GARDNER DENVER PZ-2400 Pump

 

Table 2.1: Gardner Denver PZ-2400 performance parameters

Piston/liner diameter in inches	Piston/liner diameter (mm)	Displacement per revolution (gallons)	Displacement per revolution (liter)	Maximum Displacement (GPM)	Maximum displacement (LPM)	Maximum operating pressure (PSI)	Maximum working pressure (bar)
9	229	11.57	43.78	1,272	4,816	2,908	201
8.5	216	10.32	39.06	1,135	4,296	3,260	225
8	203	9.14	34.60	1,005	3,806	3,680	254
7.5	191	8.03	30.41	884	3,345	4,188	289
7	178	7.00	26.49	770	2,914	4,807	331
6.5	165	6.03	22.84	664	2,512	5,575	348
6	152	5.14	19.46	565	2,141	6,543	451
5.5	140	4.32	16.35	475	1,779	7,500	517
5	127	3.75	13.51	393	1,487	7,500	517

 

 

Frame: a solid and stable foundation

The power end of the PZ-2400 uses a high-strength cast frame. Drawing on the design of the same series of PZ-7 pumps, it is made of high quality ductile iron. For such a large and complex structure as the frame, the casting process can be used to obtain higher overall stiffness and excellent damping performance than welding parts. This stability is critical because it must be able to maintain precise alignment of the internal transmissions under heavy piston loads of up to 185,000 pounds (822,921 n) , preventing abnormal wear due to small deformations.

Crankshaft and power train: forged durability

The PZ-2400 is equipped with hardened alloy steel crankshafts and heat treated alloy steel double helical gears (AGMA standard) . In such high horsepower applications, the use of forged crankshafts is recognized by the industry as the best choice.

The design of the double helical gear ensures a smooth and quiet transmission of power. Compared with spur gears, double helical gears have larger contact area and smoother transition during meshing, which effectively reduces impact and noise, and can reliably transmit power with an accurate gear ratio of 4.033:1.

Bearings and guide plates: minimize friction and maximize life

The PZ-2400 has an all-roller bearing construction. These include double-row spherical roller bearings for supporting the eccentric wheel and heavy-duty roller bearings for supporting the intermediate shaft. These designs ensure that the drivetrain can operate with low friction and high efficiency under extreme LOADS11.

The crosshead is made of replaceable bronze skateboards. As a classical bearing material, bronze has excellent self-lubrication, low friction coefficient and high wear resistance.

Lubrication system: the lifeblood of the power end

To ensure consistent and reliable lubrication of all moving parts, the PZ-2400 is equipped with a separate power-end lubricating oil pump assembly. Optional electric drive gearbox, but also provide special pressure lubrication system, further embodies the ultimate pursuit of the reliability of the whole equipment.

 

 

The patented y-cylinder: a revolution in fluid dynamics

One of the PZ-2400's most iconic features is its patented Y-Shaped fluid modules for harsh conditions. This innovative design is intended to fundamentally address the inherent limitations of conventional l-shaped fluid modules. There is a sharp geometric shape in the internal flow channel corner of the traditional L-type cylinder, which will become the stress concentration point. Under the repeated action of high-pressure pulse load, fatigue cracks are very easy to initiate and eventually lead to the failure of the cylinder.

The y-shaped fluid cylinder greatly reduces the internal stress concentration and provides a more optimized flow path for drilling fluid through its smooth and smooth y-shaped flow channel. Not only does this design reduce fluid turbulence and energy loss, but, crucially, it significantly improves the cylinder performance

Anti-fatigue life. Longer fatigue life means higher reliability and lower replacement frequency, directly saving customers high maintenance costs and valuable drilling time.

Material Integrity and manufacturing standards

To withstand operating pressures up to 7,500 PSI and scoured by highly abrasive drilling fluids, the PZ-2400's hydraulic cylinder module uses state-of-the-art materials and manufacturing processes.

Cylinder material: the module is made of high strength, high toughness forged alloy steel, the typical grade is 35CrMo or 40CRMNMO.

