LEWCO W-250-C Pump

Power end-indestructible mechanical heart

Power Rack: the cornerstone of precision

Structural design: the W-250-C frame is a precision-manufactured double-wall welded steel structure with internal stiffeners and gusset plates to provide superior structural strength and overall stress relief after welding.

Skid Mount: we equipped the W-250-C with a heavy duty oilfield skid mount.

Crankshaft assembly: source of strength for one-piece forging

Materials and forging process: the crankshaft is the power backbone of the pump. It is not made of castings or bolts spliced together, but using one-piece forging and machining process manufacturing. We use high nickel, high chromium modified 4340 alloy steel as raw material. This choice of material, combined with the forging process, gives the crankshaft unparalleled grain structure and fatigue strength.

Manufacturing process: each crankshaft is forged, heat treated, precision machined and dynamically balanced. The entire assembly is statically balanced to ensure smooth, vibration-free operation, which directly extends the life of the bearings and associated components. This one-piece structure avoids the fretting wear and fatigue fracture at the bolt joint interface in the multi-segment design.

Integrated lubrication channels: the crankshaft is equipped with precise drilling oil channels through which the oil is delivered directly to each bearing surface. This is a high-end, dedicated design of the logo, to ensure that in any load can achieve efficient lubrication.

Gears and bearings: precision transmission

Gear: both pinion and main gear are forged from high strength alloy steel and are of herringbone (double helical) design.

Bearings: W-250-C power end of all the use of high-quality anti-wear roller bearings. According to the authoritative Timken bearing application analysis, we selected the heavy-duty tapered roller bearing in the crankshaft main bearing position, and the cylindrical roller bearing in the connecting rod big end, to bear the pump in the operation of the high radial load and axial thrust, to ensure long-term stable operation.

Connecting rod and crosshead: complete transmission of power

Connecting rod: the connecting rod is made of rolled steel plate to ensure accurate alignment between the crankshaft and the crosshead at maximum load. The double row cylindrical roller bearings are used at the cross end and the single row roller bearings are used at the crankshaft end, which effectively reduces the friction and wear under severe working conditions.

Crosshead: although the specific material of W-250-C is not listed in all documents, we follow the highest industry standards and use a high-strength ductile iron material to provide a large and wear-resistant sliding surface, to ensure smooth and efficient power transmission.

Lubrication systems: a triple redundant protection mechanism

System design: the triple redundant lubrication system is one of the core advantages of Lewco Pump, which provides the ultimate guarantee for the long-life operation of the power end.

Internal Gravity/Splash Lubrication: provides basic, all-around lubrication coverage.

Internal gear-driven oil pump: a mechanical oil pump driven directly by the main gear, ensuring forced pressure lubrication proportional to pump speed.

External electric oil pump: a second independent electric oil pump provides full pressure lubrication even at extremely low speeds (below 200 RPM) or at the start-up instant, the problem of wear and tear caused by insufficient oil pressure in conventional pumps at these critical stages is completely solved.

System advantage: this sophisticated system ensures that all key bearings and slides are adequately protected under all operating conditions, from start-up to full speed, greatly extending the life of the power end.

Hydraulic end module: the core of pressure

Material Options:

Forged carbon steel: robust, reliable standard option for most applications.

Forged duplex stainless steel: provides superior corrosion resistance in harsh environments such as brines or corrosive chemicals.

Cast aluminum bronze: excellent resistance to corrosion and biofouling, particularly suitable for brine treatment or water injection applications.

Manufacturing and quality control: regardless of the material chosen, all modules are forged from high quality alloy steel blocks (35CrMo, 40CrMnMo) , heat treated and internally hardened. We manufacture in strict compliance with the API 7K standard and conduct a rigorous non-destructive testing (NDT) of each module to ensure its absolute integrity at the W250H model's maximum rated pressure of 5,000 PSI.

Plunger: primary seal interface

Material Options: the choice of plunger directly affects the service life and adaptability to different muds. We offer the following options:

Tungsten carbide coated plungers: sprayed hard coatings on stainless steel substrates provide excellent wear resistance in a variety of operating conditions.

Monolithic ceramic plunger (alumina/zirconia) : this is the top choice for extreme abrasion and corrosion conditions, significantly extending operation time and reducing maintenance frequency.

Cylinder liner and piston (for piston pump configuration)

Bimetal liner: we use bi-material composite structure. The casing is made of high toughness 45 # forged steel to resist pressure and impact. The inner lining is made of high chromium cast iron (Cr content > 27%) by centrifugal casting and heat treatment. The hardness of the inner lining reaches HRC 59-67, which has strong wear resistance. This combination provides more than 800 hours of service life under normal conditions.

Zirconia ceramic liner: Zirconia (Zro3) liner combined with forged steel housing. The advantages are: near-diamond hardness (> 90 HRC) , chemical inertness, and extremely long service life of more than 4,000 hours, greatly reducing maintenance downtime.

Piston: the piston assembly consists of a forged piston core of high strength steel (40CR) and seals bonded to it. We offer a variety of sealing material options:

Bonded polyurethane: excellent wear resistance and extrusion resistance in water-based or oil-based mud, operating temperature up to 250 °F.

Bonded nitrile rubber: excellent tolerance to chemical and oil-based slurries with varying aniline points.

Valve and seat: The Guardian of pressure

Material and process: the body and seat are forged from high quality alloy steels such as AISI 4119 or 20CrMnTi. A very hard (HRC ≥60) wear-resistant layer was formed on the surface by the key deep carburizing heat treatment process. It is especially important that after the heat treatment, finishing is performed to correct for the small deformations that may occur during hardening, thus ensuring a perfect seal fit and preventing high pressure leakage.

Design: we offer a variety of valve designs (E. G. Full Open, Mesh) to optimize flow and performance for specific drilling fluids and conditions.

Packing Box and packing: ensure perfect sealing

Materials: W-250-C offers premium packing boxes to match hydraulic end materials, including options of aluminum bronze or duplex stainless steel.

Packing: we offer a variety of plunger packing combinations that can be tailored to fluid type and pressure to maximize seal life and minimize leakage.

Table 1: LEWCO W-250-C performance matrix

This table allows the customer to accurately match the most appropriate pump configuration to his specific depth, pressure, and flow requirements.

Source:. Flow is calculated based on 100% volumetric efficiency.

Table 2: Summary of engineering specifications

This table provides all key data for logistics planning, rig integration, and maintenance scheduling.

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