to avoid damaging bearing seals Inspect all bolts to find if they are rust free and tight Properly torque any bolts that are loose Loose bolts are a major cause of pump unit failures Apply a light coating of oil on all nuts and bolts to prevent rust For pump units which have experienced severe operating conditions or are many years old the six month inspection interval needs to be shortened to every five months and then four H160 173 86 Page 38 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd months and then three months With some older worn units lubrication may be necessary monthly with special maintenance attention in between Pitman arm and gearbox problems Two of the most damaging situations that may occur to the pump unit are a pitm
14. well load Contact us for a recommendation abase on what you know about the well load Also see Subsection 9 3 Adjust Balance below for estimation and calculation methods 6 3 10 Pitmans and equalizer beam assembly Clean well every attachment point and pivoting surface Apply Lithium grease as specified in Section 8 Lubrication below to pivot points on the upper ends of the pitmans At the lower end of the pitmans the larger opening is slightly tapered This taper opens toward the centerline of the pump unit the smaller diameter of that opening will face outward from the pump unit and cranks Insert pitman attachment studs to secure the upper ends to the equalizer beam securing them in place with bolted caps Hammer the studs in with a rubber mallet or brass hammer to avoid damage to the studs After assembling the guard plate tighten the screw bolts using lock washers H160 173 86 Page 17 of 44 Owner s Manual dig Tianjin Ring Top Petroleum Manufacturing Co Ltd 6 3 11 Walking beam assembly The walking beam is delivered with the beam weight equalizer bearing and center bearing already attached The bearings also have yolks mounted for engaging the equalizer beam and top of the samson post respectively Bolt the equalizer beam to the two yolks on the equalizer bearing shaft four bolts applying proper torque Use lock washers and jam nuts to secure Steel tubing rubber hose fittings and mounting clips are
15. GI GC LB 2 Lithium grease Monthly check 6 mos 7 Bearing 40 F to 150 F NLGI GC LB 0 Lithium grease for seal leakage Add AGMA 5 EP Extreme 0 F to 200 F oto 200 SO GeO Mi ipressure aH suction ae ae ie educer 30 F to 200 F AGMA 4 EP T gear oil level Replace ISO VG150 3 gear oil 10 F to 200 F Motor eee Follow motor s user manual Follow motor s user manual Bearing 40 F to 40 F to 150 F H160 173 86 Page 29 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 9 Adjustment Below find discussion and equations for making various adjustments to the pump unit Please don t hesitate to consult with us on their use In some cases modified equations may be needed to meet special circumstances We enjoy the challenges of solving problems related to the use of beam pumps and are more than glad to review your work or even do the calculations for you with the data you provide 9 1 Adjust Stroke Length The length of stroke can be varied by changing which of three different crank pin mounting points on the crank are used Begin by stopping the cranks at the 2 o clock position looking at the pump with the wellhead on the right Set the brake and engage the brake stop pawl Attacha rod clamp to the polished rod above the wellhead to secure it against movement Remove the crank guard rails Attach chains cables to the cranks and with a crane pull them taught Disengage
16. an coming loose and the stripping of gear teeth in the gearbox When the stroke length of a pump unit is changed extreme care should be given to correctly clean lubricate key and tighten the wrist pin on the crank pin bearing If the nut should work loose and come off the bore in the crank will be damaged the walking beam twisted and the wrist pin destroyed When checking the oil level in the gearbox pay special attention for the presence of metal flakes in the oil Small samples can be obtained from the lower petcock or plug By wiping the oil on aclean cloth any metal cuttings can usually be seen When metal cuttings are detected the cover should be removed the gearbox flushed out and cleaned problems corrected and new oil added Periodically but at least once per year the gearbox cover should be removed and the interior closely examined with a flashlight Inspect gear teeth for abnormal wear Lubrication troughs should be checked to ensure that all of the bearings are receiving a sufficient amount of oil and that the oil level is high enough to engage the oil dippers and gears The oil should be changed and the filter cleaned on a periodic basis Gearboxes can also collect water and sludge that should be removed periodically for maximum bearing and gear life Gear Reducer Oil Replacement As described in Section 8 Lubrication typically gear reducer oil should be replaced every 18 months However many situations are not typ
17. and the National Electrical Safety Code Use the well casing as a convenient and effective ground Connections and grounding conductors should be mechanically secure and placed to avoid disruption during well service operations Verify with ohmmeter continuity measurements between the well casing and each piece of grounded equipment this measurement using locations on casing and equipment different than the grounding conductor connection The resistance between grounded equipment and the casing should not exceed 1 ohm The resistance between grounded equipment and another nearby ground should not exceed 5 ohms H160 173 86 Page 16 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd 6 3 9 Crank weights With the cranks in a vertical downward 6 o clock position lift the weights by chains and position on the cranks Primary attachment is with T bolts that slide into grooves on the cranks Be sure to apply proper torque and a jam nut to the T bolts Securing lugs with teeth to match those on the crank are placed to further prevent movement Later the positions of the weights can be adjusted with the crank in a horizontal position tilted slightly in the direction of movement remove the securing lug loosen T bolts then move the weight with the supplied special wrench replace the securing lug and re tighten the T bolts The position of the crank weights on the cranks are determined by the
18. anjin China Please pay close attention to Safety Rules covered in this manual Additional safety measures will be required by related Federal State and Local government agencies Further your company will also have safety policies and procedures for you to follow We have developed a robust and energy efficient walking beam pump unit which is a hybrid crank and beam balance design For a wellhead that requires artificial lift our pump unit provides an appropriate long stroke low frequency and high energy efficiency Further high reliability and high maintainability make our pumps a wise investment This series is suitable for pumping crude oil of moderate and low viscosity including high water content fluids This pump unit manual supplies data on the structure performance installation safety procedures lubrication schedule maintenance and adjustment Please closely review and follow this manual You may make appropriate changes according to the particular condition of the oilfield and your internal operational standards We wish you every success in your oil pumping endeavors Hopefully you will feel our presence as you work with the walking beam pumps we took pride in producing Please fill the information feedback card and return to us along with your valued suggestions for a timely response Tianjin Ring Top Petroleum Manufacturing Co Ltd 58 Fagang Road South Shuanggang Industrial Area Jinnan District Tianjin China 300350
