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Summary
The operating manual is showing the installation, use and maintenance etc. of beam
pumping unit briefly. The operator must read this operating manual carefully before
installation and use. In order to make pumping unit work normally and prolong its
operating life, the operator can supply and amend contents of this operating manual
according to the practical case of the oil field.
2. Safety regulations
In order to be sure of pumping unit running normally and person safety, user must
obey the regulation listed strictly:
1) Pumping unit installed near city, country side and field, user should advise
installing crank guard please.
2) Forbidden lubrication, checking, filling oil or adjusting driving belt when pumping
running or not stopping yet.
3) When braking, electric motor must stop first. After pumping unit stopping, crank
can rotate a certain angle still. When crank is going to stop rotation, begin to brake or
brake at needed position slowly. Avoid by all means brake urgency.
4) When pumping unit stopping or workover treatment, crank must be fixed at a
fixedly position by brake or other method in order to ensure safety.
5) When starting electric, brake must be unclenching first, and then starting electric
motor.
6) When hanger is disjoined with polishing rod, polishing rod must be fixed at well
head by clamp tools first.
7) When maintenance, fire extinguisher should be prepared.
3. Structure introduction
The beam pumping unit is constituted by frame, Sampson post, polish rod holder,
horse head, center bearing assembly, walking beam, tail bearing assembly, equalizer beam,
pitman arm, crank arm, gear box, electric motor, brake assembly, tie down assembly,
foundation, crank guard, electric motor mount, hand ladder and ground lubrication etc., as
following schematic drawing.
-1-
7
8
9
10 6
11
12
4
13 14 15 16 17 18
Schematic drawing of pumping unit structure
1. Frame 2. Samson post 3. Polish rod holder 4. Horse head 5. Center bearing assembly
6.Walking beam 7.tail bearing assembly 8. Equalizer beam 9. Pitman arm 10.Crank arm
11.Gear box 12. Electric motor 3. Brake assembly 14.Tie down assembly 15. Foundation
16.Crank guard 17. Electric motor mount 18. Hand ladder
3-1 Frame (unit 1)
The frame is welded by shape steel and steel plate. It has good strength and rigidity
and its transport is convenience. Gear box and Sampson post are installed at front; electric
motor and electric motor mount are installed at back. The mark of walking beam and
Sampson post central line vertical projection is on frame. Mark is used to adjusting the
central line between frame and oil well or walking beam.
3-2 Samson post (unit 2)
The Samson post that is structured of tripod mount, is consisted of front leg and rear
leg. Lower end connected with frame and upper extreme connected with center bearing
assembly.
3-3 Polish rod holder (unit 3)
Polish rod holder connected with bridle and polish rod.
3-4 Horse head (unit 4)
Horse head that is structured of hanging, is welded by shape steel and steel plate.
Upper extreme hang over head bracket of walking beam by mounting pin; lower end
connect with front end of walking beam by locating angle bar and safety pin. When horse
head dislocated, dismount safety pin and move head horse by working engine or crane.
3-5 Center bearing assembly (unit 5)
Center bearing assembly is composed of one shaft, one bearing housing and two
bearings. It is installed on Samson post by bolts, and connects with walking beam by
means of saddle .
3-6 Walking beam (unit 6)
-2-
It is welded by shape steel and steel plate. It has high strength and good rigidity. At
upper extreme of walking beam’s front end, there is a bracket for hanging horse head. At
bottom, there is a safety pin connecting with horse head. The back of walking beam
connects with tail bearing assembly by means of support. The middle of walking beam
connects with center bearing by saddle. When center bearing assembly and walking beam
are fixed on Samson post by bolts, in order to make horse head loading top keeping
alignment to center of well head, we do fine setting to walking beam by four adjusting
bolts of Sampson.
3-7 Tail bearing assembly (unit 7)
Rotatable shaft is assembled on equalizer housing, which can compensate little error
of manufacture and installation, and make sure pumping unit moderate working.
3-8 Equalizer beam (unit 8)
Equalizer beam connects with tail of walking beam by tail bearing assembly and both
sides connect with pitman arm by pitman arm pin.
