WHEATLEY FLG.7036 Mud Pump

Material and construction: the power end frame of Wheatley pump is made of fine grain and one piece cast iron by precision casting. Operation is critical.

Precision Machining: after the frame is cast, it will be precisely bored to ensure the dimensional accuracy and coaxiality of the crankshaft and gear shaft bearing seat, providing a stable and constant reference for the transmission system. This ultimate pursuit of the stability of the basic components is the first step in extending the life of the machine.

Crankshaft and gear train-the heart of power transmission

Crankshaft design and materials: the Wheatley pump uses a unique offset crankshaft design. By slightly shifting the crankshaft centerline, the design can significantly reduce the lateral thrust of the piston on the connecting rod during the work stroke, thereby reducing the friction between the crosshead and the guide plate. The crankshaft itself is made of high-strength cast ductile iron. This material has excellent fatigue cracking resistance and toughness because of its spheroidal graphite distribution, which is ideal for withstanding cyclic stress loads of reciprocating pumps.

Gear set design and material: Power is transmitted through continuous-tooth Sykes herringbone gears. For maximum durability, the main gear is made of heat-treated high grade ductile iron, while the pinion is machined and hardened from forged alloy steel.

Bearings, connecting rods and crossheads-for high loads

Bearing configuration: both crankshaft and gear shafts are supported by heavy duty tapered or spherical roller bearings for optimum load capacity and long life. These high quality bearings ensure smooth and accurate operation of rotating parts under great pressure.

Connecting rod and crosshead: the connecting rod is made of heavy section casting with replaceable babbitt-lined steel shell bushing at the big end and bronze bushing at the small end. This design is not only durable, but also easy to adjust the gasket to compensate for wear and tear, easy to field maintenance. The crosshead is made of high quality cast steel or iron, while the crosshead guide is made of manganese bronze. As an excellent bearing material, manganese bronze is used with cast iron or cast steel to form a sliding interface with extremely low friction coefficient and wear resistance, which effectively reduces heat generation and component wear.

Lubrication system: the entire power end of the use of simple and extremely reliable combination of splash-type and gravity supply lubrication system.

Cylinder block-a strong fortress of pressure

Material and construction: cylinder block is the basis of the hydraulic end, its standard material is high strength ductile iron. Ductile iron was chosen because it not only provides excellent pressure bearing capacity, but also has good machinability and excellent vibration absorption performance, which helps to alleviate the inherent pressure pulsation of the double-acting pump. Other material options such as forged carbon steel are also available for applications that require special corrosion resistance or higher strength. The valve cover and the cylinder cover adopt the sturdy bolt fastening design, which ensures the reliable sealing under high pressure and convenient disassembly and assembly during maintenance.

API 7K compliance: the entire design of the hydraulic end, especially the dimensions and tolerances of the valve chamber, is strictly in accordance with API 7K specifications. This is not only the guarantee of product safety and quality, but also means that its vulnerable parts have good market interchangeability, which provides great convenience for users' spare parts procurement and on-site maintenance.

Excellent wear-resistant components (wearing parts)

Cylinder liner-the first line of defense against wear

The cylinder liner is the inner cavity of the piston reciprocating motion, which is directly subjected to the erosion and wear of the drilling fluid, and is one of the fastest wear parts of the hydraulic end 1. We provide a variety of material options to adapt to different working conditions and budget requirements.

Standard Option: File Hard Steel Liners: Made of high-quality forged Steel with carburized hardened bore and a surface hardness of HRC ≥58-62. These liners provide a reliable and cost-effective solution to standard drilling conditions.

Advanced options: high chromium bimetallic cylinder liner: Structure is composed of two parts: the shell is made of high strength forged steel to withstand the hoop stress; the inner sleeve is made of proprietary high chromium iron alloy by centrifugal casting process. After heat treatment, the hardness of the inner hole can reach HRC ≥62-69, which makes the high chromium alloy have strong abrasive wear resistance and corrosion resistance. Under normal working conditions, its service life can exceed 800 hours. In addition, the"HP lip" design effectively prevents the risk of slippage of the inner casing under high pressure by means of mechanical locking.

Piston and piston rod-strength and toughness in motion

Piston: the piston is the core component that produces pressure. Our piston consists of two parts: the core and the rubber. The piston core is forged from high quality alloy steel such as 42CRMO or 45 # steel to ensure sufficient strength and toughness under high pressure. Piston rubbers are available in a variety of materials depending on the drilling fluid system:

Nitrile rubber (NBR) : suitable for conventional water-based mud, has good wear resistance and cost-effective.

Polyurethane (PU) : under more severe conditions such as oil-based mud, synthetic mud or high temperature and high pressure, polyurethane materials show better wear resistance, oil resistance and tear resistance, which can significantly extend the service life.

Piston rod: the piston rod is a key component connecting the power end and the hydraulic end, and is subjected to tremendous tensile and compressive alternating stresses. We use forged alloy steel as raw material, after strict heat treatment process to optimize its mechanical properties. Subsequently, the surface of the rod body is hard chromium plated and precision ground to form an extremely smooth (roughness Ra ≤0.4) , hard and corrosion-resistant protective layer, which can be used to improve the corrosion resistance of the rod body, this is essential to extend the life of the packing seal and prevent leakage from the hydraulic end to the power end.

Valves and seats-precision seals at extreme pressures

The valve assembly controls the unidirectional flow of drilling fluid, and its performance directly affects the volumetric efficiency of the pump. When the double-acting pump reverses direction at each stroke, the valve assembly will bear a huge pressure impact.

Material and manufacturing process: the standard valve type is wing guide valve, valve body and seat are made of 20CrMnTi and other high-quality alloy steel whole die forging. The forging ensures the compactness of the internal structure of the material and excellent strength. The forged blank is then subjected to complex heat treatment processes such as carburizing and quenching, so that its working surface hardness reaches HRC ≥60, while maintaining good toughness in the core to resist impact load.

Design and performance: this precision manufacturing process ensures a perfect fit between the body and seat for reliable"Bubble Class" sealing even under extremely high pressure and mud wash, effectively prevent reverse leakage, thus ensuring the efficient operation of the pump. For corrosive brine and other media, we can also provide bronze valve assembly to provide better corrosion resistance.

1: Wheatley Fig. 7036 performance data 4

Note: Performance data are based on volumetric efficiencies of 100% and mechanical efficiencies of 85-90% . Actual performance may vary depending on drilling fluid properties and system conditions.

Table 2: Wheatley Fig. 7036 key technical specification 4

Table 3: material options and advantages of perishable parts

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