LEWCO W-446 Pump

Strong frame: the stability guarantee of welded steel structure

The frame at the power end is the base for all internal components, and its rigidity and stability are critical. The frame of the W-446 is welded in high-strength low-alloy steel, not cast. To further enhance the strength of the structure, the frame is designed with a double-wall welded design, supplemented by internal stiffeners and gusset plates, making it an extremely robust independent precision structure. The design can handle extreme discharge pressures up to 7,500 psi, providing a stable platform for the internal components without bending or torsional vibration, thereby significantly reducing internal stress due to rack deformation, extend the life of key components such as bearings and gears.

Crankshaft: the core of one-piece forged alloy steel

Material and technology: we choose the top alloy steel (modified 4340 or 42CrMo) as the substrate. After forging, the crankshaft is also subjected to an advanced heat treatment process, and thanks to the high content of chromium and nickel in the material, it has excellent resistance to corrosion and crack propagation.

Design advantages: the crankshaft is precisely calibrated to minimize vibration and noise during high-speed operation.

Bearings and connecting rods: minimize friction under extreme loads

Bearing Configuration: single row roller bearings for connecting rod big end (crankshaft end) and double row long cylindrical roller bearings for small end (cross end) for different load characteristics. The crankshaft main bearing adopts the heavy load double row self-aligning roller bearing, which can bear the huge radial load and certain axial load at the same time, and can adapt to the tiny deflection of the crankshaft to ensure smooth operation.

Connecting rod: the connecting rod body is made of high-specification rolled steel or low-carbon alloy steel forgings and is designed to ensure perfect alignment between the crankshaft and the crosshead at maximum load, prevent abnormal wear due to deformation of the connecting rod.

Lubrication system: triple redundant component umbrella

The system integrates a variety of lubrication methods to ensure adequate film protection under all operating conditions:

Internal Splash/gravity lubrication: use gear running to agitate oil pools to provide base lubrication for some components.

Main gear driven mechanical pump: this is the main source of forced lubrication, with the pump operation synchronization, as long as the pump in operation, will be able to stably transport the lubricating oil to the key bearings and slide.

External independent electric pump: the pump operates independently of the main driveline as a secondary forced lubrication enclosure. This means that even at very low pump speeds (when mechanical pumps are less efficient) or at the moment of start-up, all key friction pairs are immediately and adequately lubricated.

Forged alloy steel modules: the first line of defense against high pressure

We insist on a monolithic forging process that is far superior to casting to produce these core components. The modules are forged from monolithic high-quality alloy steels (35CrMo, 40CrMnMo or AISI 8620) at high temperature and high pressure.23 after forging, each module is subjected to a rigorous quenching and tempering process (quenching and high temperature tempering) , to obtain the optimum combination of hardness, strength and Toughness12. Our commitment to quality is reflected in every aspect of manufacturing. All modules are manufactured and inspected in strict compliance with API 7K standards, and are inspected by non-destructive testing (NDT-RRB- methods such as ultrasonic testing, magnetic particle or penetrant testing to ensure that each module delivered to you is flawless, there are no microdefects that could be a future point of failure.

Valve Assembly: Precision Seal at 5,000 PSI pressure

Superior material and workmanship: the body and seat are made of advanced forged alloy steel (Aisi 4119,40CRNIMO or 20CrMnTi) . Its core process is deep carburizing heat treatment. By this process, an extremely hard (HRC ≥60) wear-resistant layer is formed on the surface of the part, while the original high-toughness core of the material is maintained inside. The composite structure of outer hard and inner tough makes it perfectly resistant to the high-speed erosion and wear of solid particles in drilling fluid and the huge impact force generated when the valve is opened and closed.

Precision Machining and interchangeability: after heat treatment, we finish the valve body and seat to eliminate any minor deformations that may result from the heat treatment and ensure the accuracy of its geometry. This not only ensures the perfect sealing performance, but also makes our valve assembly with the major brands of the same specification components completely interchangeable, it greatly simplifies the inventory management and procurement process for customers with mixed-brand pump sets.

Cylinder liner options: the core choice for the main wear interface
Option 1: high chromium (bimetal) cylinder liner-high performance standard of choice

Structure and process: the shell is made of high strength forged carbon steel or alloy steel, and the lining is made of high chromium (chromium content not less than 27%) cast iron wear-resistant layer by centrifugal casting process. Centrifugal casting ensures a dense, defect-free lining and a strong metallurgical bond with the housing.
Performance Characteristics: after special heat treatment, the hardness of high chromium lining can reach Rockwell hardness HRC 60-69, with excellent wear resistance and corrosion resistance.
Application suggestion: the high chromium cylinder liner has achieved an excellent balance between cost and performance. Under most drilling conditions, its service life can be more than 800 hours, which is an ideal choice to deal with medium and high strength abrasion conditions.

Option 2: Zirconia ceramic cylinder liners-the ultimate upgrade in ultimate performance

Construction and workmanship: it consists of a forged steel shell and an integral inner sleeve made of advanced zirconia (ZRO3)-based ceramic material.
Performance Characteristics: Zirconia ceramics have unparalleled performance advantages. Its hardness is extremely high (HRC > 90) and its wear resistance far exceeds that of any metal material. More importantly, compared with traditional alumina ceramics, zirconia has excellent phase transformation toughening characteristics, which improves its impact resistance (toughness) by several times and is not easy to shatter. In addition, the surface can be honed to an extremely high finish, greatly reducing friction with the piston.
Application Recommendations: Zirconia ceramic cylinder liner is the only option to achieve the lowest total cost of ownership for high abrasive formation, high solid content drilling fluid, and operations that prioritize running time. Its service life can exceed 4,000 hours, which is several times that of high chromium cylinder liners. This means less downtime for maintenance and lower consumption of spare parts, especially pistons, resulting in significant operational benefits.

Option 3: chrome plated and hardened cylinder liners-an economical and reliable base option

Structure and process: using one-piece forged steel shell, its inner hole surface through induction hardening or hard chromium plating way to form a wear-resistant layer.
Performance characteristics: surface hardness up to HRC 58-62, providing good wear resistance.
Application recommendations: chromium plating or hardened liners are a reliable and economical option for less abrasive drilling environments or where initial procurement costs are a major consideration.

Piston option: sealed power at high pressure

Piston cores: all piston cores are forged from high quality steel, such as 45 # or 40CR, and heat treated to ensure that they do not deform under high pressure.
Piston rubber: we offer a wide range of piston rubbers to match your drilling fluid system and operating temperature:
Urethane piston: especially suitable for oil-based or synthetic mud, its excellent wear resistance, tear resistance and extrusion resistance performance in high pressure conditions.
Nitrile rubber (NBR) pistons: as a versatile and cost-effective option, NBR has good tolerance to a wide range of chemicals and oil-based muds.
Structural design: we offer a variety of designs including integral vulcanized, replaceable rubber, and"Cow nose" lip structure designed to reduce"Splash"(i. e. a small amount of high-pressure liquid leaking from the piston during the return stroke, which can contaminate the cylinder liner flushing system) , to optimize sealing and extend service life.

Table 2: LEWCO W-446 continuous cycle performance data

Note: Data compiled from. Pressure ratings may vary slightly depending on the specific hydraulic end configuration. Displacement is calculated based on 100% volumetric efficiency.

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