3-9 Pitman arm (unit 9)
Pitman arm assembly is composed of pitman arm, pitman arm pin and wrist pin
assembly, which is important unit with transmitting motive power. Upper extreme is
connected with equalizer beam by pitman arm pin and lower end is fastened on crank arm
assembly by wrist pin.
3-10 Crank arm (unit 10)
Two crank arms are fixed symmetrically on driven shaft of gear box. This can make
crank clamp with driven shaft of gear box. Each crank has three same diameter bores. By
them, we can adjust stroke of pumping unit. There is gravity center radius scale of counter
weight. Setting the crank on horizontal position, loosing bolts which fix counter weight
(but not disconnect), we can move the counter weight to needed position under that crank
in horizontal by crane.
3-11 Gear box (unit 11)
Gear box is double stage divided flow, two circular arc and columned gear box.
Through triangle belt, gear box is driven by electric motor directly. Both sides of driven
shaft are installed crank. One side of driving shaft is installed big belt pulley; the other
side is installed brake pulley.
Gears of gear box are all used oil bath and splash lubricating. Combining surface of
box is smeared with sealing glue. Oil slot box with oil wiper is set between laevorotation
or dextrorotary gear and box body. Oil slot is set on combining surface of box body. Then,
the bearing can be lubricated. Peephole is set on the upper of box body, and a bleeder
cover on it. There are three variable tallness plugs at the back of box (the side near driving
shaft). One at bottom is used to fill oil and the upper two are used to inspect the tallness of
oil face.
3-12 Electric motor (unit 12)
Electric motor is installed on electric motor mount by guide rail. Electric motor can
be adjusted along front, back, left and right four directions.
3-13 Brake assembly (unit 14)
Brake assembly is the structure of hand-pull inside or outside-clasp type. After motor
stopping, no matter where crank rotate, pull brake handle by hand, draw tie rod cam, make
brake tile clasp brake wheel, then we can brake quickly, calmly and reliably.
4. Foundation
-3-
a) Prefabrication of foundation: According to pumping unit foundation diagram given
by attached Figure of this instruction book, we can grout or prefabricate foundation on the
spot.
b) Groundwork:According to foundation position drawing, the position of foundation pit
area is lined out. Foundation pit must be excavated to hard soil layer. The foundation tunnel
must be excavated to hard soil layer or under non-frozen layer 100 ~ 200mm, in order to
make sure specific pressure that soil sustain not excessive bearing specific pressure that the
area recommend. When calculated bearing specific pressure, soil load-bear is equal to which
polish rod capacity of pumping unit add total weight of pumping unit and foundation. If
movable foundation is used, then, the foundation pit must be rammed as far as possible; and
be leveled both on vertical and cross sides. Afterward, the cuspate sand or cobble which
thickness is 50mm at least is paved on hard soil layer; and be leveled again. If the surface soil
layer of well site is soft and soil character soft, the foundation pit must be excavated to hard
soil layer or under non-frozen layer 100~150 mm, and then the foundation padding layer is
grouted. After the cuspate sand or cobble is paved on padding layer, make it level. This
foundation padding layer must be attained the upper surface of movable is higher than
production tree flange about 300 mm after movable foundation is installed.
c) Choice of foundation area : Choice of location direction of foundation must be
considered the local leading wind direction. This can avoid gas or liquid is blew on the body
of pumping unit when gas or liquid leak from well; and the well site condition should be
considered at the same time. These must ensure the place enough to arrange workover and
operation equipment after pumping unit is installed.
d) The upper surface of foundation must be leveled both on two directions: forth to back,
left to right. Lining out the foundation center line, making the center straight at well head
center, the error should be smaller than 3mm.
e) Soil should be earth up around foundation and a slope kept. This can avoid water store
around the foundation.
