剪切泵说明书(中英文)

剪切泵
Shear Pump
安装使用说明书Diections For Installation And Operation
成都西部石油装备有限公司
Chengdu Weast Petroleum Equipment Co.,LTD
目录
1.作用 (1)
2.原理 (1)
3.型号说明 (3)
4.性能表 (3)
5.结构图 (5)
6.安装、使用、维护指南 (7)
引言 (7)
强调说明 (7)
安装 (8)
使用 (11)
维护 (12)
DERECTORY
1.Introduction (15)
2.Principle of operation ………………………………………
15
3.Explanation of model (17)
4.Performance table (17)
5.Structural drawing (18)
6.Guidle to installation, operation and
maintenance (20)
6.1Foreword (20)
6.2Emphases (20)
6.3Installation (20)
6.4Operation (24)
6.5Maintenance (25)
WJQ5″6J-10剪切泵使用说明书
1.作用
WJQ5″6J-10剪切泵是一种专门用于剪切聚合物和粘土并已被现场使用和理论证实有效的机械。

在钻井液系统中，聚合物（或粘土）应提前充分地剪切以后，再进入钻井液系统，才能充分发挥其效用，改善钻井液性能，如果没有充分剪切，聚合物在第一次循环中就可能堵塞振动筛网，损失大量的聚合物，增加钻井成本，并且还可能使钻井液中的大尺寸的固相颗粒变硬而难以除掉；在完井液中，由于没有充分剪切，聚合物会产生许多“鱼眼”。

这些“鱼眼”会伤害地层，使地层渗透率降低，油气层减产。

经过事实证明WJQ56J-10剪切泵具有优良的性能，它能为高分子聚合物（也能为粘土）迅速水合提供高度的剪切，解决聚合物（或粘土）在钻井液中或完井液中因水合不好而存在的突出问题。

同时，使用WJQ56J-10剪切泵能使聚合物用量减少15%以上，膨润土
用量减少30%以上，并且改善了泥饼和液流损失，降低钻井液剪切比速率，提高凝胶强度，达到了国外同类产品的先进水平，其轴封结构更可靠，使用维护更方便。

2．原理
WJQ5″6JC-10剪切泵密封采用了非常可靠的机械密封，保证无泄漏。

泵内部配有一个300mm不锈钢涡轮（其上有导叶、叶轮、44个喷嘴、4个收集室），及一个剪切板，能够产生超过s的小端剪切（液体剪切），当液流通过剪切泵时，有一半（50%）的液体在涡轮收集室的强力推进下将被剪切两次。

该涡轮剪切泵安装在一专用底座上，并用皮带轮、窄V 带和55KW/75kw防爆电动机驱动，与剪切泵配套使用的还有一个尺寸适合的ZHP150混合漏斗，这样组成了一个完善的剪切及水合作用系统。

由于该泵轴封的改进，使其寿命大大提高。

如遵循该泵安装及特殊条件应用的规则，将进一步提高其性能。

本公司将对在油田及工业应用中有利于提高该泵性能的一般及特殊建议进行处理。

注意：该泵不能用于活性泥浆系统，因为系统中的钻井固体及重晶石，它们在受到剪切时将很快损坏该泵。

原理如图一：
图一WJQ5″6JC-10剪切泵原理图
聚合物流体从V流道进入，并以平行与剪切板P的方向抽送，收集室内液流量的50%通过44个喷嘴N射出，并以高速冲击剪切板P，然后在M处90方向进入泵的蜗壳收集室。

总流V及射流N沿着剪切板流动到达剪切盘的尖端T，在尖端有许多牙齿，高速旋转的牙齿使聚合物（或粘土）再一次被剪切。

这样就完成了聚合物（或粘土）高度剪切而迅速水合。

3．型号说明
WJQ 5″ 6J-10
涡轮名义直径（英寸）
密封形式
泵进口直径（英寸）
泵出口直径（英寸）
涡轮剪切泵
4．性能表
(表1)型号流量扬转速效汽蚀功率(kw)
WJQ5
6J-10
WJQ5
6J-10
图二WJQ5″6J-10剪切泵特性曲线5．结构图
图三WJQ5″6J-10剪切泵结构图WJQ5″×6"J-10" 剪切泵零件明细表
(表2)
6．WJQ5″×6"J-10" 剪切泵安装、使用、维护指南
引言
本指南仅就WJQ5″×6"J-10" 剪切泵的安装、使用、维护中的一般性问题作了介绍，供参考，本指南不能解决的问题，请与本公司售后服务部门联系，将会及时地给你答复。