19. ank pins and inside the bores before installing H160 173 86 Page 14 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd WARNING The reducer and crank assembly has heavy rotating weights the cranks a danger that must be properly supported during movement 6 3 4 Gear reducer assembly Place gear the reducer on its platform on the base inserting the bolts from the bottom Leave the hand tight so that the gear reducer can be shifted for alignment Adjust the reducer on its platform so that the distance from the crankshaft to the samson post bolt holes on the base are the same on each side of the unit After ensuring proper alignment torque the bolts tight Note Before allowing cranks to rotate e g with lifting chains cables be sure to disengage and the brake stop pawl After the cranks swing and stabilize at the 6 o clock position the brake can safely be connected Also Note For various activities below you will need to move and secure the cranks in another position Attach chains cables to both cranks with a long sling to minimize stress on the sling and cranks After lifting the cranks to the desired position set the brake shoes set the stop pawl and chain cable the brake drum against rotation 6 3 5 Brake actuating linkage Connect the brake actuating rod to the brake on the gear reducer adjusting so that the brake handle is in a position closer to the brake than its midpoint of possible tr
20. anual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd Reminder Be alert for changes in well conditions that require balance of the pump unit to be adjusted 10 4 Quarterly Inspection Complete the steps of monthly inspection WARNING Before making adjustments or repairs to the brake or V belts stop the pump with the crank in the 6 o clock position Lockout Tagout all energy sources Clamp the polished rod at the wellhead Engage the brake stop pawl Immobilize the equalizer by chaining or otherwise anchoring it to the base Inspect the lining of brake shoes for wear and clearance adjustment The brake shoes should just clear the drum when the brake is fully disengaged When the brake handle is fully engaged there should be several notches of travel left Ensure the brake rods are straight Make adjustments and repairs as needed Inspect the brake drum for cracks and chipping especially around the hub and key area Ensure the brake drum key is properly in place and tight Check the brake stop pawl notches to see if any are chipped cracked or broken Replace the drum if these problems arise For long V belt life check belt alignment and tension Inspect the sheaves for wear and damage See the previously mentioned Heavy Duty V Belt Drive Design Manual from the Gates Corporation for troubleshooting advice Check lubricant in the prime mover as specified by manufacturer 10 5 Six Month Inspection Complete
21. avel Then it can effectively engage the brake shoes without getting too close to the end of its travel Tighten the lock nuts on the linkage to prevent loosening WARNING The purpose of the brake is for stopping the pump at the point of crank rotation desired It is NOT ADEQUATE for safely securing the pump for working around the cranks horsehead and other parts that may move For such work set the brake stop pawl chain cable the brake drum against rotation and or otherwise secure the cranks against rotation H160 173 86 Page 15 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd 6 3 6 Prime mover Install the prime mover typically an electric motor adjusting its sheave location to align with the sheave of the gear reducer each sheave being in the same plane A taut string line can help align the two sheaves Properly tighten a matched set of V belts never mix old and new belts If the sheaves have extra grooves those closest to the prime mover and gear reducer should be used for the V belts Proper sheave alignment V belt selection and V belt tension are critical to trouble free service While there are other quality options we recommend Gates Corporation V belts Hi Power and Predator and their instruction on use including the Heavy Duty V Belt Drive Design Manual 2010 For smaller diameter motor sheaves 6 to 9 inches diameter consider notched Gates Tri Power V belts Gates al
22. ay require more extensive isolation such as guards around the well heads gated access etc Please know though that we are eager to help you meet any guard requirements including custom designs WARNING Stay clear of the crank sweep area and possible horsehead movement while installing the crank guards and wellhead guards Also post appropriate warning signs for operators and bystanders Again we are ready to help meet this need with standard and custom signage of a quality that will endure harsh outdoor environments 4640 415 2790 Top view of crank guard rails red and support frame with dimensions mm H160 173 86 Page 22 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd 2400 J 4540 D Fully assembled Pump Unit with dimensions mm H160 173 86 Page 23 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 7 Operate the Pump Unit Your Ring Top beam pump was fully assembled and tested under rated loads at our factory By following our installation and operating instructions you can be confident of safe long lived and properly performing pump unit WARNING The integral ladder on the samson post is NOT to be used at any time while the unit is in operation This pump unit can operate with the rotation of the crank either clockwise or counterclockwise The preferred direction is clockwise viewing the pump
23. cating grease at our factory H160 173 86 Page 10 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd 6 Assembly and Installation WARNING Installation adjustment and operation of a walking beam pump involve A dangerous equipment flammable oil well products and remote locations This combination of factors requires a high level of attention to safety During installation and service work proper PPE personal protective equipment must be used by workers These include eye protection hard hats steel toed boots shoes and work gloves Clothing should be close fitting and exclude neckties lanyards and jewelry Clothing should also be non synthetic e g cotton and wool to reduce flammability while working around petroleum While good PPE helps reduce some risks the positioning of heavy loads and pump movement e g products rotation and up down still present serious risks of injury and death Work teams require adequate training experience and planning to perform the following tasks safely This Owner s Manual will alert you to many dangers so review it carefully As always ensure that local state and federal safety regulations are observed Further your company s safety and technical standards may apply to the use of this beam pump 6 1 Bolt Torques During assembly of the pump unit ensure that all connections are clean and free of debris For some surfaces it will be necessary to
24. check and clean while they are elevated and properly supported The following table lists torque values for properly tightening bolts on the pump unit Diameter values refer to outer thread dimensions Diameter of 42 mm screw bolt pound inches 14 389 kN meters 1 626 Jam nuts locking nuts are not installed as tight as specified above Full size jam nuts should be torqued to about 1 2 to 2 3 of the values listed Reduced height jam nuts should be torqued to about 1 4 to 1 3 of the values listed Alternately hand tighten the jam nut until there is no up and down play and then tighten 1 2 or 1 4 turn more H160 173 86 Page 11 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 6 2 Attach Base to Foundation The pump unit foundation can be of two different types a single monolithic concrete foundation or a multipart prefabricated concrete foundation A monolithic foundation is poured in place at a well site A multipart prefabricated foundation includes multiple blocks with slots for positioning anchor bolts With either type of foundation the soil on the site must first be properly leveled and compacted The foundation and bolt attachment design for any given installation will vary depending on soil conditions strength of concrete used polished rod load and established user practices Please contact us to discuss the details of foundation design for your installation One im