Manufacturing Process: the manufacturing process follows industry standards such as API 7K and JB/TQ252-81. Each cylinder forging is subjected to three stages of forging and internal hardening and is subjected to rigorous non-destructive testing (NDT) to ensure that its internal structure is free of any defects such as interlayers, cracks, and porosity. Welding repair of any kind is not allowed, which ensures the original strength and integrity of each hydraulic cylinder.

Manifolds: a fabricated log-style suction manifold is used at the suction end of the pump to ensure smooth fluid entry, while a hydrostatic-tested cast steel discharge manifold is used at the discharge end, the design and strength of the manifold is sufficient to support the full output pressure of the pump.

Global Interoperability and compliance certification

The PZ-2400 has been designed to meet the entry requirements and equipment compatibility of different markets worldwide.

Flanged connections: Standard API connections are used for pump suction and discharge outlets. These flange connections follow the strict
API 6A specifications ensure safe, reliable sealing at 7,500 PSI and seamless docking with standard drilling equipment worldwide.

Third-party certification: depending on customer requirements, PZ-2400 can be certified by DNV (Det Norske Veritas) , ABS (American Bureau of Shipping) , API or other authorized third party. These certifications are necessary to gain access to the offshore drilling and high standard regulatory markets and demonstrate that the design, manufacture and performance of the PZ-2400 meet the highest international safety and quality standards.

 

 

Cylinder liner: the first line of defense against wear and tear

 

Cylinder liner is the core component which directly contacts with high pressure and high abrasive drilling fluid, and its performance directly affects the efficiency and life of the pump. The REDLINETM series offers a variety of material options to meet different drilling challenges.

Material Options:

Zirconia: as a high-performance ceramic material, Zirconia has extremely high hardness and excellent wear resistance. It is the ultimate solution to highly abrasive drilling fluids, such as those containing large amounts of quartz sand.

Chrome-iron: this is a cost-effective wear-resistant material, and its high-hardness chrome alloy matrix provides durable, reliable protection for most conventional drilling fluids.

Valves and seats: the heart of pumping action

 

Materials and processes:

Body and seat: forged from 20CrMnTi or 20CrMoCi alloy steel. These materials have excellent impact toughness.

Case hardening: after forging, the part is carburized to a depth of 1.80-2.22 mm, followed by quenching to an ultra-high surface hardness of HRC58-65.

Engineering analysis: this complex process has created both"Outside hard and tough" characteristics of high-performance parts. The extremely hard surface layer can effectively resist the high-speed scouring and erosion of solid particles in the drilling fluid, while the inner core with high toughness can absorb the huge impact force generated when the high-pressure fluid is closed, prevents brittle fracture of components. High-performance polyurethane (Urethane, CPU/TPU) or nitrile-butadiene rubber (NBR) is used to provide a reliable seal after millions of cycles.

Piston: the key to sealing pressure

 

The REDLINETM piston is designed to be a perfect fit with the REDLINETM liner to maintain a reliable seal under extreme pressures and to maximize pump volumetric efficiency.

Material and design: offers a variety of high performance pistons including high wear resistant polyurethane, "Blue Lightning" and * * "Bonded White Lightning"* * . The adhesive design directly vulcanizes the high-quality polymer rubber on the metal core to form a whole, which effectively prevents the rubber from being extruded or torn under high pressure, and significantly improves the life and reliability of the piston.

Guide for the selection of wearing parts

 

To simplify the customer's purchasing and inventory management process, the following table integrates key information about the main PZ-2400 perishable parts, including material type and reference part number.

