CN101122993A - Pumping unit inspection maintenance and fee determination method - Google Patents
Pumping unit inspection maintenance and fee determination method Download PDFInfo
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- CN101122993A CN101122993A CNA2007101128303A CN200710112830A CN101122993A CN 101122993 A CN101122993 A CN 101122993A CN A2007101128303 A CNA2007101128303 A CN A2007101128303A CN 200710112830 A CN200710112830 A CN 200710112830A CN 101122993 A CN101122993 A CN 101122993A
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Abstract
The invention relates to a repair, inspection and cost estimation method for oil pumping units among producing facilities and devices of oil and gas fields. The invention mainly comprises following steps: (1) maintaining and inspecting the oil pumping unit in a fixed period; (2) evaluating quality of inspecting results in accordance with relevant oil pumping unit quality standards, and carrying out repair works in accordance with oil pumping unit quality evaluation results; (3) estimating repair cost in accordance with contents of inspecting and repair works, and the estimated cost is a reference and standard of oil pumping unit maintenance cost investment; and (4) testing and accepting repair results, checking whether the repair quality meets the quality requirements of oil pumping unit and whether the unit can be put into normal use. Beneficial effects of the invention are: through timely maintenance, small repair, intermediate repair and large repair of an oil pumping unit, eliminating fault risks of the unit, the possibility of accidents is decreased, service life of the unit is prolonged, operation effects and profits of the unit is increased, and the negative influence and the environment pollution to production of an enterprise are prohibited, which is caused by accidents of the oil pumping unit.
Description
1. The technical field is as follows:
the invention relates to a method for inspecting and maintaining production facilities and equipment of an oil and gas field, in particular to a method for inspecting and maintaining pumping units and measuring and calculating expenses.
2. Background art:
oil and gas field production facilities and equipment are the basis of oil and gas field production, and like any factory, the facilities and equipment also go through the whole process from construction to production to gradual abrasion, corrosion, damage to scrapping. In the life cycle of facilities and equipment, the maintenance and the updating also follow certain rules like other industries. Due to the complexity and the particularity of facilities and equipment of oil field enterprises, systematic summary research on the maintenance and updating rules of oil and gas field production facilities and equipment has not been carried out for years inside and outside the industry, the maintenance and updating specifications of the oil and gas field production facilities and the equipment are in a missing state for a long time, and the ageing of the oil and gas field facilities and the equipment is serious due to untimely maintenance and updating of the production facilities and the equipment, so that the production and operation of the oil and gas field are seriously influenced.
At present, oil and gas fields are maintained after the oil pumping machine is used, namely, the oil pumping machine is not damaged or maintained, the oil pumping machine is lack of planning and normalization in maintenance, and the maintenance method and the cost measurement are in a missing state for a long time.
3. The invention content is as follows:
the invention aims to provide a method for detecting, maintaining and measuring the cost of pumping units, aiming at the defects in the prior art, and solving the problems that the oil-gas field facilities and equipment are seriously aged and the production and operation of the oil-gas field are seriously influenced due to the lack of standards of normalization and planning of the pumping units and the lack of standards of detection and maintenance cost.
The technical scheme is that the oil pumping unit inspection and maintenance mainly comprises the following steps:
(1) Maintaining and detecting the oil pumping unit in a fixed period;
(2) The quality of the detection result is evaluated according to the quality standard of the related pumping unit, and corresponding maintenance is carried out according to the quality evaluation result of the pumping unit;
(3) Estimating the overhaul cost according to the detection and maintenance contents, wherein the overhaul cost estimation can provide reference and standard for the investment of the overhaul cost of the pumping unit and solve the problem of insufficient investment or excessive investment;
(4) And (4) testing and accepting the maintenance result, and checking whether the maintenance quality meets the quality requirement of the oil pumping unit and whether the oil pumping unit can be put into normal use.
