GARDNER DENVER THE Pump

Power Racks: Superior rigidity and durability

The power rack of GD-215T (THE) is precision cast in high specification ductile iron. In contrast to standard gray iron, ductile iron has a spheroidal graphite rather than a flaky graphite, which gives the material excellent ductility and tensile strength, giving it both the high rigidity of castings and the impact toughness close to that of steel.

In addition, the frame adopts a solid monolithic structure, the main shaft and intermediate shaft of the bearing seat integrated into one, further enhancing the overall rigidity and strength of the structure. At the same time, the maintainability is fully considered in the design, and the top cover is equipped with easy disassembly, which is convenient for field personnel to check and maintain the internal components.

Transmission system: precise, strong and smooth power transmission

Every detail of the transmission system is carefully designed to ensure that the transmission of power from the input end to the piston rod is efficient, smooth and extremely low loss.

Eccentric shaft and bearings: the eccentric shaft is supported by heavy duty double row spherical roller bearings. This choice is crucial, as spherical roller bearings are capable of withstanding both large radial and axial loads, perfectly responding to multidirectional compound forces from the connecting rod, ensuring smooth rotation of the eccentric shaft under harsh operating conditions, and ensuring the smooth rotation of the eccentric shaft, and has an extremely long service life.

Connecting rod: The connecting rod is also forged of high strength ductile iron or 42CrMo alloy steel for optimum strength to weight ratio. The big end is connected with an eccentric shaft by a double row roller bearing, which is a remarkable quality characteristic. Compared with the traditional sliding bearing bush, it greatly reduces friction and wear and improves power transmission efficiency.

Gear: the core of the transmission system is the alloy steel main gear after heat treatment. We usually use herringbone gear designs, or helical gears with high precision grinding, which provide a smoother and quieter meshing process, as well as a larger contact area, compared to ordinary spur gears, capable of delivering higher torques. All gears are rigidly
Carburizing heat treatment and precision grinding process to obtain extremely high surface hardness and wear resistance, while maintaining the toughness of the tooth core.

Crosshead and guide plate: the Crosshead is made of solid cast iron and fitted with a replaceable bronze crosshead skateboard. It was a deliberate design choice: bronze, as an excellent wear-resistant material, provided a low-friction sacrificial wear surface between the crosshead and the rack rails.

Hydraulic end-the frontier of conquering abrasion condition

Hydraulic cylinder: the core of high pressure seal

Hydraulic cylinder is the core component to bear and transmit huge pressure, and its material and manufacturing process determine the safety and durability of the whole pump.

Superior material and forging process: we use top grade high strength forged alloy steel as the base material for hydraulic cylinders, Aisi 4135,35CrMo or AISI 8620.

Advanced Manufacturing Technology:

Heat treatment: each forging stock must be subjected to a rigorous, computer-controlled heat treatment program to achieve a perfect balance of hardness and toughness, to ensure that brittle fracture does not occur under long-term high pressure cycling.

Autofrettage: this is a key technique to improve the fatigue life of hydraulic cylinders. By applying ultra-high pressure to the inner wall of the hydraulic cylinder, permanent plastic deformation is produced, and a layer of strong residual compressive stress is formed on the inner surface. This layer of prestress can effectively offset the tensile stress generated by the high-pressure fluid during operation, which greatly delays the initiation and propagation of fatigue cracks, and improves the service life of the hydraulic cylinder by an order of magnitude.

CNC precision machining: all cylinders are precision machined on advanced CNC boring machines to achieve impeccable dimensional tolerances and surface finish, ensure that the valve, cylinder liners and other components of the perfect alignment and reliable seal.

Interchangeability design: the hydraulic cylinder adopts modular and interchangeable design, which not only simplifies the production process, but also brings great convenience to customers' on-site service and spare parts inventory management.

Wear parts: for the super wear-resistant and health of Seiko

We are well aware that components in direct contact with highly abrasive drilling fluids are bound to wear out. Our strategy is to make these perishable parts easy to replace while having a very long service life.

Cylinder liners: our standard bimetallic cylinder liners are a classic example of composite engineering.

Housing: Made of tough, highly malleable 45 # forged steel with a tensile strength of over 610 MPa to withstand the tremendous hoop stress of high-pressure fluid and prevent liner cracking.