Table 5.1: Gardner Denver Pz-2400 REDLINETM

Parts	Dimensions/specifications	Material/type	Reference part number (example)
Cylinder liner	6"	Zirconia (Ceramic)	MB60-15
	6"	Supreme	1502060
	61/2"	Zirconia (Ceramic)	MB64-15
	61/2"	Supreme	1502062
Piston	6"	Urethane	015180269
	6"	Blue Lightning	0151802
	61/2"	Urethane	015180301
	61/2"	Green Duo HP	05595650HP
Valve Assembly	Full Open	Valve body (polyurethane rubber)	9700382(Roughneck Bonded)
	Full Open	Seat	9702652
	Full Open	Rubber cover for valves (polyurethane)	9705236
	Full Open	Spring	8201684
Seals	Bonnet seal	Polyurethane l-type	P129U
	Sealing of cylinder liner	Supreme	-

 

 

Gardner Denver understands that no two drilling projects are alike. Thus, the PZ-2400 is not a rigid"Product", but a highly flexible"Platform" capable of being customized through a rich array of options, and the PZ-2400 is not a rigid"Product" but a highly flexible"Platform" capable of being customized through a variety of options, precisely matching a variety of complex operating environments from the Texas Shale Basin to the deep waters of the Gulf of Mexico.

 

A wide range of applications

The remarkable performance of the PZ-2400 makes it capable of performing some of today's most challenging drilling tasks.

Land over-sized rigs: ultra-long horizontal sections have become the norm in shale oil and gas development. The PZ-2400's power and high-pressure capabilities make it an ideal power source for these"Long-haul" operations, ensuring that drilling fluid can be effectively delivered to the bottom of the hole for critical tasks such as cuttings carrying and cooling.

Offshore drilling: its compact, lightweight design makes it ideal for space-constrained drilling vessels and semi-submersible platforms 1. At the same time, available
DNV and ABS Classification Society certification is a strong proof that it meets the highest safety and compliance standards for offshore operations, making it a reliable choice for deepwater and ultra-deepwater drilling projects.

Rich customization options

To meet the specific needs of different customers, the PZ-2400 provides a range of standard and optional functional modules that allow customers to create the pump set that best suits their operating environment, power source, and maintenance strategy.

Skid mounting scheme: large maintenance skids with non-slip deck are optional to provide safer and more spacious maintenance operation space for field personnel and improve maintenance efficiency and safety.

Perfusion system: centrifugal perfusion pump can be installed to ensure that the mud pump at high speed when the cylinder can be fully filled, effectively prevent the occurrence of cavitation, protect the hydraulic end parts from damage.

Pulse control: optional suction line pressurizer and discharge line pulse buffer to smooth the output flow of the pump and reduce the pressure impact on the pump itself and the downstream high-pressure manifold system, improve the stability and life of the whole system.

Easy Maintenance: P-Quip's quick-change cylinder gland and piston rod systems are available, greatly reducing the time required to replace perishable parts. The Lexan viewing window cover on the power side rack allows the operator to visually inspect the internal components without opening the cover, facilitating rapid detection of potential problems.

Intelligent Monitoring: Smart Pump Intelligent Monitoring Technology can be integrated, through sensors to collect the operating data of the Pump (such as pressure, temperature, vibration) , real-time condition monitoring and predictive maintenance analysis, help customers move from passive maintenance to active maintenance.

Drive scheme: for the integrated, all-electric drive modern drill floor design, the electric drive top drive gearbox option can be provided to achieve seamless integration with the main power grid of the rig.

PZ-2400 full list of technical specifications

Table 7.1: Gardner Pz-2400 Denver

 

Category	Parameters	Values
Performance	Maximum input power	2,400 BHP (1,790 kW)
	Maximum rated speed	110 RPM
	Stroke length	14 inches (356 mm)
	Maximum piston rod load	185,000 lbs
Transmission	Gear ratio	4.033:1
	Intermediate shaft speed (at 110 pump speed)	444RPM
Physical specifications	Pump weight (including standard pry and hydraulic tension)	63,500 lbs
	Pump weight (including electric top drive gearbox)	88,000 lbs
	Dimensions (length x width x height)	Approximately 195.6 x 115.3 x 123.4 inches
Connection	Suction/discharge connections	API standard
Hydraulic end	Type of cylinder	Patented y-module
	Maximum rated pressure	7,500 PSI
Warranty	Power end	5 years

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