GARDNER DENVER PZ11 Pump

Foundation: forged alloy steel modules

Significantly improved fatigue life: we use high quality forged alloy steels such as 35CrMo, 40CrMnMo and 4135/4140 as the base materials for the modules. These materials have high hardenability, excellent high temperature strength and excellent toughness, is the ideal choice to deal with extreme conditions.

Our quality commitment extends beyond the materials themselves. We strictly follow the API 7K manufacturing standard, and use multi-stage heat treatment processes such as quenching and tempering, as well as proprietary Autofrettage technology.

In addition, we offer an innovative"L" type split cylinder module design that separates the suction and discharge modules for true modularity. The core advantage of this design is economy: when one of the suction or discharge modules breaks, it can be replaced independently, thereby significantly reducing maintenance costs and spare parts inventory pressure. At the same time, the split design also simplifies the valve and seat replacement process, improve the efficiency of field maintenance. This reflects our deep understanding of the whole life cycle cost of drilling equipment, and provides customers with a more intelligent and economical upgrade plan.

Wear interface: advanced cylinder liner with piston system

The cylinder liner and piston are the core wear parts that directly contact with the highly abrasive and corrosive drilling fluid, and their service life directly affects the non-production time (NPT) of the drilling platform.

Cylinder liner technology:

High chromium (bimetal) cylinder liner: the shell is made of high strength forged steel (AISI 1045) to provide structural support; the lining is made of centrifugally cast high chromium cast iron to form a wear resistant surface with hardness up to HRC 60-69. This is a cost-effective and reliable option for most drilling environments.

Zirconia ceramic cylinder liner: zirconia ceramic material has super high hardness (HRC > 85) , excellent thermal stability and excellent corrosion resistance, its service life can reach 3 to 5 times of high chromium cylinder liner.

Piston technology:

Our one-piece vulcanized piston design combines a high-strength forged steel piston core with our proprietary elastomer formulation. We offer a variety of elastomer options to suit different operating conditions:

High performance polyurethane: suitable for conventional water-based muds, providing top-notch abrasion resistance.

Special nitrile rubber (NBR/HNBR) : designed for high temperature or oil-based, synthetic based mud environment, with excellent resistance to chemical corrosion and high temperature performance. Our elastomeric formulations are carefully designed to provide maximum resistance to extrusion, wear and chemical degradation.

Table 1: performance comparison of cylinder liner materials

The following table is intended to help customers select the most appropriate liner product based on a clear cost ⁇ benefit analysis of their specific drilling project.

Flow control under pressure: valve and seat assembly

Design & Materials:

The one-piece fully open body and seat design is monolithically forged from top alloy steels such as 20CrMnTi, 40CrNiMo, AISI 8620 or 4119. Compared with the casting or welding wing valve, the continuous metal streamline structure of the forging valve body can better resist the high-strength impact stress generated when the valve is closed, and fundamentally prevent fatigue fracture.

Advanced Heat Treatment Process:

We use a sophisticated carburizing and quenching process to give the valve assembly dual performance:

Hard surface: carburizing forms a high-carbon zone on the surface of the component, which is transformed into an ultra-hard martensite structure (hardness HRC ≥60) after quenching, which is sufficient to resist the high-speed erosion of abrasive particles in the drilling mud.

Tough Core: keep the original low-carbon parts of the core, quenching after the formation of a high-toughness structure, can effectively absorb the valve each time the impact of the tremendous energy generated without breaking.

This"Outer rigid and inner tough" structure is the key to extend the life of the valve assembly. Chromium (CR) and manganese (MN) elements in 20CrMnTi and other alloy steels improve the hardenability of the material and ensure the formation of a sufficiently deep hardened layer, while titanium (Ti) plays a role in grain refinement, the toughness and overall strength of the core are further enhanced.

Replaceable valve glue:

Our matching use of high-quality polyurethane valve glue, not only provides reliable seal, but also easy to replace, effectively reducing maintenance costs and downtime 51.

Operational Challenges: the high cost of traditional liner replacement methods

Conventional cylinder liner fitting relies on studs and nuts. In the field operation, in order to achieve the required pretightening torque, it is often necessary to use"Hammer and Force Bar", which is not only inefficient, but also poses a great safety risk to the field personnel. Each cylinder liner change means a long non-production time (NPT) , which directly affects the progress of drilling projects and economic benefits.