Lining: high chromium (26-28% chromium) cast iron made by centrifugal casting. After special heat treatment, the hardness of the inner wall can reach HRC 59-67. It has extraordinary wear resistance and excellent corrosion resistance. It is designed to resist the continuous erosion of hard particles such as quartz sand in drilling mud.

High-end options: for the most challenging conditions, we also offer ceramic linings made of zirconia. Its hardness is more than HRC 90, wear resistance is much higher than high ferrochrome, can provide several times the traditional bimetallic cylinder liner service life.

Pistons: advanced bonded polyurethane pistons. We select a special formula of multi-hardness polyurethane material, so that it can be oil-based and water-based mud in both the performance of outstanding, effective resistance to wear, high temperature and extrusion deformation. Its unique"Cow nose" lip design provides superior sealing and reduces leakage, thereby reducing flushing system contamination and extending piston and cylinder liner life.

Valve and valve seat: standard with the API-7 standard three-reinforced polyurethane rubber valve and valve seat 10. The metal body and seats are made of carburized high quality alloy steel and are precision machined to API specifications. The carburizing process forms an extremely hard wear-resistant layer on the surface of the part, while maintaining the toughness of the core to withstand the tremendous impact of the valve opening and closing without fracture.

Piston rod: integrally forged and heat treated in high quality alloy steel (42CrMo) with high tensile and fatigue strength. Chrome finishes are available to enhance durability in corrosive environments, depending on customer requirements.

System integrity: reliable sealing and easy maintenance

Vervain: threaded vervain design. Compared with the traditional multi-bolt flange structure, the threaded connection can provide more reliable sealing under high pressure, and the disassembly and assembly are faster when replacing the valve, which greatly shortens the maintenance time.

Piston flushing system: a complete piston flushing and lubricating system is standard on THE GD-215T. The system continuously sprays cooling and lubricating fluid into the contact area between the piston and the cylinder liner, effectively reducing the working temperature and flushing away the intruding abrasive particles in time, this function is essential to extend the life of the piston and cylinder liner, which are key wearing parts.

The table below summarizes the materials and workmanship of the key components at the hydraulic end, providing a visual representation of Gardner's attention to detail.

Table 3.1: material and manufacturing process specifications for key hydraulic components

Core technical specifications

Table 4.1: GD-215T (THE)

Performance Matrix: flexible configuration of flow and pressure

Table 4.2: GD-215T (THE) performance matrix

Application flexibility

Thanks to its robust design and wide selection of materials, THE GD-215T (THE) exhibits exceptional adaptability to a wide range of demanding applications, including but not limited to:

Mud, grouting and cementing services: its core applications, capable of reliably pumping high-solid, highly abrasive fluids.

Oilfield services: for acidizing, fracturing support and other downhole operations that require precise pressure control.

Pipeline transportation: can be used for long-distance pipeline pumping of crude oil, chemical products and other media.

Mine drainage: can efficiently deal with the mine water containing solid particles.

General industrial services: including high pressure hydraulic cleaning, general water supply services, etc. .

This wide range of applications means that one GD-215T (THE) pump can serve multiple operations, maximizing equipment utilization and investment value.

Key supporting systems

In order to ensure the safe and smooth operation of the pump set, we strongly recommend and provide a series of key supporting systems.

Pulse buffer: in the mud pump discharge line on the installation of high-quality pulse buffer is crucial. It can effectively absorb the pressure fluctuation caused by the reciprocating movement of the pump, make the discharge flow more stable, thus reducing the vibration of the whole manifold system and protecting the downstream precision instruments and equipment from impact damage. We offer high-quality bumpers that are perfectly matched with pumps and interchangeable with major brands. The internal capsule is made of high-quality materials resistant to oil-based mud to ensure long-term reliable service.

Safety Valve/relief valve: in accordance with industry safety regulations, a pressure safety valve must be installed in the discharge line near the pump. This is an indispensable safety device, which can automatically open the pressure relief when the system pressure unexpectedly exceeds the set value, and prevent overpressure caused by pipeline blockage and other reasons, thus avoiding catastrophic equipment damage and personnel injury. Our standard Gardner Denver factory safety valves are the ultimate in safe operation.

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