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Philosophy of design: excellent engineering leads to extraordinary performance

The performance of the LEWCO W-440-LP is built on three engineering pillars:

Top material selection: carefully selected alloy steel with specific properties to effectively resist fatigue, corrosion and wear.

Solid structure technology: using forging and precision welding and other advanced manufacturing processes, to create a core component with inherent strength.

Redundant system design: integrating redundant functions such as double lubrication system to ensure continuous and stable operation under any working conditions.

Wide range of applications

With its flexible design, the LEWCO W-440-LP is capable of operating in a wide variety of oilfield environments. Both piston and plunger configurations can be customized to meet the customer's specific needs for optimal performance.

Low-pressure high-displacement (LP) configuration: this configuration uses a larger piston and liner combination (e. g. 6 inches to 4-1/2 inches) and is capable of providing a high displacement output of up to 661 GPM (gallons per minute) , it is ideal for shallow well drilling and high displacement drilling fluid circulation.

High Pressure (HP) configuration: the pump is capable of generating rated pressures up to 2,816 psi through the use of smaller sized plungers and liners (e. g. 4"To 3-1/2") , perfect for well servicing, workover, cementing, and other operations that require high-pressure injection.

This adaptability makes the W-440-LP a truly integrated solution for pumping requirements from drilling to well completion.

Power end-an indestructible source of power

Power Rack: welded steel structure as solid as a rock

The power rack of the W-440-LP is a precision-manufactured double-wall welded steel structure with integrated stiffeners and gusset plates to provide additional strength and rigidity.

Crankshaft assembly: integrally forged alloy steel core

The W-440-LP dispenses with the"Multiple bolt-on" design, which is prone to stress concentration and fatigue fracture at joints, the structure is made of forged and welded alloy steel, which is technically more difficult but far stronger and more reliable than the former.

Material Depth Analysis: we use top alloy steel materials, such as high nickel chromium content of modified 4340 alloy steel or 42CrMo 13. High nickel content can effectively inhibit the initiation and propagation of microcracks, while high chromium content provides excellent corrosion resistance to ensure that the crankshaft remains strong in harsh environments.

Essence of the process: the forging process distributes the internal grain streamlines of the steel along the shape of the crankshaft, resulting in unparalleled strength and fatigue resistance. Each crankshaft is treated with precise power balancing, which minimizes noise and vibration in operation and has the direct benefit of significantly extending the life of the bearings and the crankshaft itself.

Gears and transmissions: the science of smooth power transmission

The W-440-LP's driveline features pinion and main gears in a * * double helical (herringbone) * * design. Compared with the traditional spur gear, the herringbone gear meshing process is more smooth and continuous, which can achieve uniform load transfer throughout the tooth width, effectively eliminate impact and noise, and operate very quietly and efficiently.

Redundant lubrication system: the patron saint of reliability

One of the most common causes of power end failure is insufficient lubrication, especially at low speed, the traditional splash lubrication system is inefficient. In order to solve this problem, W-440-LP is equipped with a triple redundant lubrication system, which provides the ultimate guarantee for the continuous and reliable operation of the equipment.

The system consists of the following three parts working together:

Internal Gravity/Splash Lubrication: provides basic lubrication protection.

Internal gear-driven mechanical pump: as the main lubrication system, directly driven by the main gear, to ensure that the supply of lubricating oil and pump speed is proportional to achieve efficient lubrication.

External stand-alone electric pump: as a key redundancy safeguard, driven by a stand-alone motor (e. g. Brown & Sharpe or equivalent pump) . It ensures adequate pressure lubrication of all critical components even before pump start-up or at very low speeds, eliminating the risk of wear and tear in conventional pumps under these conditions.

Hydraulic end-control of high pressure environment

Forging Power: L-type hydraulic end module

The W-440-LP is designed with an industry-recognized two-piece l-shaped module that facilitates on-site maintenance and the replacement of perishable parts. Our commitment to hydraulic end modules begins with the most basic material choices. All modules are made of high tensile strength quenched and tempered forged alloy steel. We use top alloy steels including 35CrMo, 40CrMoMn, AISI 4135 and even AISI 8620 to ensure superior mechanical properties.

The forging process gives the module a dense internal structure and superior strength. On this basis, each forging is processed to a strict tolerance range by a precision numerical control machine tool, and a controllable heat treatment is applied. This combination of processes allows the inside of the module to remain tough enough to absorb impact, while the surface obtains a high degree of hardness to resist high-pressure fluid erosion and stress corrosion cracking. Before leaving the factory, all modules must pass the strict non-destructive testing (NDT) to ensure that there is no internal defects, to provide customers with absolutely reliable quality assurance.

Combination of wearing parts: performance tailored to the formation

We are well aware that there is no single solution for all drilling environments. Therefore, we offer a range of high-performance wear parts options for the W-440-LP that allow customers the flexibility to configure the hydraulic end of the pump according to specific abrasive or corrosive conditions, thus maximizing the length of the maintenance cycle, reduce overall operating costs.