The detailed scheme is as follows: the detection and maintenance contents of the oil pumping unit comprise minor repair, middle repair and major repair, the maintenance contents are that according to the contents specified by the regular maintenance of the oil pumping unit or problems found in daily spot inspection and regular inspection, relevant parts are disassembled to carry out inspection, adjustment, repair or replacement on invalid parts, the oil pumping unit or an assembly is partially disassembled, and the assembly is identified, maintained or replaced, main parts and standard parts are repaired or replaced, so that the normal function of the oil pumping unit is restored.
The method for measuring and calculating the maintenance cost of the pumping unit comprises the following steps:
the maintenance cost is composed of the cost of maintenance, minor repair, intermediate repair and major repair of the oil pumping unit.
(1) Maintenance cost for single pumping unit in prediction period
The maintenance cost of the predicted time period can be calculated according to the single cost of major and minor maintenance of the pumping units of different types and the annual occurrence frequency, as shown in formula 2.
C i ＝Q Big (a) ×F Big (a) +Q In (1) ×F In +Q Small ×F Small +Q Maintenance ×F Maintenance (formula 1)
In the formula:
C i annual maintenance cost for a single pumping unit;
F big (a) 、F In 、F Small 、F Maintenance Respectively the single large, medium and small repair and maintenance costs of each type of single pumping unit;
Q big (a) 、Q In (1) 、Q Small 、Q Maintenance Respectively the times of major repair, minor repair and maintenance in the year.
i is the age (i =1, 2.., 18).
(2) Measuring and calculating total maintenance cost of pumping unit
After the service life distribution data of various pumping units in different management ranges are mastered, the maintenance cost of all the pumping units in different management ranges in the measured year can be calculated according to the rule of the cost of a single pumping unit. The management range can be a reservoir operation management area, an oil production plant, a branch company, a medium petrochemical industry and the like.
The formula for measuring and calculating the maintenance cost of a certain type of pumping unit in a certain management area is as follows:
In the formula:
b is the maintenance cost of the oil pumping unit which is calculated and taken year by year;
C i measuring and calculating annual inspection and maintenance cost for a certain oil pumping unit;
i =1, 2., n, for pumping unit number
A formula for measuring and calculating the maintenance cost of all pumping units in a certain oil reservoir management area:
(formula 3)
In the formula:
a is the maintenance cost of all types of pumping units in different management ranges for predicting annual occurrence;
B i the maintenance cost of the pumping units in different management ranges for predicting annual occurrence is calculated;
i =1,2, n, which is the pumping unit category.
The pumping unit is a beam pumping unit or a belt pumping unit commonly used for oil-gas field development.
Preferably, the maintenance period is 1 month, the minor repair period is 3 months, the medium repair period is 1 year, and the major repair period is 5 years.
The invention has the beneficial effects that: the oil pumping machine is periodically maintained, repaired for a short time, repaired for a medium time and repaired for a long time, so that the fault hidden danger of the oil pumping machine is eliminated, the accident is reduced, the service life of the oil pumping machine is prolonged, the operation effect and the benefit of the oil pumping machine are improved, and the adverse effect and the environmental pollution of the enterprise production caused by the accident of the oil pumping machine are avoided.
The problem that the oil pumping unit is lack of planning and normalization in maintenance of the oil and gas field is solved by periodically implementing inspection and maintenance; the expense measurement solves the problem of standard loss of expense investment of the oil pumping unit in the oil and gas field, and provides guidance for reasonable inspection and maintenance expense investment.
4. The specific implementation mode is as follows:
the embodiment is as follows:
taking conventional beam-pumping units and belt-type pumping units in oil-gas fields as examples, the method for maintenance and expense measurement is described in detail:
1 inspection and maintenance content and period
1.1 conventional beam-pumping unit
1.1.1 minor repair
1.1.1.1 minor repair cycle: 3 months old
1.1.1.2 minor repair content: according to the content specified by the regular maintenance of the pumping unit or the problems found in daily spot inspection and regular inspection, relevant parts are disassembled to carry out inspection, adjustment, repair or replacement on the failed parts so as to restore the normal function of the pumping unit. The working contents are completed by the oil well team and the maintenance team of the oil recovery team on site.