25. e a level to check that the polished rod is vertical in various stroke positions Make adjustments as needed Some lateral adjustment can be made with adjusting bolts on the horsehead The walking beam can be moved on the center bearing seat atop the samson post Adjust the center bearing set screws in order that the center of Carrier bar aims toward the well head Move the entire pump unit on its foundation if required Note Pump alignment with the wellhead must accurate to within 1 16 of an inch After adjustment is complete tighten the set screws and jam nuts at the top of the samson post Also tighten the adjusting bolts on the horsehead Finally recheck the spacing of pitmans and reducer output shaft as described above Subsection 6 3 14 Pitman alignment 6 3 19 After final alignment Support both cranks equally with chain cable slings Unchain the brake drum and disengage the brake drum stop pawl Check to ensure the crank sweep area is clear and then release the brake Slowly lower the cranks with the crane to the bottom 6 o clock position and reset the brake H160 173 86 Page 21 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd Ensure that foundation bolts and all other bolts on the pump unit are tightened to proper torques 6 3 20 Install crank guards and safety signs Before operating the pump install the crank guard rails While we have a standard design your operating environment m
26. ellhead Cranks are fixed to the shaft prior to shipping A V belt sheave is attached to one end of the input shaft and a brake drum is attached to the other The reducer gears and shafts are lubricated with premium extreme pressure gear oil The reducer is shipped without gear oil so be certain to properly fill before applying torque from the motor To confirm proper gear oil level the reducer has a view port conveniently visible from the rear of the pump opposite the wellhead When facing the pump unit with the well on the right the preferred direction of revolution of the reducer output shaft is clockwise In the event of severe wear on reducer gear teeth the life of the reducer might be extended by reversing rotation Crank pins are attached to the desired crank bores at our factory before shipment Pre lubricated self aligning roller bearings are connected to the crank pins for attaching the pitmans For connection to the crank one crank pin has left hand threads and the other right hand threads 5 6 Crank Weights Crank weights are attached to the cranks with T bolts and a set cog There are integral gear tracks on the cranks which can be used to adjust the position of crank weights for obtain optimum balance The cranks also have permanently cast distance marks to indicate the position of crank weights H160 173 86 Page 9 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd 5 7 Electric Motor a
27. emove any securing chains disengage the brake stop pawl and finally release the brake shoes with the brake handle 3 5 Electric components and the electric power lines should be protected preventing damage from exposure to sun and weather Ensure proper electrical grounds 3 6 When adjusting the position of balance weights set the crank in a horizontal position slightly tilted in direction of adjustment Afterwards properly torque bolts and install safety cog 3 7 When adjusting the stroke carefully review the technical and safety instructions for this challenging operation in Subsection 9 1 Adjust Pump Stroke 3 8 When mounting the horsehead ensure that both safety pins are installed properly and secured with new cotter pins Also firmly tighten adjusting bolts 3 9 Prepare fire fighting apparatus and resources to be used in case of fire from the prime mover well head etc Also have first aid kits training and resources for other accidents 3 10 Be mindful of the remote location of typical pump units and plan accordingly for possible accidents and breakdowns including transportation vehicles 3 11 Closely follow regular maintenance adjustment and lubrication schedules Remove loose objects which can affect safety and smooth operation 3 12 Wear appropriate PPE personal protective equipment and close fitting non synthetic clothing Jewelry neckties and lanyards can also present risks PPE includes safety glas
28. ent pump units have been exported to and are becoming increasingly popular in North America the Middle East West Asia and North Africa markets We enjoy a long history of manufacturing pump units with solid technique and a thorough quality management system We also have a qualified team for after sales service Our consistent objective is to provide products which are safe reliable easy to operate and energy efficient We adhere to the principle of quality first Meanwhile we persist in providing appropriate and satisfactory products and service to our end users Our walking beam pump units are manufactured in adherence ISO 9001 2000 API Specifications 11E and Q1 plus China Standard SY T5044 2003 Our manufacturing license in China is XK14 003 00039 We take pride in performance qualities as well as attention to the image and detailing of our products and company Not only is our design and production management team highly skilled and capable but we cheerfully provide genuine service to our customers API Specification Q1 Quality Management System API Specification 11E Pumping Units License Number 11E 0080 H160 173 86 Page 3 of 44 Owner s Manual AG 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 2 Letter to Users Thank you for purchasing our pump unit As you read this manual and use our products we invite you to become our friend We welcome visits to our headquarters manufacturing plant and test facilities in Ti
29. ficial seal when shipped with the product To fully receive our quality guarantee and technical support send the card back with an official seal signature within 2 months after installing your pump unit Pumping Unit Model Serial Number Purchase Date Identification Number of Well Location of Well Local Surface Temperature Range at Well Well Depth Fractional Imbalance Strokes per Minute Prime Mover HP Polished Rod Load Liquid quantity produced daily Person Completing Date this card this card Completed Using company official seal signature Using company full name Telephone Fax Email Send to Tianjin Ring Top Petroleum Manufacturing Co Ltd 58 Fagang Road South Shuanggang Industrial Area Jinnan District Tianjin China 300350 Tel 86 22 88823659 Fax 86 22 88823327 www tjringtop com info tjringtop com H160 173 86 Page 44 of 44 Owner s Manual
30. from the side with the wellhead on the right If excessive wear or pitting of reducer gear teeth occurs changing the direction of rotation can help since different contact surfaces of the gear teeth carry the load prolonging the life of the reducer A qualified electrician can reverse the rotation of three phase electric motors by changing the motor s electrical connections 7 1 Initial Lubrication Add grease to the center bearing equalizer bearing and crank pin bearings until a small amount is seen coming out the weep holes for the bearings Add grease slowly to avoid damaging the bearing seals Use quality grease as specified in Section 8 Lubrication below Also the wireline will require initial lubrication Other bearings are lubricated before shipment If you are separately purchasing a prime mover or other equipment to be used with the pump unit follow the manufacturer s recommendations for lubricant as well as any other safety maintenance and performance issues relating to those products CAUTION When the equipment leaves our factory the gear reducer does not contain lubricant The internal reducer gears have only a light coating of oil to prevent rust Before use add gear oil as specified in Section 8 Lubrication below 7 2 Safe Operation Never operate pump units without all proper guards and warning signage in place API RP 11ER Recommended Practice for Guarding of Pumping Units contains guidance you sho
