oil rib mud pump pricelist

The present invention relates generally to valves used in pumps handling abrasive fluids. More specifically, the present invention comprises a plastic valve body design which provides results equal to or greater than steel valves with significantly reduced cost and manufacturing time.

Pumping systems which are used to pump drilling mud and other abrasive fluids generally incorporate positive displacement pistons or plungers which operate in a reciprocating manner in individual cylinders. Each piston or plunger cylinder has a suction and discharge valve and valve seat operating alternatingly and independently to control flow into and out of each cylinder. The valve typically comprises a disc-shaped body portion which includes an elastomeric valve insert which serves to seal the valve when in the closed position and also serves to cushion the impact of the valve body in the valve seat. The lower conical seating surface of the valve body also makes contact with the valve seat when the valve is in the closed position.

Early prior art valve assembly designs included a steel valve body and steel valve seat that were both heat treated to increase wear resistance. However, heat treating usually caused warpage in the sealing surface, and thus a rubber insert was typically used to help seal between irregular warped steel valve bodies and the valve seat surfaces. The rubber insert also helped to seal around solid particles in the mud that were trapped between the valve seat. These valves provided acceptable performance at low pressures, but the rubber insert failed frequently due to extrusion and abrasion damage. The insert generally required replacement up to 10 times over the life of the steel valve body and steel valve seat.

Later, circa 1965, a new valve assembly design referred to as the TRW Mission Design was introduced. This design incorporated a 4-web carburized valve seat that became an industry standard. The design also incorporated an elastomer insert on the valve body. The elastomer insert was manufactured from a polyurethane material having a 90-shore A durometer hardness, a high strength modulus, and excellent abrasion and extrusion resistance compared to prior rubber inserts. Use of polyurethane inserts raised the effective valve pressure rating of the valve assembly. These valve assemblies required less frequent changing of inserts, and the 90-shore A durometer hardness also became an industry standard. The few disadvantages to these polyurethane inserts were that the hard 90-shore A material had a very low resilience, provided poor sealability in worn valve seats and/or unprimed pumps, and had less abrasion resistance compared to softer polyurethanes. An example of a metal valve body having an elastomeric seal is described in U.S. Pat. No. 4,860,995 to Rogers.

Pumping systems which are used to pump abrasive fluids undergo tremendous pressure and valve bodies and seats therefore suffer impact and stress high wear. One of the most significant points of impact stress in the valve assembly is the point of contact of the valve body and the valve seat when the valve is in the fully closed position. The extremely high differential pressures in the valve cause the valve body to engage the valve seat with a very high impact. The repetitive impact eventually causes the valve body to become worn and fatigued, necessitating its replacement. Because of high pump pressures (between 1000 and 5000 psi) and the abrasive solid particles suspended in the drilling mud, prior art valve bodies and valve seats were required to be constructed of steel that was both heat treated and carburized to increase durability.

Although various types of plastic materials have been available for years or even decades, the industry has generally taught against the use of plastic valve bodies in high pressure applications because of the assumption that plastic lacked the strength and durability at these pressures. The few attempts to design a plastic valve for high pressure applications have failed. For example, U.S. Pat. No. 5,062,452 to Johnson discloses a valve member comprising a lower support portion and an upper seal portion. The support portion is made of a relatively rigid plastic, a hard cast polyurethane, and the seal portion is made of a relatively soft plastic, a softer grade of polyurethane. The Johnson patent mentions both oil well and water well applications for this valve. However, testing has proven that this valve is unusable in oil well applications.

One problem in using urethane as taught in Johnson is that these plastics generally lack rigidity. Further, these plastics are temperature sensitive and lose what rigidity they have very quickly as temperature increases. As a result, the valves described in the Johnson patent fail at high pressures, and thus can only be used in very low pressure applications. In addition, Johnson teaches that the valve member is made of cast urethane using an open molded process. This process is very labor and time intensive and thus considerably increases the cost of the assembly.

The present invention comprises a plastic valve body design and construction which has strength and durability similar to that of steel valve bodies but with significantly reduced manufacturing time and cost. The valve body design of the present invention comprises a unique and unobvious combination of a previously unused plastic material in this application and a complex rib design that results in performance similar to that of steel valves.

The ability of the plastic material to deflect and plastically deform results in reduced impact stress and wear. This ability to deform to the mating valve seat essentially eliminates extrusion gaps and allows use of more desirable softer polyurethane inserts, which is not possible with steel valve bodies. The rib design of the present invention provides a high sectional modulus and moment of inertia for overall design stiffness and strength. Both materials are injection moldable, which allow short manufacturing time cycles and low cost. Thus, the plastic valve design of the present invention provides results similar to that of steel valves but with considerably less manufacturing time and cost.

FIG. 1 is a perspective view of a mud pump valve assembly comprised of a valve body 22 according to the present invention and a valve seat 24 as shown. FIG. 2 illustrates the valve body 22 by itself. For purposes of simplicity, the valve body 22 in FIG. 1 is discussed, with discussion applying equally well to the valve body in FIG. 2.

Referring to FIG. 1, the valve assembly is shown in the full open position. The valve body 22 is preferably comprised either of a plastic nylon/Kevlar.RTM. composite material or of Delrin.RTM. and includes a complex rib design according to the present invention. The valve seat 24 is preferably comprised of carburized steel.

The valve body 22 comprises an upper valve guide 26 which maintains proper registration of the valve body 22 within the pump housing (not shown). A lower valve guide 28 serves to maintain proper alignment of the valve body 22 with respect to the valve seat 24. The valve body 22 is generally disc-shaped and includes a complex rib design comprised of a plurality of ribbed members 32 according to the present invention. This rib design is discussed further below. The outer portion of the disc-shaped valve body 22 has a generally C-shaped cross-section with an annular groove 38 being defined by interior 33 of the C-shaped portion. A plurality of second ribbed members 34 connect interior 33 of the C-shaped portion to the upper and lower valve guides 26 and 28.