5. Pumping unit installation
a) Installation of frame
Fig.1: Set pumping unit frame on foundation, making vertical central line of frame is
superposition with foundation center, and keeping the distance between central point of
Samson post on frame (There is an obvious central symbol on frame when pumping unit
leave factory) and well head center equal to the length of walking beam forearm. Then,
making level to the upper platform of gear box frame (upper surface of the frame),
longitudinal horizontal error is smaller than 5mm/m, transverse horizontal error is smaller
than 2mm/m. Adjusting pad can be set under the frame when adjusting level. After
adjusting level, the frame should be fastened with foundation by anchor bolts. Anchor
bolts must be fastened equably. The horizontal degree of longitudinal and transverse of
gear box should be checked again.
crane
-5-
Fig.4: Rear leg and center bearing assembly are assembled on front leg ( installed
ground lubrication ) ; Fig.5: Samson post is lifted on the frame and fastened by bolts;
Fig.6: Hand ladder is assembled on Samson post by bolts.
crane
cr ane
5mm
Fig.8: Installation of equalizer beam, tail bearing assembly and pitman arm
-7-
Fig.9: Assemble tail bearing assembly, pitman arm and equalizer beam on walking beam
cra ne
-8-
Fig.10 Assemble walking beam on Samson post
h) Installation of horse head
Fig.11: The horse head is lifted and hanging on walking beam. The left and right gap
between horse head and walking beam must be equal basically. It can be adjusted by the
bolts on the both side of horse head. Assemble safety pin of horse head. (Check if the
central projection of horse head hanger is in regulation circular and can be fine adjusted by
the adjusting bolts of Samson. The whole adjusting bolts of Samson post must be
fastened.)
c ra ne
- 11 -
Lubrication of gear box: filled with ISO VG220 gear oil, when temperature is 0°to
140°F; filled with ISO VG150 gear oil, when temperature is -30°to 110°F. Generally, the
time of oil change is 6 month. In special case, oil change can be taken whenever necessary.
Every time of oil change, gear in gear box interior and bearing should be washed by light
oil. The dirty in oil trough must be cleared up. Washed by kerosene and gasoline is
forbidden.
In special environment area may select suitable lubrication oil (grease) according to
local case.
9. Maintenance
Maintenance of pumping unit should be done according to procedure as follows:
9.1 To the new pumping unit installed in a month, fastening operation done according
to regulation as follows:
1) After running 24 hours, fastener must be fastened for the first time according to
specify torque.
2) After running 7 days, fastener must be fastened for the second time.
3) After running 30 days, fastener must be fastened for the third time.
9.2 For the pumping unit running in order, maintenance should be done as follows:
1) Checking the fastening case between pumping unit and foundation. Be sure of the
pumping unit is not move on the foundation; foundation is not move or jump relative to
ground.
2) Keeping flowing water slope and drainage ditch unblocked around foundation.
3) Checking load of the pumping unit and balance result periodically. Be sure of the
pumping unit is not over loading and work under the optimum balance condition.
4) Inputting lubricating oil (grease) or lubricating oil change periodically.
5) Checking the attrition of brake block and adjusting, lubricating the all joints of
brake system periodically.
6) Checking and adjusting the slack or tight degree of driving belt.
7) Checking and fastening the connecting parts, for example: bolt of polishing rod
slip and locking nut of crank pin etc.
8) Checking if electric equipment is reliability.
9) Checking the lubrication and attrition case of gear box gear surface and bearing.
10) Checking the stability of the whole pumping unit running.
9.3 Maintenance periodically
1) Maintenance period
Generally, an overall maintenance is needed after using for 6 month. If in well
working condition, then 6-12 month is permitted.
2) Maintenance contents
a). Maintenance of electric motor: Disconnect the forth and back end cover of electric
motor, check the lubrication and attrition case of forth bearing and back bearing and then
according the to the case change bearing, lubricating oil change or filled in.
b). Maintenance of gear box: opening the peep hole cover plate, checking the attrition
condition of each gear pair. If the gear tooth attrition in single side or spot corrosion is
seriously, then the driving shaft, middle shaft and output shaft can be all turn around and
readjusted. In this way, the forced-side of gear tooth is changed and operating life of gear
- 12 -
box is prolonged. According to the work surroundings and real case, sampling analyze
lubricating oil and decided the time of gear box lubricating oil change. If one of the
parameter is not qualification, such as: percentage of water and solid material in oil,
viscosity, acidity etc. the lubricating oil must be changed. If the lubricating oil is emulsify
and deterioration, the lubricating oil must be all put out, and then washing gear pair of gear
box interior and each bearing, then, filling in the new lubricating oil again. If gear box is
not rework at once, then pumping unit must be running 10 minutes to be sure of the guard
oil film is taken on the surface of gear box gear and bearing. If axial drunkenness of gear
box driving shaft and output shaft is great, the adjusting can be done by adding or reducing
number of gasket of both-sides bearing cover. Because a certain axial gap is remained
when driving shaft, middle shaft and output shaft installed, a little drunkenness is
normally.