31. hree options in Section 4 Specifications inches Lequa Distance from the center bearing to the equalizer bearing see illustration Fully assembled Pump Unit with dimensions in Subsection 6 3 20 above inches Lyotroa Distance from the center bearing to the polished rod center line see illustration Fully assembled Pump Unit with dimensions in Subsection 6 3 20 above inches Note The radius and length numbers can be any units e g inches or mm so long as the two radii or two lengths are the same units Also if crank weights are located at different positions on the crank the term after B will need to be duplicated and added for additional position 9 3 1 Electric Current method A convenient technique is to connect an ammeter or power current transducer assembly to the motor s power lines Be sure to keep ammeter jaws square to the power line being monitored Take a number of max current draw readings e g six pump stokes Then calculate averages for up and down stroke max values separately The fractional imbalance is determined by the following equation Lup wt F imbal k ldown When the fractional imbalance is positive upstroke current is relatively too large the counterweight is too low and the crank weights should be moved toward the ends of cranks more crank weights may be required When the fractional imbalance is negative upstroke current is relatively too small the counterweig
32. ht is too much and the crank weights should be moved toward the reducer output shaft CAUTION If the pump unit is severely underbalanced the torque exerted on the gear reducer by the weight of the polished rod can cause the motor to generate electricity This generated electricity can appear to be power consumption indicated by an ammeter Listening to the gearbox operation and observing dynamic V belt tension can help identify this situation When an ammeter measurement indicates that a pump unit is out of balance the following equation can be used to estimate how much to move the crank weights A positive result indicates moving the crank weights toward the ends of the cranks A negative result indicates moving the crank weights toward the crank shaft H160 173 86 Page 33 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd B t t Lpol rod Raajust Fimpal Rew Rpins r pets cwts equal Where Raajust Distance to move crank weights from initial position at which electric current measurements were made inches Bstruct Unit structural imbalance pounds Wewts Total weight of crank weights pounds Rewts Radius of crank shaft to crank weights initial position inches Ryins Radius of crank pin bore in use three possibilities inches Lequa Distance from the center bearing to the equalizer bearing inches Lpolroa Distance from the center bearing to the polished rod center line inches N
33. ical Your local lubricant supplier plus your own experience and practice in the area will determine more precisely how often this important step should take place Laboratory tests of oil samples are extremely helpful in determining an appropriate time for gear oil replacement Electrical Grounding Recheck the effectiveness of grounding specified in Subsection 6 3 8 Power Supply Verify with ohmmeter continuity measurements between the well casing and each piece of grounded equipment this measurement using locations on casing and equipment different than the grounding conductor connection The resistance between grounded equipment and the casing should not exceed 1 ohm The resistance between grounded equipment and another nearby ground should not exceed 5 ohms H160 173 86 Page 39 of 44 Owner s Manual dig Tianjin Ring Top Petroleum Manufacturing Co Ltd 11 Common Problems and Solutions a Unstable operation Loosening and axial movement of crank pin Reducer gear box overheating irregular noise Abnormal reducing gear bearing function Abnormal operation of motor Oil leaking out of gear reducer Improper brake operation Abnormal horsehead operation Reducer working surfaces damaged H160 173 86 Samson post swaying base and or samson post vibrating abnormal noise of motor Alignment marks show movement irregular noise Oil temperature is over 140 F irregular noise Oil temperature
34. in the drum Remove the chain from the cranks and attach to the horsehead Mount the horsehead as described in Subsection 6 3 18 above H160 173 86 Page 27 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd 8 Lubrication When filling or adding gear oil to the reducer ensure proper oil level e g between the two lines on the sight glass The lower part of the gear reducer can collect water from condensation especially in climates which are humid and or have pronounced fluctuating temperatures Water in the reducer can emulsify with the oil reduce its lubricating ability and contribute to corrosion So inspect and drain water regularly adjusting how often according how much water is found Oil sample about a pint analysis can help determine how often the gear oil should be replaced Note The gear oil lubrication recommendations in this manual are only general guide Your local lubricant supplier will be familiar with local conditions and can give more specific advice Also you should be familiar with the detailed guidance in API s RP 11G Recommended practice for the installation and lubrication of pumping units Use SAE motor oil only in emergencies The emulsifiers in motor oil will combine with moisture from the air to turn the oil cloudy reduce its effectiveness and generate sludge In some cases of intermittent operation weather extremes or difficult service access synthetic gear oil may be
35. ion is degrees clockwise from the 12 o clock 0 position Polished rod position is expressed as fraction of stroke above lowermost point H160 173 86 Page 36 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 10 Regular Maintenance The following contains edited excerpts from the Lease Pumper s Handbook from The Commission on Marginally Producing Oil and Gas Wells of Oklahoma We urge you to study that publication thoroughly it is freely downloadable here Another publication you should obtain review and apply is API s RP 11G Recommended Practice for Installation and Lubrication of Pumping Units 10 1 Daily Inspection Your Ring Top pump unit is very dependable and can operate for years between serious problems Still daily inspections can extend the life of the unit by locating problems before damage has occurred When making any inspection listen carefully to the sounds the pump unit makes they can tell a lot about its condition The inspection should also include a check for lubricating oil grease leaks at reducer box and bearing seals Do not confuse grease coming from weep holes for leaking bearing seals Look on the unit and on the ground for loose objects such as bolts nuts and washers 10 2 Weekly Inspection Perform the steps of the daily inspection Walk completely around the pump unit and observe it in operation Stop at good observation points to watch asse
36. ith proper maintenance bearings typically last for the life of the unit However below are the specifications for various beam pump bearings Reducer Reducer Reducer Input Shaft Middle Output Shaft Bearing Bearing Bearing 22318CA 22228CA 22324CA NU2316 NU2320 23136CA Type Crank Pin Center Equalizer H160 173 86 Bearing Bearing Bearing H160 173 86 Page 42 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 13 Technical Documents included with Pump Unit One copy each 13 1 User s Manual This user s manual was custom prepared for your pump unit However our enthusiastic support does not end with the preparation of this manual Please contact us with any questions comments or suggestions about your pump unit installation and operations 13 2 Product Certificate Your product certificate 13 3 Packing List Your packing list 13 4 Registration Card for Pump Unit Please timely complete and return the included registration card The brief information on the location and use of your pump unit can help us in getting appropriate updates to you H160 173 86 Page 43 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 14 Registration Card for this Beam Pump Unit Dear users After purchasing and installing your pump unit please fill this card carefully and post fax or email to our company for quality guarantee and technical services The card has our of