Even though many types of plastic materials have been around for years or even decades, including the materials referenced above, plastic has not been used in valves designed for high pressure applications. Those in the industry have generally believed that a plastic valve assembly would lack sufficient strength in drilling mud pump applications. In fact, Applicant encountered difficulty in attempting to test this valve because many oilfield drilling contractors in the industry would not believe that a plastic valve could withstand such pressures. Therefore, the art has generally taught away from the use of plastic materials for valves in drilling mud pump and other high pressure applications.

The valve body 22 of the present invention is designed using a plastic material to reduce cost and manufacturing lead time. The valve body 22 is manufactured using an injection molded process, which accomplishes the above goals. One drawback to injection molding is that it tends to limit the maximum cross-section of thickness and strength of the valve body 22. However, this limitation was overcome by a novel rib design according to the present invention which reduces localized thickness and reduces the material cost. The rib design increases the sectional modulus and stiffness of the valve body 22 and provides increased strength and durability to the valve body 22 that rivals or surpasses that of steel valves.

In general, wear in the bearing surface of a valve is directly proportional to the impact stress on the bearing area of the valve. Impact stress ".sigma.," which is reduced by the increased flexibility of the design of the present invention, is calculated using the follow formula: ##EQU1## where: .sigma..sub.s =stress resulting when the seat bearing load, due to pump pressure forcing the valve against the seat, is applied statically;

Because of the non-axisymetrical seat bearing loads and the ribbed design of the present invention, complex computer finite element analysis is necessary to determine the values of ".sigma..sub.s " and "y." Utilizing computer finite element stress analysis it has been calculated that "y" is increased by a factor of 11 to 1 for this design manufactured with an injection molded plastic material; furthermore, ".sigma..sub.s " is reduced by 50% in the localized areas of impact. Additionally "h" is reduced 50% in the present invention. A lower value of "h" is acceptable for this design because the plastic material deforms to mate with the irregular seat surface, which is comprised of steel and generally is warped by carburization. As a consequence, less insert interference is necessary to assure proper sealability of the valve insert; thus "h" is similarly reduced. Utilizing the above calculated values, impact stress ".sigma.+ is calculated to be reduced by up to 90% for this design.

Despite this reduction, at higher pump pressures the impact stress on the valve of this invention still exceeds the tensile strength of the nylon/Kevlar.RTM. (aramid) composite material. However, after break-in of the valve in initial pump service, the nylon particles on the surface of the valve are either worn away or compacted into the remaining material. A high concentration of the Kevlar fibers are then exposed to impact from the seat bearing loads. Because Kevlar has a very high tensile strength, greater than steel, the wear slows significantly after the initial break-in period. This hypothesis has been verified by field tests of the design.

Thus, this plastic valve design is a unique combination of a complex rib design with a plastic material that results in unexpected performance. The plastic material of the present invention allows large deflection under load, particularly in the material immediately adjacent to the impact bearing area with the valve seat 24. The ability of the plastic material to deflect and plastically deform results in reduced impact stress and wear. This ability to deform to the mating valve seat essentially eliminates extrusion gaps and thus allows use of softer polyurethane inserts. In addition, the deflection of the plastic material is most significant in the localized area of impact. Further, the novel rib design of the present invention results in high sectional modulus and moment of inertia for overall design stiffness and strength.

Therefore, the plastic valve composition and complex rib design of the present invention provide a valve body with a strength and durability equal to or greater than that of steel valve bodies with considerably reduced manufacturing time and manufacturing cost. Also, this design allows use of softer polyurethane inserts which add improved sealability, resilience, and abrasion resistance.

Although the method and apparatus of the present invention has been described in connection with the preferred embodiment, it is not intended to be limited to the specific form set forth herein, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents, as can be reasonably included within the spirit and scope of the invention as defined by the appended claims.

Wedge-Band is the banded version of the hard-working Super Power-Wedge v-belt. Wedge-Band is an excellent choice for virtually any application where increased horsepower capacity and output is needed, or where conventional multiple belt drives are impractical because of space or weight limitations. The specially compounded wrapped construction is ideal for clutching operations. Banded v-belts are ideally suited for pulsating or heavily shock loaded drives and drives with extremely long center distances. Wedge-Band is oil and heat resistant, static dissipating, and it won’t turn over or jump off the drive.

Tie-band is highly engineered to permanently bond multiple belts together enabling the belts to function as a single unit with even load distribution and wear

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WX(R) & WXA(R) hard metal/rubber heavy duty slurry pumps are designed for the most difficult pumping applications for highly abrasive , high density or corrosive slurries. Extra thick sections at the critical wear points and superior Impeller structure ensures improved performance with extended wear and minimised maintenance, thus improving cost of ownership.

Rubber lined pumps expand applications to chemical products handling, several different rubber options are available to meet different application requirements.Best fitted in aggressive applications, like mill discharge and tailing transfer

WXA( R ) pumps are improved version of WX(R) pumps, in that it has an adjustable wear plate seated in at the Throatbush. This can be adjusted while the pump is running.

Usage of versatile wear-resistant and corrosion-resistant materials allows WX(R)/ WXA( R ) series slurry pumps to service in various industries, such as mining mill discharge, delivery of tailings, ash removal in power plant， FGD and coal washing in coal plant, etc.，resulting in low operating cost, as well as minimized maintenance and down time.