c). Checking carefully if each rotating joint of pumping unit is abnormity, such as:
center bearing, tail bearing, pitman arm pin and crank pin bearing and then fastening bolt,
fill in or changing lubricating oil.
d). Check if each main fastener is in rupture, corrosion and lack part case, such as:
equalizer beam bolt, connecting bolt of walking beam Sampson post and anchor bolt of
frame, and then changing the new parts and fastening nut.
e). Readjust brake unit, change or repair brake block, crank pin, taper sleeve etc.
consumable accessory.
9.4 Maintenance worker notice
1) Maintenance worker must master and execute maintenance system of pumping unit
strictly.
2) After gear box washed by petroleum solvent, petroleum solvent must be clear away
by lubricating oil and refilling the suitable lubricating oil into gear box at once. The max
oil temperature of is not over 70℃ when gear box working.
3) The suitable viscosity of lubricating oil must be kept and impurity, sand and water
is forbidden to sneak into lubricating oil.
4) If pumping unit goes wrong, user must stop operating to check and repair
immediately.
5) Noticing the fastening condition of fastener at any time.
6) Recording and reserving the condition of pumping unit using and maintenance.
10. Failure and solution (see tab. 3)
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Tab. 3 Failure and solution
Number Failure character Sign Reason of failure Prevent and solution
Whole pumping unit losing Sampson post swinging seriously. 1. Foundation is not firm. 1. Building foundation according to design
stability and damaged Frame and gear box vibrating seriously; 2. Drainage blocked cause the foundation requirement.
Non-uniform noisy sending out from sinkage. 2. Dredging drainage, repairing flowing water
electric motor 3.Connection between Sampson post and slope.
frame is not firm. 3. Fastening bolt.
1 4. Pumping unit is non-balance seriously. 4. Adjusting counter weight.
5. Anchor bolt is relaxed. 5. Fastening bolt.
6. Running overload, frequency of stroke 6. Formulating running regulation according to
is over. instruction book.
7. Pumping unit deviating central line of 7. Centering according to well head center and
well head seriously. foundation central line strictly.
1. Fitting up crank pin correctly according to
Sending out noisy periodical; crank pin 1.Assembly of crank pin is wrong.
2 Crank pin looseness requirement
having axial displacement 2. Nut of crank pin is relaxed.
2. Fastening nut.
1. Connecting key is destruction. 1. Changing new key.
2. Connection of crank and output shaft is 2. Fastening the bolt of crank aft.
Destruction of joint between crank Crank jumping suddenly, equalizer beam
3 relaxing. 3. Repairing key-seat and fitting with new key
and gear box output shaft. rocking and turning round.
3. Key-seat on shaft is destruction. or rotating crank output shaft 90°and fitting
with new key.
Pumping unit is non-balance lead Periodical noisy sending out from electric 1. Counter weight bolt is relaxed. 1. Fastening square head bolt.
to gear box overload and electric motor; counter weight moving. 2. Stop-block is relaxed. 2. Fastening fixing bolt of stop-block.
4
motor trip. 3. Square head bolt mating in crank slot is 3. Making square head bolt according as slot.
not well.
5 Steel cable joint of hanger is Cable jumping when horse head up and 1. Polishing and polishing rod slip size is 1. Changing polishing rod slip.
relaxing. down. not suitable causing position moving. 2. Changing steel cable.
2. Cable is pulled brokenly. 3. Adjusting the relative position (preventing
3. Stroke adjusting is wrong, and then stroked distance) between polishing rod and
make pump plunger collide with pump hanger.
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barrel.
Numbe Prevent and solution
Failure character Sign Reason of failure
r
No braking or braking 1. Brake block is attrition. 1. Changing brake block.
auto. 2. Brake pulley is polluted by oil. 2. Wiping out the oil of brake pulley.