37. lowly lower the crane hook holding the polished rod until full load is on the pump unit Reset the pump brake and remove the rod clamp from the wellhead WARNING Keep hands clear of polished rod at the wellhead since slipping rod clamps present a danger of crushed hands and fingers Also during these procedures be mindful of the danger of crank horsehead pitman and other pump movement 7 4 Initial Operation Perform a check of the pump unit ensuring that the unit is clear of tools parts and miscellany The first revolution should be done as slowly as possible closely observing clearance of the cranks and pitmans including belt cover and crank guards Adequate clearance between the carrier bar and the wellhead should also be confirmed WARNING Rapid braking can damage the gears in the reducer Apply a slow steady engagement of the brake Slowly run the pump for a few minutes Stop the pump with the horsehead at its highest point To then secure the pump fully set the brake engage the brake stop pawl Lockout Tagout the prime mover and attach a polished rod clamp at the wellhead to secure against movement Now check all bolts on the unit to ensure they are properly tightened Note Never allow the full weight of the well load to bear against the brake stop pawl A crane may be required to free it Place the pump back into operation reversing the prior steps to secure the pump and run for thirty minutes During thi
38. mbled parts for one complete revolution looking for unusual motion and vibration and listening for unusual noises A line of contrasting color should be painted across one face of the crank pin nut and for a few inches on the crank Another line should be painted across the crank and reducer output shaft These lines allow you to recognize any change in the alignment of the components even if the crank is in motion During the daily inspections afterward note the smallest changes that may indicate that a nut or crank is loosening If problems are found stop the pump immediately for closer inspection and repair Examine the foundation looking for soil erosion that could destabilize the foundation Also look for damaging cracks and other evidence of incipient foundation failure Reminder In the first week after installing the pump or changing the stroke length the crank pin nuts should be closely checked for movement every day Also bolt torque V belt tension gear oil and bearing lubrication must be checked after the first week of operating a newly installed pump unit 10 3 Monthly Inspection Complete the steps of the weekly inspection Check the fluid level in the gearbox if there is evidence of a leak Observe wireline for fraying and adequate lubrication Check for signs of rust on bolts refreshing oil grease coating as needed Lubricate worn leaking center equalizer and crank pin bearings H160 173 86 Page 37 of 44 Owner s M
39. mp unit is not properly balanced Gear oil does not meet specs 4 Excessive normal wear Page 40 of 44 Ensure foundation meets drawing specifications Repair concrete at loose anchor points Add metal spacers to ensure good fit between base and foundation Properly align unit with wellhead Adjust working condition according to this manual Adjust balance of unit Clean solids from well Secure and tighten nuts Clean the crank pin bores Replace the crank pin Add or remove gear oil Replace the gear oil according to lubrication recommendations Tighten bearing supports Clean or replace the bearing Adjust bearing gap Repair key way Ensure pump unit is balanced and motor is adequately sized Reverse rotation direction Add oil Repair or replace motor Ensure proper gear oil level Tighten the case screws evenly Clean the connection surface and apply sealant if required Properly torque plugs in check bores Adjust gap between brake shoes and brake drum Replace brake shoes Replace brake drum 4 Clean brake shoes drum and other brake components Coat all of wireline surface with wire rope lubricant 2 Adjust the balance of unit 3 Adjust the position of center bearing on samson post or base of pump unit Correct horsehead position on walk beam Replace worn steel rope Operate under recommended condition Adjust unit balance Replace gear oil Repair or replace the
40. nd Belt Cover Shown here is the use of an electric motor as the prime mover Proper V belt tension and alignment is established when the motor is installed We recommend API TR 11L6 Technical Report on Electric Motor Prime Mover for Beam Pumping Unit Service as a guide on specifying and procuring motors 5 8 Brake and Brake Handle The brake actuation assembly is composed of a set of rigid rods and pivots One end of the actuation assembly is linked to the brake handle the other is fit onto brake shoes which engage the brake drum attached to the reducer input shaft The brake handle is positioned at the back of base for convenient access The brake is intended to stop of the unit during pump installation pump maintenance and well service After braking the pump unit to a stop secure the brake handle and then swing the pivoting brake stop pawl into the notched brake drum flange 5 9 Pitmans Equalizer and Equalizer Bearing The two pitmans connect the cranks to the equalizer one end of each pitman to the crank pins and the other end to the equalizer The pins which connect the pitmans to the equalizer allow enough movement to balance the forces on the equalizer bearing The middle of the equalizer is bolted to the equalizer bearing assembly The equalizer bearing is a self aligning bearing The equalizer bearing assembly is attached to the bottom of the walking beam near the beam balance weight The bearing is properly filled with lubri
41. ngage the stop pawl and chain the brake drum against clockwise rotation 6 3 17 Mount horsehead Sling the horsehead with wireline vertically by crane and hang on the walking beam notch for the horsehead The horsehead will pivot on the notch until the lower stop pipe rests against the stop on the walking beam Insert the safety pins secured with cotter pins Check that the horsehead is aligned with the beam and hand tighten the adjustment bolts WARNING The safety pins must be kept in position and adjusting bolts kept tight except for when the horsehead is being adjusted removed or replaced Note Comply with all applicable safety requirements for guarding the area of horsehead movement API RP 11ER Recommended Practice for Guarding of Pumping Units contains guidance you should be familiar with Ring Top can supply horsehead wellhead guards H160 173 86 Page 20 of 44 Owner s Manual dia Tianjin Ring Top Petroleum Manufacturing Co Ltd Walking Beam is level for mounting the Horsehead 6 3 18 Alignment with well head Hold the carrier bar away from the polished rod with a rope taking care to not be under the horsehead Use a plumb bob from the center of the horsehead down along the polished rod Ensure the distance from the string to the center of the polished rod is the same as the distance between the string and where the center of the wireline will travel Additionally after test initial running of the pump us
42. now if you are one of those people That is when the unit stops pumping it will naturally stop on the down stroke with the polished rod in a lowered position This helps keep the rod free of dirt extending the life of the rod and packing Below find some of the more useful and simple calculations that can be applied However we suggest you obtain and study more thorough analysis and recommendations to be found in the publication API RP 11L Design calculations for sucker rod pumping systems The pump unit must balance the weight of the polished rod plus provide force to move the polished rod and lift the fluid above the underground pump plunger The ideal counterbalance effect pounds of the pump unit is a balance between the upstroke and downstroke polished rod loads It can be estimated by the equation CBE ideat 1 06 0 5Wetuia Wyoa 1 0 127SG Where CBEjgeq Ideal counterbalance effect pounds This is also an estimate of the average polished rod load PR pounds Wauid Weight of the fluid above the down hole pump plunger pounds This is calculated from density of the fluid e g crude oil water depth of the well diameter of the plunger and diameter of the polished rod see below W rod Weight of the polished rod pounds This can be calculated from the density of the steel rod the diameter of the polished rod and the depth of the well SG Specific gravity of the fluid being pumped e g crude oil water dime