强调说明
该泵只能在设计范围内使用。

该泵主密封是机械密封,填料密封为辅密封,当机封失效后，方可压紧填料密封,否则造成密封不必要损坏。

该泵空转不能超过5秒,必须注满液体泥浆方可运转,否则会造成机封损坏。

安装
图四WJQ5″6J-10剪切泵安装系统流程图
剪切泵系统由剪切泵、混合漏斗、管线及聚合物（或粘土）水合罐组成。

为便于安装和运输，聚合物（或粘土）水合罐由井场泥浆罐的一个隔仓组成。

图五WJQ5″6J-10剪切泵外形图
法兰尺寸（单位：inch）
表（3）
注：DN法兰通径，D法兰外径，d连接螺纹孔中心距，b法兰厚度，n-d连接螺栓孔数及孔径。

WJQ5″×6"J－10"剪切泵总成明细表(表4)
泵安装
泵的安装位置应尽可能靠近抽送源，以缩短吸入段的长度，减少吸入损失。

泵安装基础应水平，牢固可靠，以避免振动。

皮带轮的安装
A.两皮带轮轴线必须平行，且端面误差不得超过2mm。

B.皮带必须找正、绷紧。

C.电机安装必须平稳、牢固。

进口管路安装
A.吸入管路截面积必须大于或等于泵流道断面积。

B.吸入管路中不允许安装节流阀，但可以安装常开阀以减少液流紊乱，该阀只能在拆泵进行检修时才能关闭。

C.为避免吸入管路中产生汽泡，抽送源和泵之间应从高到低逐渐过渡。

如果用户需要泵在有吸程状况下使用，请采用真空泵或底阀引水。

D．泵入口处的管路必须平直，其长度至少为吸入管路直径的二倍。

E．当临时使用软管吸入管路时，必须保证软管不被压缩，这是因为吸入段管内压力一般都比大气压低，在大气压作用下，软管被压缩，从而导致流量降低甚至断流。

出口管路
A．为便于泵的检修，出口管路中应该安装常开阀。

B．所有管路（包括入口管路）必须有自己的支撑，绝不允许由泵承受管路重量。

C．当工作条件不明或不稳定时，出口管路中必须安装节流阀，以保证泵在设计点运行。

D．当泵出口与压力设备相接时，在节流阀和泵出口之间必须安装止回阀，以防止液体回流，否则，回流液会导致泵发生“水锤现象”而损坏。

使用
准备
A．用手转动泵轴，必须保证运转灵活，各处不得有摩擦声。

B．检查转向，必须确保与泵体所示转向一致。

C．全开入口段的阀门。

D．给泵体和入口段管路注满液体，以排出空气。

运转操作
A．准备工作全部结束后，开动电机。

润滑
A．轴承润滑
a．轴承采用30号机油润滑，润滑油应加至油标的中线，不要加过多油，否则将导致轴承振动和过热。

每90天
或1000小时换油一次。

b．在特殊情况下，轴承可用与润滑油相容的润滑脂润滑。

B．填料腔润滑
a．填料腔必须经常润滑，以防止填料过热而损坏，一般要求每天至少一次。

b．注入润滑脂时必须旋转泵轴，以使其充分进入填料腔，直到填料压盖端有油脂渗出为止。

维护（参照图三及零件明细表2）
A．拆卸：
a．拆下皮带轮组件。

b．拆下填料压板组件（26）。

c．卸下泵壳（1）。

d．拆除叶轮组件（2）、剪切板（3）、加强板（4）：先拆下螺母（33、34）（螺母为反扣）及垫圈（35），注意如无
叶轮扳手，则用木制垫块和木榔头敲击涡轮背部辐筋，
退出叶轮组件（2）（拆出时应先在皮带轮端卡住轴，以
防转动）。