1.1.2 Middling repair
1.1.2.1 repair cycle: 1 year
1.1.2.2 medium amendments: the method comprises the steps of minor repair, partial disassembly of the oil pumping unit or assembly, identification, maintenance or replacement of the assembly, repair or replacement of main parts and standard parts, maintenance, leakage stoppage, oil change and the like of a reduction gearbox, matching of safety protection facilities and corrosion prevention operation on severe corrosion. The repair work content is mainly completed by an oil production team maintenance team or a professional maintenance team on site.
1.1.3 major repair
The method is to carry out recovery planned repair on the whole pumping unit or assembly, and during repair, most or all of the pumping unit or assembly should be disassembled, a reference part should be repaired, all worn parts should be repaired or replaced, faults and defects should be eliminated, and external spray painting should be carried out to recover the specified precision, performance and appearance of the pumping unit or assembly. Maintenance work done at the repair shop by a professional maintenance team with maintenance qualifications.
1.2 belt oil pumping unit
1.2.1 minor repair
1.2.1.1 minor repair cycle: 3 months old
1.2.1.2 minor modifications: according to the content of the regular maintenance and repair of the pumping unit or the problems found in the routine spot inspection and regular inspection, relevant parts are disassembled to carry out inspection, adjustment, repair or replacement of the failed parts so as to recover the normal function of the pumping unit. The working contents are completed by the oil production team group and the oil production team maintenance team together on site.
1.2.2 Middling repair
1.2.2.1 middle repair term: 1 year
1.2.2.2 medium amendments: except minor repair, the oil pumping unit or assembly is partially disassembled, the assembly is identified, maintained or replaced, main parts and reference parts are repaired or replaced, a reduction gearbox is maintained, leaking stoppage, oil changing and the like, the chain case is changed with oil, safety protection facilities are matched, and corrosion prevention operation is carried out on severe corrosion. The repair work content is mainly completed on site by an oil extraction team maintenance team or a professional maintenance team.
1.2.3 overhaul
The method is to carry out recovery planned repair on the whole pumping unit or assembly, and during repair, most or all of the pumping unit or assembly should be disassembled, a reference part should be repaired, all worn parts should be repaired or replaced, faults and defects should be eliminated, and external painting should be carried out to recover the specified precision, performance and appearance of the pumping unit or assembly. Maintenance work done at a repair shop by a professional maintenance team with maintenance qualifications.
2. Inspection and evaluation
2.1 preparation before inspection
2.1.1 the maintainer must be skilled in mastering the structure, performance, principle and use of the pumping unit equipment and safety protection measures.
2.1.2 the internal maintenance personnel must have the certificate of job going on duty or the operation certificate of the oil pumping unit, and the outsourcing repair unit must maintain the quality complete, and maintain, detection equipment complete, personnel quality is too hard.
2.1.3 necessary drawings, technical data and the like are prepared.
2.1.4 overhaul the pumping unit, when the pumping unit enters the factory, the inspector realizes the condition and the overhaul workload of the pumping unit and compiles an overhaul schedule and a scheme.
2.1.5 prepare for service equipment, tools, materials and labor insurance products.