P-Quip system: technical analysis

The P-Quip system is undoubtedly an important technological innovation on the market. Here's how it works:

Compression: the use of strong spring mechanism (disc spring group) on the cylinder liner to apply a constant and known clamping force, effectively prevent the cylinder liner during pump operation of the micro-movement, thereby extending the life of the cylinder liner and piston.

Release: use a small external hydraulic pump to release pressure from the Spring Assembly to release the liner plate safely and quickly.

Although the P-Quip system solves the traditional problems of brute force and security, it introduces a new set of complexities. It relies on external hydraulic pumps, high-pressure tubing, and couplings. These additional equipment in the harsh environment of the drilling platform, there is a risk of loss, damage or failure, but may become a new point of failure, delay the maintenance process.

Our enhanced solution: pure mechanical cylinder press-fit system

We are here to launch a proprietary solution that represents the next generation of cylinder press-fit technology. Its core strength lies in the pure mechanical structure, completely get rid of the dependence on external hydraulic system.

How it works:

Our design is inspired by the industry-leading"Sur-lock" mechanical torque enhancement concept. We integrate a precision torque multiplier gear system (pinion and ring gear) into the liner Platen Nut Assembly. This revolutionary design allows the operator to easily generate and accurately control tremendous clamping forces using only a standard impact or torque wrench. The installation and disassembly time of the entire cylinder liner is shortened to minutes.

Comparative Advantage:

Extreme Safety: eliminates the double risk of hammering and high-pressure hydraulic line leaks.

Unparalleled Speed: the time to change the cylinder liner is much less than the traditional way, even faster than the hydraulic auxiliary system. We set a target replacement time of less than 5 minutes, far longer than the 15 minutes claimed by the P-Quip system.

Minimalist: no external pumps, tubing, or special connections. The system is self-contained, robust, and requires no additional maintenance.

Cost-effectiveness: lower life-cycle costs by minimizing non-production time, simplifying required tools, and improving security.

Table 2: Comparative Analysis of time and safety of cylinder liner pressure fitting system

This table clearly shows the direct operational and economic advantages of investing in our system.

Core frame: the advantages of ductile iron frames

The power end frame is the foundation of the entire pump and withstands tremendous operating stress and vibration. The cast ductile iron frame used in the PZ-11 is a superior design choice compared to the welded steel plate frame used in some pump types.

Driveline: precision built to maximize power transmission

Crankshaft and gears: we use forged alloy steel crankshafts and heat-treated double herringbone AGMA standard gears. Double herringbone gear design provides a smoother, quieter transmission with greater load capacity and longer life than spur gears.

Bearing configuration: We Strictly Follow the OEM specification for the use of specific types of bearings at key locations on the power side, including double row spherical roller bearings for eccentric shaft spindle bearings, double row spherical roller bearings for eccentric shaft spindles, double row spherical roller bearings for eccentric shafts, double row spherical roller bearings for eccentric shafts, double row spherical roller bearings for eccentric shafts, double row spherical roller bearings for eccentric shafts, and double row spherical roller bearings for eccentric shafts, and heavy duty roller bearings 90 for pinion shafts and connecting rods. This attention to detail ensures that our power-end components meet or exceed OEM performance standards.

Long Life of the system: Advanced Lubrication system

Power end with splash lubrication and forced lubrication of the combination of dual lubrication system. The internal oil pump will be clean, cooling oil continuously delivered to all the key bearings and gear meshing point, which is the fundamental guarantee for long-life operation. The system is standard equipped with replaceable oil filter and oil pressure gauge, and optional oil cooler, in order to adapt to the continuous operation in high temperature environment.

Table 3: performance data of Pz-11 mud pumps with our components

The following table provides drilling engineers with a key reference for matching pump performance to specific well conditions. All data are calculated based on 90% mechanical efficiency and 100% volumetric efficiency.

Sources of data:

A guide to interchangeability

Table 4: List of OEM fully interchangeable parts

This form provides the purchasing and maintenance team with a key tool that removes all doubt about compatibility and simplifies the ordering process, thereby building trust and facilitating business with customers.

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