e．拆除加强套（32）和机封动环组件（31）。

f．拆除护板（5）和填料箱（6）。

g．退出轴套（30），如果轴套过紧，可用楔形块敲击其尾部（轴肩处）使其松动。

h．退出挡泥环（24）。

i．拆下左、右端盖（7、19）。

j．从轴承托架内退出轴承总成。

k．松掉锁紧垫圈，拆出锁紧螺母（17）和锁紧垫圈（18）。

l．拆下轴承托架，退出轴承（14）（用垫块垫上，敲击轴中心）。

m．退出轴承（9）（用3英寸套筒对准轴承内圈，敲击套筒使内轴承退出）。

B．检查
a．叶轮：严重汽蚀（特别是主叶片）、过度腐蚀、磨损、破损时，要求更换叶轮。

b．轴：径向跳动超过，轴承座及油封位置严重擦伤，轴上螺纹、沟槽、台肩及其它表面有损伤时，要求修整轴，
无法修整时，则更换轴。

c．轴套：表面粗糙及损伤严重时，更换轴套。

d．经过拆卸的油封必须更换。

e．滚动轴承：对过度磨损，运转时过紧、过松或有噪声的轴承必须更换（新轴承只有在更换时才能开封，所换轴
承必须和泵原用轴承型号、尺寸一致）。

f．O型密封圈：一般经过拆卸的O型密封圈应更换，对其它密封垫片等，只要没有破损，也可以再用。

C．装配（参照图三及零件明细表2）
a．装配前所有零件必须清洗，特别是O型圈密封槽，螺纹、轴承及轴承润滑部位，要仔细清洗，对一些粗糙部位还
应用细纱布打磨。

b．装轴承（14）时，两轴承应背对背安装，旋进锁紧螺母后要扣住锁紧垫片，锁紧螺母紧固力矩：346牛·米。

c．在装轴套（30）时，在轴上涂一薄层减摩剂。

d．叶轮背面和护板之间的间隙为。

e．填料压盖不能拧得过紧，否则泵运转时可能导致填料烧坏。

f．装配顺序按拆卸逆方向进行，装配好后，转动轴应灵活，各部位不得有阻卡。

如有阻卡，调节螺栓（26）和螺母
（27）。

上紧螺栓（26）是将泵轴及轴上的零件向右移
动，松动螺栓（26）是将轴及轴上的零件向左移动。

注意：无论是将轴左调或右调，调整完毕后，一定要将螺栓（26）上紧，螺母（27）并紧，以防止轴运转时轴向窜动。

D．故障及排除
a．填料密封泄漏严重，填料严重磨损，轴套表面磨损。

——拆下填料，用一细铁丝弯曲90，在轴套壁上移动，如果检查到有过深的沟槽则更换轴套，填料压盖压得过紧导致填料磨损严重。

b．聚胺脂油封（20）磨损严重导致泄漏。

——排出：更换聚胺脂油封（20）。

一般情况，当泵运转3-6个月后，应更换一次轴封处的聚胺脂油封和轴套。

c．填料烧坏。

——原因：填料压盖压得过紧，引起发热。

——排出：更换填料，压盖不能压得过紧。

d．叶轮或副叶轮转动不正常。

——原因：叶轮背面和护板间隙过小，或副叶轮与护板和填料盒之间间隙过小。

——排出：用螺栓（26）和螺母（27）调节间隙。

调节完后用手转动轴，各部位不得有阻卡、摩擦声，转动灵活。

e．W JQ5″6J-10剪切泵一般故障及排除一览表5。

WJQ5″6J-10剪切泵故障及排除
（表5）
序
号
故障原因排除方法
1轴功率过
大
1、叶轮与泵壳端面
或叶轮与衬套发
生摩擦或副叶轮
发生摩擦。

2、泵在比设计点扬
程低得多的条件
下运行。

3、填料压盖压得太
紧。

4、皮带打滑。

1、调整叶轮与泵壳端面
及叶轮与衬套的间隙，
或副叶轮的间隙，消除
摩擦。

2、检查所配工作机是否
符合要求，并关小排出
阀门，使泵在设计点工
作。

3、重新调整压盖紧固力。

4、张紧皮带（检查两皮带
轮安装位置是否合
适）。

2扬程下降
1、大块颗粒堵塞吸1、
清除堵塞物。

4、泵产生汽蚀。

4、改善吸入条件，防止空
气进入泵内。

5密封泄漏
严重
1、机封损坏。

2、轴套磨损严重。

3、密封填料磨损过
大。

4、盘根环斜卷。

5、杂质、异物进入盘
根环。

6、盘根环斜口一致。

1、更换机封。

2、更换轴套。

3、装填新的盘根环。

4、重新组装盘根环。

5、清除杂质、异物，清洗
密封件。

6、重新按要求错位装填
盘根环。

1.Introduction
The WJQ5″6J-10shear pump generation is uniquely designed pump for shearing polymers and clays.
To improve the drill fluid properties, the polymers or clays should be highly sheared before adding them to the drill fluid system. If not sheared, the polymers maybe jam the strainer and will result in losing amount of polymer and increasing drilling costs, and the large-size solids in the drill fluid will harden and difficult to clear away as well. The WJQ5″6J-10shear pump has proven best for applying the high shear necessary to hydrate polymers and clays and to their best properties. Using the WJQ5″6J-10shear pump reduces the bentonite clay needed by 33% or more and polymer needed by 15% or more. It also improve fluid loss and filter cake, builds gel strength, and low shear rate viscosity to better hold up solids. With reliable shaft seal structure and more convenient in operation and maintenance, it comes up to advanced world standards in the same products.
2．Principle of operation
The WJQ5″6J-10shear pump adopts a set of mechanical seal for no leakage at stuffing box. Inside pump is a 300 series stainless steel turbine containing 44 nozzles, four scoops and shear plate. Fifty percent of the fluid is sheared twice each time through the pump. This turbine shear pump is mounted on a special base with belts
and sheaves to drive pump, OSHA type belt guard and a 75HP/102(55kw/75kw) 1480 RPM EXPLOSION PROOF U/L approved electric motor, 460 volts, 3 phase 60 cycle. Included is a special hopper(ZHP150) with nozzle sized for this application and one mud kit as a package in order to build a complete shear and hydration system. The pump is designed to give longer service life through the improved shaft seal.