43. nsionless This is the ratio of the density of the fluid divided by the density of water at 4 C 1 gram per cc The above equation is only for typical steel polished rods with a specific gravity of about 7 85 compared to water Let us know if you need an equation for polished rods made of fiberglass or other material Also friction load is not included which can only be estimated from dynamometer analysis or experience with similar wells nearby The term W iq in the above equation is calculated as follows Wriuia 0 443SG LwenApiunger 0 294W oa Where Lwe Depth of the well feet Aptunger Area of the plunger square inches The heavier the rod string the farther out on the crank the crank weights must be but you know that Once the CBE qeq is known the position of the crank weights can be determined The API geometry analysis in Subsection 9 3 3 below provides detailed analysis but we can H160 173 86 Page 32 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd more simply estimate the crank weight positions with the following equation Re ts Lequal CBEiaeat Bstruct Wewts k ea pins pol rod Where Bstruct Unit structural imbalance pounds Section 4 Specifications Wewts Total weight of crank weights Section 4 Specifications pounds Rewts Radius of crank shaft to crank weights Y point on crank weights inches Rpin Radius of crank pin bore in use t
44. ntil the walking beam is level Reapply the brake engage the stop pawl and chain the brake drum against rotation WARNING Do not perform well service without first removing the horsehead Always keep in mind that a stationary pump can suddenly start moving Gravity is an ever present factor Automatic start stop controls on motors can be a risk to the unwary Lockout Tagout of energy sources and securing cranks against rotation are recurring critical safety steps Disconnect the carrier bar from the polished rod Attach a rope or chain to the carrier bar so that a worker can hold it away from the polished rod Attach a chain to the horsehead from the crane Back out the adjustment bolts on each side of the horsehead until the bolt ends are flush with the inside of the side plates Remove the two horsehead safety pins Lift the horsehead from the beam and place it on the ground away from the work area Disengage the stop pawl and unchain the brake drum Slowly release the brake to lower the cranks to the 6 o clock position Apply the brake again engage the stop pawl and chain the brake drum against rotation H160 173 86 Page 26 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd After well service is finished again attach chains to the cranks from the crane Unchain the drum disengage the stop pawl and release the brake Lift the cranks until the beam is level Apply the brake engage the stop pawl and cha
45. ote If the crank weights are at different distances from the crank shaft use an average value This type of analysis and adjustment is rather approximate anyway 9 3 2 Dynamometer Test A dynamometer can be used to directly measure the load on the polished rod at the pump This information can then be used to determine if the pump unit is properly balanced Analysis on the data can further be used to determine the best stroke of the pump to use whether the pump is optimally sized not too big or too small and if some type of intermittent or variable speed control is advisable First a dynamometer is attached to the polished rod there are a few different types one type is placed between the carrier bar and the polished rod clamp Then force readings are collected throughout the pump cycle This data is then used to compare up and down loadings for balance plus calculate torque at the gear reducer output shaft see formulae and data below Note There are a number of automated testing and software tools which can analyze and suggest optimal pump operation such as crank weight position adjustments Analysis of the dynamometer data can also give clues to condition of the down hole pump 9 3 3 API geometry analysis To calculate torque at the gear reducer we supply information specified by API Spec 11E Specification for Pumping Units in the table Polished Rod Position and Torque Factors below Here we describe some of the calc
46. pletely fill the lines with grease Use the type of grease specified in Section 8 Lubrication Two bearing sets combine to form the center bearing but only one lubricating point is required as grease can flow between the two sets 6 3 16 Horsehead assembly At the top of the horsehead remove the securing plate from the semi circular seat for the wireline Fold the wireline symmetrically along its length place over the seat and replace the securing plate and tighten the bolts Then mount the carrier bar above the wireline terminals lugs pulling the wireline and ensuring that the carrier bar is level and parallel to the bottom of the horsehead Two cotter pins in the carrier bar keep the wireline in position when the wireline is not under tension Next attach the wireline bail whose purpose is to keep the wireline in place should it be slack and movement takes place Finally place the two adjustment bolts in the threaded bores on the sides of the horsehead screwing in just enough so that the ends of the bolts are flush with the inside surface of the horsehead side plates The adjustment bolts will be in position for tightening but not susceptible to damage by hitting the walking beam from inside the horsehead during the mounting procedure Attach chains to the two cranks Pull the chains taut with the crane and check for equal support on each crank Release the brake Slowly raise the cranks until the beam is level Reset the brake e
47. portant guide you should review and apply is API s RP 11G Recommended Practice for Installation and Lubrication of Pumping Units This manual reflects information in that publication but study of RP 11G will give you a more thorough understanding of best industry practices WARNING Do not stand under any elevated loads such as the pump unit base This is important whether moving or stationary lifting by crane or forklift The best orientation of the pump is with the horsehead pointing in the opposite direction of prevailing winds Approaching the pump is best done from the rear and if well releases are occurring the rear will be the least affected The height of the top face of the foundation is determined to give adequate clearance between the top of the well head Christmas tree and the lowest position of the Carrier bar The lowest height H from Carrier bar to the top face of foundation and the distance L from the center of samson post to the wellhead are given in the following table refer to the above Beam Pump Unit Structure diagram for Land H measuring points Pumpunit fe In order to measure distance L there is a counter sunk measuring point located on the pump unit base directly below the center bearing location To properly align the base with the well head there is another center line mark on the base between the mounting points of the front legs of the samson post When installing the pump unit for any
48. rights in China We have highly motivated staff with very capable engineers and skilled trades Our well equipped 60 000 Square meters of workshop space allows us to rapidly meet demand for artificial lift units Our design capabilities include a wide range of types and sizes to meet practically any need for efficient reliable cost effective beam pumps Other products we supply to the oil field industry include drill pipe drill couplings casing tubing and innovative drill bits We have had a certified ISO 9001 2000 quality management system since 2002 as well as various API certifications since 2006 We continually refine and develop walking beam pump designs to meet the specific needs of our customers Custom orders for pumps with client specified design features are welcomed In addition to conventional crank and beam balance designs product variations include motorized adjustment of beam balanced units double horsehead units concrete beam balance weights and custom structural steel options Further innovations by our company are equipment such as the SB serial sand pump automated control equipment and robust gear reducers from 40D to 912D Tianjin Ring Top provided pump units to the China National Petroleum Corporation for use the Yanchang Oilfield Daqing Oilfield and Huabei Branch Another major customer is Sinopec in the Northern China Oilfield Our products are known for quality after sales service and power efficiency Energy effici