2.2 minor repair
2.2.1 conventional beam-pumping unit
2.2.1.1 repair the reduction box; 2.2.1.2 repairing the brake system; 2.2.1.3 minor repair of bearings of all parts; minor repair of 2.2.1.4 Motor
2.2.1.5 minor repair of other parts;
2.2.2 Belt-type Pumping Unit
2.2.2.1 repair the reduction box; 2.2.2.2 repairing the brake system; 2.2.2.3 roller repair; 2.2.2.4 minor repair of the upper and lower chain wheels and the chain; 2.2.2.5 to-and-fro frame and balance box minor repair; 2.2.2.6 minor repair of the motor; 2.2.2.7 minor repair of the load belt; 2.2.2.8 minor modifications of other parts
2.3 middle repair
2.3.1 conventional beam-pumping unit
2.3.1.1 includes all the contents of minor repair;
2.3.1.2 reduction gearbox center repair
2.3.1.2.1, opening a visual hole cover plate of the reduction gearbox, checking whether the gear contacts with spots and is damaged by scratches, pitting corrosion or cracks, measuring the abrasion condition of the tooth surface, and measuring whether the gear backlash exceeds the standard or not; when the standard of the major repair of 9.2.2.5.3.1 in the standard SY/T5044-2003 is reached, the major repair is applied to a repair factory, and if the major repair is not reached, the cleaning is carried out to check whether the oil scraping tongue can scrape oil normally;
2.3.1.2.2, opening a bearing end cover of the reduction gearbox, checking the abrasion condition of a bearing, replacing the input shaft head seal and the output shaft head seal of the reduction gearbox, and simultaneously plugging oil leakage of a middle joint (box closing surface) and a middle shaft end cover of the reduction gearbox;
2.3.1.2.3, after the reduction gearbox is thoroughly cleaned by using a special lubricating vehicle of the oil pumping unit, replacing new lubricating oil;
2.3.1.2.4 plugging the oil leakage of the reduction gearbox and replacing a sealing element;
2.3.1.3 brake center repair
2.3.1.3.1, disassembling the brake system, and replacing a brake pad, a brake spring or a brake assembly;
2.3.1.3.2 disassembling the brake wheel, checking the aperture and the key slot of the brake wheel, and replacing the brake wheel when the roundness or cylindricity of the aperture is more than half of the diameter tolerance, the key slot is damaged and the surface has cracks;
2.3.1.3.3, correcting the brake link mechanism, and timely replacing the brake link mechanism with serious deformation;
2.3.1.4 intermediate repair of Beam Assembly
2.3.1.4.1, checking whether the horse head fixing is reliable or not, and whether the fixing pin is rusted or not, or else, replacing the horse head fixing pin;
2.3.1.4.2, checking whether the horse head positioning pin is reliable, if the spring fails or is loosened, replacing the horse head positioning pin in time, and if the problem of large fit clearance caused by abrasion occurs, returning to a factory for maintenance in time;
2.3.1.4.3 matching pedals at two sides of the walking beam with a safety belt hook;
2.3.1.4.4, detaching the middle bearing slip, checking whether the slip is firmly combined with the shaft or not, and timely replacing the slip if the slip is failed; opening a bearing end cover, and repairing or replacing the assembly according to the abrasion or damage degree of the bearing;
2.3.1.4.5, opening the end cover of the tail bearing, and repairing or replacing the assembly according to the abrasion or damage degree of the bearing;
2.3.1.4.6, checking whether the connecting rod is deformed or not and whether the connecting rod pin is reliable or not, and otherwise, replacing the connecting rod or the connecting rod pin;
2.3.1.5 Chassis, support middle repair
2.3.1.5.1, punching reinforcing ribs on the parts with cracks and welding;
2.3.1.5.2 reinforcing or replacing unreliable pressing bars and pressing bar screws;
2.3.1.5.3 repairing deformed or lost metal pieces such as ladders, wales and the like;
2.3.1.5.4, checking each fixing bolt of the chassis and the bracket, and timely replacing the fixing bolts with serious corrosion;
2.3.1.6 Motor center repair
2.3.1.6.1, opening end covers of front and rear bearings of the motor, cleaning dust and dirt in the motor, and replacing the front and rear bearings of the motor;
2.3.1.6.2 inspecting the wiring terminal and the lead of the motor, and timely replacing the wiring terminal and the lead with aging or coking phenomena;
2.3.1.6.3, checking whether the motor belt pulley has serious abrasion, cracks and other phenomena, and if the motor belt pulley has replacement;
2.3.1.6.4, checking whether the fan wheel of the motor has a damage phenomenon or not, and if so, replacing the fan wheel;
2.3.1.6.5 detecting the insulation resistance of the motor, wherein the insulation resistance value is not higher than 5 omega,
2.3.1.7 repair in other parts
2.3.1.7.1 modifying or repairing safety protection facilities such as crawling ladders, safety shields, guardrails and the like;
2.3.1.7.2, repairing, welding and correcting the damaged, broken and bent connecting steel skeleton;
2.3.1.7.3 fastening balance block screws and locking blocks, and adjusting the balance of the oil pumping unit to be more than 85%;
2.3.1.7.4, inspecting the rope hanger and the hair braid rope, and if corrosion, wire breakage and strand scattering phenomena are found, maintaining or replacing the new hair braid rope in time;
2.3.1.8 complete machine paint spraying for oil pumping unit with serious corrosion
2.3.1.8.1, degreasing the greasy dirt part of the oil pumping unit, and gasoline or light oil can not be used for ensuring safety during degreasing;
2.3.1.8.2 removing old paint and iron rust from the oil pumping unit;
2.3.1.8.3 after the oil and rust removal, spraying the antirust paint twice and spraying the finish paint twice.