There are many principles of proper pump installation and application as well as special considerations for the pump design which, if followed, will further enhance the performance of your WJQ5″6J-10 turbine shear pump.
This document will deal with both general and specific recommendations for improved WJQ5″6J-10turbine shear pump performance in both oilfield and industrial applications.
Warning! This pump can not be used on active mud system since it will shear drill solids and barite. These solids will also damage pump very quickly.
The principle sees figure 1.
Figure 1 Principle diagram of WJQ5″6J-10 shear pump
Fluid enters at “V” and is pumped parallel to the shear “P”. The chambers scoops 50% of the volume being pumped and jets that fluid through 44 nozzles “N” and impacts the shear plate “P” at very high velocity at “M” 90 degrees to the fluid entering the pump. The total fluid “V” and “N” travels down the shear plate to “T” where the fluid is further sheared due to the shape and speed of the plate tip.
3．Explanation of model
WJQ 5″ 6J-10
Turbine nominal dia.(Inches)
Seal form
Pump inlet dia.（Inches）
Pump outlet dia.（Inches）
Turbine shear pump 4．Performance Table
(Table 1)
Model Capac
ity
(m3/h)
Hea
d
(m)
Speed
(r/mi
n)
Efficie
ncy
(%)
NPS
H
(m)
Power(kw)
Sha
ft
pow
er
Moto
r
powe
r
WJQ5″
6JC-
1553222802834655 10
WJQ5″
6JC-
1553222802834675 10
Performance curve:WJQ56JC-10
6．Guide to installation, operation and maintenance of the WJQ5″×6"JC-10" shear pump.
Foreword
The general problems to installation, operation and maintenance of the WJQ5″×6"J-10" shear pump are introduced in the guide(for your information only), please contact our company for insolvable problems in this guide and will be replied in time.
Emphases
Operate the pump only in the performance range and service for which it was designed.
This pump employs mechanial seal as its primary seal and packing seal as its secondary seal. Packing seal can be compacted only when mechanical seal is disabled. Otherwise, the seal may be damaged.
No-load running time of the pump cannot exceed 5s. The pump must run under the condition of being filled with liquid slurry. Otherwise, the mechanical seal may be damaged.
Installation
Flow diagram of WJQ5″×6"J-10"
shear pump installation system
The shear pump system is formed by shear pump, mixing hopper, pipeline and polymer/clay hydrator. For installation and transportation, the polymer/clay hydrator is formed by a separate compartment.
WJQ5″6JC-10 Shear pump Sketch
Flange Dimensions（inch）
(Table 3)
Note：DN-Flange inside dia., D-Flange outside dia., bolt circle, b-Flange thickness, n-d—No.& size of bolt holes.
WJQ5″×6"JC－10"Shear pump assembly list
(Table 4)
Pump installation
The pump should be located near the liquid source so that the suction line can be short and reduce losses. The
foundation should be sufficiently rigid and substantial to absorb any vibration and support the base plate at all points. The base plate should be installed in a level position.
Pulley installation
A. The axes of two pulleys must be parallel to each other
and the end surface error can not exceed 2mm.
B. The belts should be aligned and tightened.
C. The electric motor must be mounted stably.
Connection of suction pipes
A. The suction line should be equal to or larger than the pump suction.
B. The capacity of a centrifugal pump should never be adjusted by throttling the suction line, but a positive shut-off valve of a type to cause minimal turbulence should be installed in the suction line to permit the closing of the line for removal of the pump for inspection and