49. roleum Manufacturing Co Ltd Use an accurate level to check that the center bearing seat plate is level in all directions If needed place metal spacing shims under the post legs usually not necessary After a level seat plate is ensured properly torque the bolts attaching the samson post to the base The top center bearing seat plate on the samson post has a bolt hole with a hollow core bolt installed Pass the string of plumb bob through the center of the bolt to check if that reference point is directly over the mark on the base cross piece The reference mark on the base is identified in the overhead base view found in Subsection 6 2 Attach Base to Foundation WARNING Do not stand under any part of this shit during samson post assembly and installation Gravity is a bitch And you know what happened to Samson right 6 3 3 Cranks crank pins and gear reducer The gear reducer is supplied with the two cranks already attached to its output shaft Now the two install crank pins on the cranks When facing the pump unit from the wellhead the left hand thread crank pin is installed on the left and the right hand thread crank pin is installed on the right Right hand thread means it is turned clockwise to tighten Left hand thread means it is turned counter clockwise to tighten Note Itis important to clean the crank pins and bores use a safe approved solvent Also be sure to apply a thin film of oil on the cr
50. s operation be mindful of H160 173 86 Page 25 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 1 Sounds generated by the pump such as the gear reducer and V belts skilled personnel can hear if the pump is clearly out of balance Solid attachment to the foundation Smooth steady movement with no side to side swaying of pump mechanism and completely vertical polished rod movement Proper alignment and movement of the wireline on the horsehead 5 Good operation of the reducer brake with brake handle stopping with movement to spare After stopping check for Proper V belt tension Overheating components Oil leakage from the gear reducer e w N B Proper balance if problems are apparent Now operate for about two hours and then check the balance of the pump according to procedures in Subsection 9 3 Adjust Balance Note Bolt torque V belt tension gear oil and bearing lubrication must be rechecked after the first week of operation 7 5 Well Service Stop the cranks in the eight o clock position looking at the pump with the wellhead to the right Set the brake and engage the brake stop pawl Lockout Tagout the prime mover Attach a polished rod clamp at the wellhead to hold it in position Remove crank guards and attach chains to the cranks at the bore near the end of the cranks from a crane Pull the chains taut disengage the stop pawl and release the brake Lift the cranks u
51. ses with side shields hard hats gloves and steel toed shoes boots H160 173 86 Page 5 of 44 Owner s Manual 4 Specifications Model H160 173 86 AG Tianjin Ring Top Petroleum Manufacturing Co Ltd Polished Rod Capacity pounds diameter 17 300 Ibs Stroke Lengths for the 3 different crank bores inches 55 66 86 Wireline and polished rod diameters inches 1 and 1 5 Typical stroke Frequency options strokes per minute with 970 rpm prime mover 6 4 9 6 11 7 Maximum Counter Balance Moment pound inches 172 000 Ib ins Overall Dimensions inches 300 x 252 x 108 Total Pump Unit Weight pounds excluding motor but including belt guard and crank guards 29 365 Ibs Balance Weights Beam Balance Weight pounds 2 205 Ibs Crank Balance Weight pounds 1 340 Ibs x 4 5 360 lbs total Weight of Cranks pounds Center of Gravity inches 756 Ibs x 2 27 8 Crank Pin Weight each pounds Structure Unbalance downward force at wireline to keep beam level w o pitmans connected to cranks Distance from reducer output shaft center to centers of crank pin bores inches mm 27 6 Ibs 1 450 Ibs 21 26 26 98 31 49 540 mm 660 mm 800 mm Reducer Gear type Involute Double Reduction Maximum Torque Rating pound inches 160 000 Ib ins Overall Gear Ratio 28 506 Belt Sheave Diameter inches mm
52. sh seeds cence e a i a a a 9 5 7 Electric Motor and Belt Cover s sssesesesesssssssssseseseseseseseseressrsssesesesesesesereseseeseseses 10 5 8 Brake and Brake Handle snnesesesesesesesesererssseseseseseseseserererssseseseseseseseseseseeseseses 10 5 9 Pitmans Equalizer and Equalizer Bearing sesesesssesessesesesssrsrssrsesesesrsssssses 10 6 Assembly and Installation sce oss cscs cscs ieee nice csee shaw take vicdaes cic taseinwcscs 11 6 1 Bolt TOTGUCS cistern tc n ccna akties iad e cin naan 11 6 2 Attach Base to FOUNGAtION oi cieseiceieieyae actioned 12 6 3 Assemble P mp OME isinsin a aai 13 7 Operate the Pump Unit cciicininnnninaa ea 24 7 1 Imitial Lubrication eemnmetelee mance nent net nar ap aaa iaiia titer mer aeaaeai 24 7 2 Safe OOPSLA lON cesccinituvnsaniccancsoasvansundiamnstahininalansnaysiuissonchnieeanitenineataicnncceiasansintaamees 24 7 3 Attach to Polished Rod Load seeesesesssssesesesesessssesesesesesesesereressesesesesesesenersesss 25 7 4 mMitial OperatiOn ssioe iior ienie otio EEE AE aE SEE rK EEE at 25 7 5 Well SeryiCe cxicaccancsasuascivssnsscica uous sxsucsadcunsielnansdunauensietbvansiabteontatsemeeeumeancaescouehs 26 8 L brication s soises esenee ei sosise viese si Edes a 28 9 AG MSTMENE cissecceccteseec tenes etacdeseucesaceetcelasoncesibintceteninncdeaedecelanietieenesnoiis 30 9 1 Adj st Stroke Length gsccisssadiaccenscuecaneeastsvanctansaansiedawinatsincoudbutsnanciatssaucssusoanieesnmne
53. so provides useful portable instruments for checking alignment of sheaves laser beam and tension of V belts vibration frequency When fewer pump strokes per minute are needed one option is a smaller diameter motor sheave However smaller diameter sheaves tend to shorten V belt life Another option for fewer strokes per minute is to select a motor with rom lower than 970 rpm as specified in this manual 6 3 7 Belt cover Install the belt cover taking care that the cover has adequate clearance between it and the V belts motor sheave and reducer sheave Note Ensure compliance with all applicable safety regulations for guarding of belts and sheaves API RP 11ER Recommended Practice for Guarding of Pump Units contains guidance you should be familiar with 6 3 8 Power Supply The power supply and control panel for the prime mover must be installed and tested according to manufacturer specifications Generally ensure that proper grounding wire routing and applicable electrical regulatory standards are met Also check that the resulting direction of revolution of the prime mover is correct WARNING Contact with electricity at the pump unit can cause serious injury or death Electrical power must be locked out prior to performing any work on the electric motor All electrical work must be performed by a qualified electrician For safe grounding practices refer to locally applicable regulations the National Electrical Code
54. tions removing all paint rust and dirt Use a safe solvent and emery cloth but NO power grinders Adjust beam supports to allow mating to the new crank bores Use machinist s blue to confirm a good fit and apply a thin coat of oil before final tightening in the desired crank bore H160 173 86 Page 30 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd Keeping the brake engaged and secured remove the come a longs and or ratchet boomers With the brake shoes fully tight against the brake drum unchain the brake and disengage the stop pawl Make any adjustments to crank weights required by the new configuration Finally attach the polished rod load to the pump unit as described above in Subsection 7 3 Attach to Polished Rod Load and return the pump unit to service 9 2 Adjust Stroke Frequency Stroke frequency depends on the diameter of sheaves on the prime mover plus its rom For a 970 rpm electric motor sheave diameters corresponding to different stroke frequencies are listed in the following table Pump Unit Stroke Electric Motor Reducer Input Shaft Reducer Ratio RPM sheave dia sheave dia H160 173 86 9 6 with 970 rpm G indies 31 9 inches Eui te Ba To determine pump strokes per minute from a prime mover and sheave pulley sizes the following equation applies pump strokes motor sheave dia 1 motor rpm minute reducer sheave dia reducer ratio In this eq