6
3. Spring is malfunction. 3. Changing spring.
4. Brake stroke adjusting isn’t suitable. 4. Adjusting the stroke of adjusting rod.
Gear box is overheating. Temperature of oil Decreasing lubricating oil and droping oil level to
7 pond is higher than Lubricating oil is too much. Oil viscosity is not suitable. prescriptive position. Adjusting lubricating oil trademark.
70℃.
Gear or bearing is rust 1. Running interruption in moist surroundings. Water is filled in 1. Letting old oil off and washing cleanly. Changing
8 corrosion badly. box. Lubricating oil is not suitable or deterioration. suitable lubricating oil.
2. ventilation is not enough 2. Checking blowhole and making it ventilate.
Serious spot corrosion is 1. Gear box running is under overload. 1. Decreasing load and adjusting counter weight.
appearance. 2. Lubricating oil doesn’t tally with technical regulation 2. Choosing suitable lubricating oil according to technical
(Some little corrected requirement. regulation requirement.
9
spot corrosion 3. Lubricating oil lose lubricant ability. Lubricating oil is 3. Changing the new lubricating oil.
disappeared soon is emulsify or polluted by impurity.
normally)
Bearing and other parts Bearing is heat or 1. Lubricating isn’t enough or oil is polluted by metal impurity. 1. Filling in lubricating oil or changing new lubricating
running abnormally, noise is at bearing 2. The gap between oil wiper and end plane of gear is excess. oil.
10 burning and jamming. support. 3. Gear box is overload; bearing and gear is breakdown. 2. Adjusting gap between 0.5-1.0mm.
4. Bearing or sealing part is relaxed and lead to friction. 3. Decreasing load and adjusting balance.
4. Fastening bolt of box cover and connection.
Gear box leak oil. The sealing part seep 1. Bolt is relaxed; big grain solid impurity is in sealing glue 1. Fastening bolt, changing sealing glue.
11 oil. which makes engagement badly between box cover and the box. 2. Dredging oil return bore and blowhole.
2. Oil return bore or blowhole is blocked. 3. Compacting shaft sleeve.
Driving shaft of gear box There is knock sound 1. Mating of gear and shaft is relaxing. 1. Changing gear or driving shaft.
12
occur axial drunkenness. in gear box. 2. Bearing is abrasion and destruction. 2. Changing bearing.
13 Pitman arm is pulled The sign before pulled 1. There is relative rotary motion between crank and driven 1. Checking coaxial degree (price scissors) of two crank
- 15 -
brokenly. brokenly is crank shaft, which make this two crank non- parallel and lead to pin bore and adjusting.
vibration obviously; pitman arm forced non-uniform. 2. Changing bearing.
equalizer beam twist 2. Crank pin bearing is broken or jammed. 3. Emending Sampson post and fastening the bolt
and rock. 3. Sampson post is slope and lead to the two connecting rod between Sampson post and frame..
forced non-uniform. 4. Changing connecting rod.
- 16 -
11. Tools and documents for pumping unit
11.1 When pumping unit is leaving factory, tools and accessory is rationing as
follows:
1) A set of special tools but general tools self are prepared by user.
2) Anchor bolt (lever or non-lever) of movable foundation according to buyer’s
request.
3) A set of pulleys of electric motor in this pumping unit according to buyer’s order.
11.2 When pumping unit is leaving factory, technique document as follows:
Operating manual 1 copy
Attached tables and figures 1 copy
Production qualification 1 copy
Packing list 1 copy
Notes: The tool provide with regard packing list as principle.