2.3.2 Belt-type Pumping Unit
2.3.2.1 Included in minor repair
2.3.2.2 reduction gearbox center repair
2.3.2.2.1 opening a visual hole cover plate of the reduction gearbox, checking whether the gear contacts with spots or not, detecting whether damage phenomena such as scratch, pitting corrosion or crack exist, measuring the abrasion condition of the tooth surface, turning the abraded gear, and carrying out major repair in a repair shop if the abraded gear is serious;
2.3.2.2.2, opening a bearing end cover of the reduction gearbox, checking the abrasion condition of a bearing, replacing the input and output shaft head sealing of the reduction gearbox, and simultaneously plugging oil leakage of a middle seam (box closing surface) and a middle shaft end cover of the reduction gearbox;
2.3.2.2.3, after the reduction gearbox is thoroughly cleaned by using a special lubricating vehicle of the oil pumping unit, new lubricating oil is replaced;
2.3.2.3 intermediate repair of the brake device; 2.3.2.4 middle repair of upper and lower chain wheels and chains; 2.3.2.5 roller middle repair; 2.3.2.6 to-and-fro frame and balance box middle repair; 2.2.2.6 intermediate repair of the motor; 2.3.2.7 middle repair of the load belt; 2.3.2.8 minor repair of other parts; 2.3.2.9 Anticorrosive paint spraying for severely rusted oil pumping unit
2.4 overhaul
4.4.1 conventional beam-pumping unit
2.4.1.1 reduction gearbox overhaul
2.4.1.1.1 reduction box overhaul conditions: the reduction gearbox has serious oil leakage, impact, shaft movement and abnormal sound, and after the gearbox is opened, the three-shaft (driving, middle and driven) gear and the bearing are obviously abraded or damaged, so that the normal production requirement cannot be met.
2.4.1.1.2 reduction gearbox overhaul content
a) Repairing or replacing the driving shaft, the driven shaft and the intermediate shaft;
b) Repairing or replacing the driving gear and the driven gear;
c) Cleaning and checking the box body, the oil bottom, the oil duct and repairing the oil scraping box;
d) Replacing the three-shaft bearing, the oil baffle disc, the oil thrower disc and the sealing piece;
e) Replacing the cover plates and screws of all the parts;
f) And (3) removing oil, removing rust and spraying paint integrally.
2.4.1.1.3 reduction gearbox disintegration
2.4.1.1.3.1, disassembling the crank, namely disassembling the clamping bolt when the crank is disassembled, and then disassembling the crank by using a crank disassembling and assembling machine; if the dismounting machine without crank is used, the dovetail slot of crank can be spread by low hydraulic jack or oblique iron until the dovetail slot appears at the position of the large shaft and the crank shaft hole
A gap of 0.2-0.5mm, and the force is not too large.
2.4.1.1.3.2 the small end of the connector of the key puller is screwed into the internal thread of the crank key, and the limit is not less than 5 buttons. Lifting the key puller to screw the end with the internal thread into the large end of the key pulling joint, and then at least 3 persons cooperatively pull the sliding hammer of the key puller to impact the tail end until the crank key is pulled out.