55. ts 30 9 2 Adjust Stroke Frequency s s sesesessssesesrereseseseseseereseereeseseseencsrerssseseonsneseseeesesesee 31 9 3 Adjust Bala ne iui gviae ania avn ieviesies ie eso usa iiavas iena Sra eE Eae iier es 32 10 Regular Maintenance eesesesesessssssssooeoessssssssssooocesessssssssooceeesssssssssooosesesss 37 10 1 Daily oh lt 1 54 9 0 6 Beepeerryerere Reyer tery iieis iaa EEEE EEEE EEE 37 10 2 Weekly Inspection easy sy iesaiccs ins vecsivcossicpsuw eaginsndivsp aeneo a eE csonc sony iea ee 37 10 3 Monthly INSPECTION sssini anie a RR aia 37 10 4 Q arterly TiS Pec tl OM si paiicssncsuasiisasgionasnioricnssursaitavnnsipusitasnshdewiistercadeanindarasssrensesnuainuntins 38 10 5 Six Month INSPectiOn dienes in ass iu os so iguanas Vives ig EE AEE EEEE e 38 11 Common Problems and Solutions csssssssssessccecessssssssccssseceeeeesssseees 40 12 Replacement PAU Sin ccissatsicaiseiaciinasias incendie Uiaseianl ania 42 12 1 Seals and WSUS ccs ec cece cee cede eae hes 42 12 2 Bearin pS irere ina TEE E NE E E E EE 42 13 Technical Documents included with Pump Uniit sssssssssssssssssssees 43 14 Registration Card for this Beam Pump Unit ssssssscssssssreeeesseseeees 44 H160 173 86 Page 2 of 44 Owner s Manual AG Tianjin Ring Top Petroleum Manufacturing Co Ltd 1 About our Company Tianjin Ring Top Petroleum Manufacturing Co Ltd is a privately owned company with independent import and export
56. turing Co Ltd H160 173 86 Polished Rod Position and Torque Factors Stroke inches Crank Position Polished rod position Torque Factor TF meters 0 0 000 0 000 0 049 0 028 0 016 15 0 016 0 017 0 307 0 248 0 199 0 073 0 073 0 636 0 502 0 396 45 0 166 0 163 0 884 0 699 0 552 60 0 281 0 276 1 021 0 817 0 653 75 0 407 0 401 1 052 0 859 0 697 90 0 531 0 527 1 009 0 838 0 689 0 647 0 647 0 920 0 773 0 642 0 751 0 755 0 806 0 679 0 565 0 840 0 847 0 676 0 563 0 465 0 913 0 921 0 528 0 426 0 345 0 966 0 972 0 352 0 264 0 204 0 996 0 998 0 135 0 076 0 045 0 996 0 994 0 131 0 137 0 127 0 963 0 957 0 425 0 360 0 301 0 895 0 888 0 701 0 566 0 461 0 797 0 791 0 912 0 731 0 591 0 679 0 674 1 043 0 840 0 679 0 550 0 545 1 095 0 889 0 720 0 419 0 413 1 080 0 879 0 712 0 293 0 287 1 001 0 813 0 657 0 181 0 175 0 860 0 692 0 555 0 089 0 085 0 652 0 517 0 409 0 027 0 024 0 379 0 291 0 225 0 000 0 000 0 049 0 028 0 016 Note Crank posit
57. uation the sheave diameters can be in either inches or mm so long as the same units are used for both sheaves Also consider V belt velocity with different sheaves and motor speeds Values should be between 2000 and 5000 feet per second Under 2000 ft min leads to shorter belt life Over 5000 ft min requires dynamically balanced sheaves The following equation applies where velocity is ft min and motor sheave diameter is inches m motor sheave dia motor rpm velocity 1D A formula for calculating motor sheave diameter inches from reducer sheave diameter inches gear reducer ratio stroke frequency and motor rpm revolutions per minute f reducer sheave dia reducer ratio strokes per min motor sheave dia lt amp amp motor rpm Next is a formula for calculating V belt length inches Reducer sheave diameter D motor sheave diameter d and distance between the sheave centers C are all inches D d V belt length 2C 1 57 D d ac For the above and many other calculations we have developed spreadsheets which are available upon request H160 173 86 Page 31 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd 9 3 Adjust Balance Having run for two hours after installation or when the well load is known to change adjust the pump unit balance to ensure balanced operation Some people like to balance the load with a slightly rod heavy attitude you k
58. ulations outlined in API Spec 11E Please contact us for suggested calculation spreadsheets and other assistance for this analysis The net torque of exerted on the output shaft of the gear reducer by the cranks can be calculated by the formula Tn TF PR Betruct Msin Where Ty Net reducer output shaft torque pound inches TF Torque factor inches The table below has values for various crank positions H160 173 86 Page 34 of 44 Owner s Manual dia i Tianjin Ring Top Petroleum Manufacturing Co Ltd PR Polished rod load at 8 pounds measured calculated or estimated Bstruct Unit structural imbalance pounds See table in Section 4 Specifications above M Maximum moment of crank counterbalance pound inches 0 Position of crank degrees Clockwise from 12 o clock 0 with wellhead to the right The polished rod load PR can be measured with a dynamometer calculated as described above estimated from experience with similar wells etc Maximum moment of crank counterbalance M can be calculated by the formula This value can tell if the gear reducer is over loaded on the up stroke M TFat 90 CBEat 90 Bstruct Where CBE Net counterbalance effect pounds This value is determined by the weight position of crank weights cranks crank pins and also structural imbalance includes beam balance weight This isthe downward force required at the polished rod to hold the beam without moving and with
59. uld be familiar with As always local state and federal regulations must be met as well as applicable corporate safety standards Control the area ensuring that only knowledgeable trained personnel are participating in operational activities Keep extraneous observers well away from potential harm H160 173 86 Page 24 of 44 Owner s Manual AG Tianjin Ring Top Petroleum Manufacturing Co Ltd 7 3 Attach to Polished Rod Load In Subsection 6 3 19 After final alignment we left the cranks in the 6 o clock position which is near to the top of the up stroke of the pump unit Pull the wireline and carrier bar away from the polished rod with a rope chain or cable If the polished rod does not extend above the horsehead add a polished rod extension Slowly lift the polished rod with a crane from above the horsehead for the length of the stroke Place a rod clamp just above the wellhead to ensure the polished rod does not fall WARNING Always operate the crane and lifting hook from above the horsehead Catching the bottom of the horsehead could cause it to fall off Mobile cranes require skill to operate To avoid accidents crane operators must understand the crane manual and proper operation Open the carrier bar and position it on the polished rod Close and secure the carrier bar Attach a rod clamp just above the carrier bar and tighten according to clamp manufacturers torque specifications Release the pump brake and s
60. uld fit smoothly on the crank pin connections Note Do not use a hammer to position the lower ends of the pitmans on the crank pins damage to the bearings could result If pitmans do not fit the crank pins squarely the equalizer beam bolts can be loosened to get proper alignment then retightened Finally align the bolt holes place bolts and properly torque the connecting bolts 6 3 14 Pitman alignment Accurately measure the gap between the reducer output shaft and the closest part of the pitmans on each side cranks are now in the 6 o clock position The gaps should be identical within 1 8 of an inch If not slightly turn the walking beam on the samson post until alignment is proper Now fully torque the bolts connecting the center bearing yolk to the top of the samson post Note Improper alignment of the pitmans to the crankshaft can cause stress to the pump unit and excessive component wear After Pitmans are attached Cranks at the 6 o clock position 6 3 15 Remote lubrication lines Steel tubing rubber hose fittings and mounting clips H160 173 86 Page 19 of 44 Owner s Manual dia 7 Tianjin Ring Top Petroleum Manufacturing Co Ltd are provided for remotely adding grease to the center bearing in addition to the equalizer bearing mentioned above Attach and connect the grease lines to the samson post Before connecting to the equalizer bearing line on the walking beam and directly to the center bearing com

H160-173-86 Owner`s Manual - Tianjin Ring

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