12. Attached tables and attached figures
Attached table 1: Technical parameter for C456D-305-144TH
Attached table 2 Frequency of stroke and the corresponding belt pulley for C456D-305-144TH
Attached table 3: Position factor and torque factor of polishing rod for C456D-305-144TH
Attached table 4: Computing table of net torque of gear box (The crank is clockwise to revolve)
Attached table 5: Computing table of net torque of gear box (The crank is counterclockwise to revolve)
Attached figure : Foundation diagram for C456D-305-144TH
Attached table 1: Technical parameter for C456D-305-144TH
Mode
C456D-305-144TH
Item Parameter
Polish Rod Capacity (Lbs) 30500
Stroke Lengths(in) 144 120 97
-1
Strokes Frequency(min ) 3 - 10
Balance mode Crank balance
Model JS-456
Reducer Ratio 28.744
Gear box
Peak Torque Rating(Inlbs) 456000
Oil Tank( US gal) 88
Model Y280M-8
Electric motor Power(kW) 45
Rotary speed (r/min) 740
Unbalance weight of structure (lbs ) -229
Total weight(t) 26
Outline Dimensions
434×106×351
(Length×Width×Height)(In)
Note: the total weight excluding electric motor’s weight; the outline dimensions
excluding crank guards
- 17 -
Attached table 2: Frequency of stroke and the corresponding belt pulley for C456D-305-144TH
Frequency of stroke (min-1) 6 8 10
Diameter of C belt pulley (mm) 260 345 430
(Note: Pulley type should be supplied according to user request of order)
Attached table 3: Position factor and torque factor of polishing rod of C456D-305-144TH
- 18 -
Crank Position factor PR, % Torque factor TF, m
Angle Stroke length, m Stroke length, m
θ(°)
2.46 3.1 3.68 2.46 3.1 3.68
0
0.00007784 0.00021273 0.00047115 -0.02408122 -0.05057990 -0.09238556
15
0.01867164 0.01811597 0.01718632 0.37246496 0.46931205 0.56606552
30
0.07814663 0.07939468 0.07996991 0.73570028 0.94976721 1.18377366
45
0.17225167 0.17720868 0.18149247 1.01627435 1.31173376 1.63787307
60
0.29031043 0.29902692 0.30703640 1.18316041 1.50719593 1.85521858
75
0.41984410 0.43041774 0.43989596 1.23389227 1.54025501 1.85344753
90
0.54944271 0.55911843 0.56702998 1.18895095 1.45275907 1.70813752
105
0.67044573 0.67695357 0.68105216 1.07699212 1.29362507 1.49488275
120
0.77709469 0.77944355 0.77898485 0.92243602 1.09839126 1.26038300
135
0.86574398 0.86436739 0.86009458 0.74028306 0.88447766 1.02235639
150
0.93384419 0.93032897 0.92413722 0.53649978 0.65457895 0.77830889
165
0.97912973 0.97571876 0.97019247 0.31109178 0.40190661 0.51262573
180
0.99920724 0.99814388 0.99591788 0.06246720 0.11604184 0.20188020
195
0.99166204 0.99444601 0.99728676 -0.20724706 -0.20882133 -0.17543791
210
0.95473874 0.96155917 0.96941725 -0.48709306 -0.56288134 -0.61730026
225
0.88841759 0.89820500 0.90915344 -0.75561890 -0.91409845 -1.07520953
240
0.79533783 0.80653729 0.81815344 -0.98558039 -1.21727916 -1.46931587
255
0.68096040 0.69239457 0.70329944 -1.15258581 -1.43479838 -1.74065221
270
0.55290192 0.56402418 0.57407875 -1.24096870 -1.54840633 -1.87403764
285
0.41996526 0.43052832 0.44004672 -1.24366438 -1.55475859 -1.87807712
300
0.29139489 0.30101598 0.31001809 -1.15883986 -1.45559025 -1.76238277
315
0.17647809 0.18445935 0.19238570 -0.98729492 -1.25189746 -1.52875330
330
0.08428270 0.08979457 0.09568021 -0.73265131 -0.94399658 -1.17226722
345
0.02320959 0.02578503 0.02880940 -0.40458748 -0.53693654 -0.68913327
instruction 1. S-stroke length (m); 2.TF- Torque factor (m); 3.crank angle, The position of the above dead
center for 0 degrees, face to pumping unit, the mouth of a well follows a hour hand to revolve in
the right side of turn cape; 4.PR-Polish rod displacement that lower dead center calculates to
the percentage of the all stroke length.
- 19 -
Attached table 4: Computing table of net torque of gear box. (The crank is clockwise to revolve)
M n TF (W G ) M sin
- 20 -
Attached table 5: Computing table of net torque of gear box. (The crank is anticlockwise to revolve)
M n TF (W G ) M sin
- 21 -
56 72
1016
400
W ell head
406
920
18 75
Cent re line of sam son pos t
Fr a m e
- 22 -