maintenance.
C. The suction line should be designed to eliminate any air pockets. The pipes should gradually slope downwards to the supply source to eliminate air pockets. Please use a vacuum pump or foot valve for priming if you operate the pump the pump under the condition of suction lift.
D．The suction line should have a straight section into the pump of a length equivalent to at least two times its diameter.
E．For temporary hook-up when flexible hose is used, a non-collapsing hose is essential since the suction line pressure is often below atmospheric pressure. A collapsed suction line will result in below average or complete loss of flow.
Discharge pipes
A．A positive shut-off valve should be located in the discharge pipe to permit the closing the line for removal of the pump for inspection and maintenance.
B．All pipes(including suction pipes) should be independently supported and accurately aligned. The pump must not support the weight of pipe or compensate for misalignment.
C．If operating conditions are not known with sufficient accuracy, it will be necessary to provide a throttle valve in the discharge line to ensure that the pump operates at the design point.
D．If the pump is connected to a pressurized system, it is important to install a check valve between the discharge and the throttling valve. The check valve will prevent back flow through the pump. Back flow may cause the impeller to become loose on the shaft. A loose impeller will likely lead to mechanic damaged and fluid leakage beneath the shaft sleeve.
Operation
Preparation
A．Pump rotates freely by hand.
B．Check the pump rotate direction, the correct direction can be found by an arrow on the casing.
C．Open the suction valve fully.
D．Pump and suction line full of fluid for venting air.
Operation for running
Start the motor after finishing all the preparations.
Lubrication
C．B earings lubrication
c．A dd a good grade of 10w30 weight motor oil until the middle level of dipstick. Do not overfill the
oil. High levels nay cause churning and
overheating of the bearings. Oil should be changed
every 90 days or 1000 hours.
d．U nder the special condition, you may select a grease which can dissolve with the motor oil for
lubrication.
D．S tuffing box lubrication
c．T he stuffing box may be re-lubricated with grease as often as necessary to prevent the packing form
overheating. It should be lubricated at least once
a day.
d．O n filling, grease should be pumped into the box while turning the shaft until it comes out around
the packing gland.
Maintenance（Reference to figure 3 and table 2）B．D isassembly：
n．R emove the pulley kit.
o．R emove the Pressing board（29）.
p．R emove the pump case（1）.
q．R emove impeller（2）,shear plate（3）and Strengthening board（4）：Screw the left-hanged nuts
（36&37） off use a wrench(Restrain the shaft at
the pulley end to prevent rotation, If you do not have a wrench). Put a block of wood against the ribs of turbine and hit the wooden block with a hammer to withdraw the impeller（2）.
r．R emove reinforce sleeve(35) and mechanical seal （34）.
s．W ithdraw protecting board（5） and stuffing box （6）.
t．R emove the shaft sleeve（33）. A wedge may be driven between the end of the sleeve and the shoulder of the shaft to free the sleeve.
u．R emove the blocking mud ring（24）.
v．R emove left right cover（7&19）.