Cylinder liner: the peak of wear-resisting technology

Matrix of cylinder liner performance and application

Type of cylinder liner	Shell material	Lining material	Manufacturing process	Bore hardness (HRC)	Average service life (hours)	Key Strengths	Ideal application scenarios
Bimetallic high chromium	Wrought alloy steel	High chromium cast iron (CR > 27%)	Centrifugal casting, heat treatment	60-65	> 800	Excellent wear resistance, high cost performance	Conventional and medium abrasive drilling fluids with high sand content
Zirconia ceramics	Wrought alloy steel	Zirconia ceramics (ZRO3)	Press fit, precision grinding	> 90	> 4000	Extreme wear and corrosion resistance, long life	Strong corrosive, high abrasive drilling fluid, deep wells, hard formation and other extreme conditions

Pistons and seals: integrity under high pressure

The piston core is forged from high quality 45 # or 40CR steel and quenched and tempered for optimum strength. The piston rubber is specially formulated

Polyurethane or nitrile rubber (NBR) materials, which are carefully selected for their superior heat resistance, oil-based mud resistance and abrasion resistance33. We also offer one-piece bonded polyurethane piston options, which are designed to effectively resist abrasive fluids and provide longer life in high-pressure conditions.

Valves and seats: the Guardians of Precision Machining

The performance of the valve assembly (this model is API # 4 standard) directly affects the pump volumetric efficiency and overall performance 7. Our valve body and seat are made of high quality alloy steel (e.g

Aisi 4119,40CrNiMo, 20CrMnTi or AISI 8620) .

The key process in the manufacturing process is deep carburizing followed by quenching and tempering. This complex heat treatment process forms an extremely hard (HRC ≥60) wear-resistant layer on the surface of the component, while maintaining sufficient toughness in the core to withstand impact loads. Combined with high-precision CNC machine tool to grind the sealing surface, the final valve assembly has excellent sealing performance, and the service life is 4 to 5 times that of ordinary products, which can effectively improve pump efficiency, for customers directly save operating costs.

Performance and technical specifications

Overview of key technical parameters

Rated input power: 440 HP (328 kW)

Rated strokes: 320spm (strokes/min)

Stroke length: 6"(152.4 mm)

Gear ratio: 4.578:1

Valve Box Specification: API # 4

Suction line Flange: 6"150 # Flange."

Discharge line Flange: 3"900 # Flange

Dimensions (length x width x height) : 98"X 48" x 44"(2490 x 1220 x 1118mm)

Approximate weight: 9,840 lbs (4,463 kg)

Performance parameter table of W-440-LP mud pump

Cylinder liner dimensions (in.)	Rated pressure (psi)	Pump Speed (SPM)	Input Power (HP)	Displacement (GPM)
6	1,027	320	440	661
		270	380	551
		220	320	441
		170	260	330
		120	200	220
5-1/2	1,222	320	440	555
		270	380	463
		220	320	370
		170	260	278
		120	200	185
5	1,479	320	440	459
		270	380	382
		220	320	306
		170	260	229
		120	200	153
4-1/2	1,710	320	440	397
		270	380	335
		220	320	273
		170	260	211
		120	200	149
4	2,169	320	440	313
		270	380	264
		220	320	215
		170	260	167
		120	200	118
3-1/2	2,816	320	440	240
		270	380	202
		220	320	165
		170	260	127
		120	200	90

Source: 7

System integration

To facilitate seamless integration of the W-440-LP into existing systems, we offer standard flange interfaces: 6"150 # flange for suction and 3" 900 # flange for discharge. At the same time, we can also provide integrated skid-mounted solutions, pump and diesel engine (e. g. Detroit 60 series) , transmission (e. g. Allison 750) and auxiliary pump are integrated on the same skid-mounted base and delivered for operation according to customer requirements, this greatly simplifies on-site installation and commissioning.

Our quality commitment-beyond the blueprint

Enforcement of the API 7K standard

Lewco W-440-LP and all its core load-bearing components are designed, manufactured and tested in strict compliance with the API 7K Specification of the American Petroleum Institute.

Culture of manufacturing excellence

Our commitment to quality is rooted in a culture of manufacturing excellence. We ISO 9001 quality management system as a framework for the production of each link for strict control. From the selection of high-quality forging raw materials, to the use of advanced CNC machine tools for precision machining, to the implementation of strictly controlled heat treatment process, as well as a comprehensive non-destructive testing (NDT) of key components, we strive for excellence in every detail.

Global support and component interchangeability

A core advantage of the W-440-LP is the high interchangeability of its components. All of our wear parts and most of our major components are designed to be 100% interchangeable with mainstream OEM brand pumps.

This design provides significant logistical and financial advantages to large drilling contractors. When customers have multiple pump types from different manufacturers in their rig teams, they do not need to have a separate set of spare parts for our pumps. This greatly simplifies spare parts inventory management, reduces inventory holding costs, and ensures quick access to required parts on any rig. This seamless integration eliminates the need for customers to worry about purchasing new pumps, making the LEWCO W-440-LP ideal for integration into its existing operations.

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