w．P ull the complete shaft and bearing subassembly from the frame.
x．R emove the lock nut(17) and the lock-washer(18).
y．R emove the bearing frame and bearings(14) from the shaft. Note:Impacting of the entire shaft
assembly against a board on the ground will remove
the bearing assembly.
z．T he bearing（9） may now be pressed off the shaft.
Note: A piece of 3 standard wall pipe slipped
over the shaft and impacted against the inner race
of the bearing works exceptionally well. B．Inspection
g．Impeller：Replace if the impeller shows excessive erosion, corrosion, extreme wear, or vane
breakage.
h．Shaft: Check for run-out to see that the shaft has not been bent. If run-out exceeds , replace the
shaft. Bearing seats and oil seal area must be
smooth and free of scratches or grooves. Shaft
threads must be in good condition. Replace shaft,
if necessary.
i．Shaft sleeve: Sleeve surface in the stuffing box
must be smooth and free of grooves. If grooved,
replace it.
j．Oil seal: The removed oil seal must be replaced.
k．Ball bearings: Replace if worn, loose, or rough and noisy when rotated. New bearings should not be
unwrapped until ready for use replacement bearings
must be of the proper size and type as supplied with
the original equipment.
l．Seal O-ring: It is recommended that all O-ring and gasket seals should be removed during disassembly
and replaced. In those cases ones can be reused if
they are not worn or otherwise damaged. C．Assembly (reference to figure 3 and table 2)
g．A ll parts should be clean before assembly. This is especially important for O-ring grooves, threads,
gasket surfaces, bearings and bearings surfaces.
Any burrs should be removed with crocus cloth.
h．F irstly slip the bearings (14) onto the shaft. The
two bearings are to be mounted back-to-back (that is, the sides of the bearings with the manufacturer’s name and the bearing number are placed together), with lock-washer in place tighten locknut with the bevel positioned against the bearings tighten the locknut to 346M/1N of torque. Then, put the shaft with bearings(14) into the frame from left and slip the bearing(14) onto the shaft from right of frame.
i．T he sleeved area of the shaft must be lightly coated with anti-seized compound before installing the sleeve(33).
j．I nstall the impeller. The clearance between the back of impeller and protecting plate is 。

k．W ith the packing gland in position, swing the gland bolts into place. Initially tighten the gland hard to compress the packing. Then back off the gland bolts and retighten only finger tight. Caution: Tighten the gland against the packing finger tight only If packing is over-tightened it may be burned when the pump is started.
l．A ssembly can be proceeded as the opposite sequence of disassembly. The pump rotates frees by hand
after assembly. If not free, adjust the shaft
assembly by loosening or tightening the
bolt(26)/nut(27).
Note：In spite of adjust the shaft to left or right, the bolt(26)/nut(27) must be tighten to prevent the shaft move after adjusting complete.
E．Failures and shooting
f．T he packing seal leaks seriously, the packing and shaft sleeve surface have been seriously worn.
——Remove the packing. Bend a wire with 90 degrees and pull it down the sleeve surface and renew the
shaft sleeve if grooved. If packing is
over-tightened it may be excessively worn.
g．T he polyurethane lip seal’s(20) excessive erosion may result in excessive leakage.
——Replace it.。