2.4.1.1.3.3 the lifting hole at the tail end of the crank is lifted by a travelling crane to swing up and down, the swing angle is about 30 ℃, and simultaneously, an operator forcibly pushes the crank outwards to detach the crank. Note that the person's standing position should clear the direction in which the crank is exiting.
2.4.1.1.4 reduction box unpacking: and (4) detaching all the side cover bolts and the side covers, and detaching all the box body tightening bolts of the reduction box. Carefully put down the locating pins at both ends of the box body, then slowly lift the upper shell piece by a crane, hold the upper shell piece by hands at both sides without damaging the shell combination surface, and hang the upper shell body at a specified position. The small, medium and large three shafts are sequentially lifted out and placed on a wood base plate, and the placing environment must be clean and cannot be placed on a hard ground.
2.4.1.1.5 cleaning of the housing: and (3) cleaning residual lubricating oil in the shell, wiping the shell clean, cleaning each inlet oil channel and each oil return channel, cleaning oil sludge at the bottom of the oil scraping box, slightly scraping residual sealing glue at the upper shell, the lower shell and each side cover, and cleaning the shell without damaging the surface. After the shell is cleaned, the inner wall is coated with iron red antirust paint.
2.4.1.1.6 overhauling of gears and shafts:
a) The inspection gear is one of the following cases and should be replaced. a. The gear has cracks, the gear teeth and the tooth roots have cracks, the tooth surfaces have gluing and obvious stepped grinding marks, metal is peeled off, and the like. C. 80% of the gear has a pitting area exceeding 50%. d. The maximum abrasion loss of the fixed chord tooth thickness exceeds the specification of a standard SY/T5044-2003 table 21;
b) Checking whether the fit of the shaft-tooth key connection part of the middle tooth assembly and the large tooth assembly is loosened, and repairing if the fit is loosened. When the wear of the gear reference hole causes the roundness and cylindricity to exceed half of the diameter tolerance, the gear reference hole can be repaired by methods of enlarging the shaft diameter or boring, and the matching of the repaired hole and the repaired shaft is consistent with the original matching.
c) And (5) checking whether the small shaft end and the large shaft end are worn or not, and replacing when the wear exceeds a specified tolerance by half. The shaft can be repaired by metal spraying, electric welding and then turning or other methods; the shaft keyway is damaged and re-keying is required.
d) When the gear reference key slot is damaged, the original key slot is allowed to be re-opened at a position which is 90 degrees or 120 degrees away from the original key slot; when the key slots on the shaft are damaged, the original key slots are allowed to be re-opened at the positions separated by 90 degrees or 120 degrees.
e) And a new shaft or gear is required to be replaced when the shaft or gear is seriously damaged, and the new shaft or gear meets the requirements of the original machine drawing.
2.4.1.1.7 overhauling or replacing the bearing: checking whether the bearing roller and the inner and outer rings have pitting corrosion and steps, then checking whether the side clearance of the bearing exceeds the specification by using a feeler gauge, if so, replacing the bearing, and when replacing the bearing, applying the model specified by the original design and not replacing the bearing with the bearings of other models; the inner and outer diameters of the bearing can be repaired by brush plating or other methods which do not influence the precision of the bearing.
2.4.1.1.8 repair welding of the box body: when the box body has cracks and seeps oil, the repair welding can be carried out by adopting a cast iron welding rod after heating, and the box body needs to be slowly cooled by a slow cooling method after the repair welding, so that the cracks caused by too fast cooling are prevented; and patching can be carried out by adopting a patching method.
2.4.1.1.9 assembly of reduction box:
2.4.1.1.9.1, hanging the assembled shaft tooth assemblies into the lower shell in sequence, determining the large tooth at the middle position, and adjusting the clearance between the oil scraping tongue and the side surface of the left-hand gear and the right-hand gear of the middle shaft to be within 0.5 mm. The gear is driven by a hand disk, so that the operation is stable without resistance blocking.
2.4.1.1.9.2 coating the sealant on the upper and lower joint surfaces, and surrounding the shell for a circle without a leakage part, wherein the sealant can not be coated too much, and the adhesive tape is preferably 5 mm. The upper shell is stably hoisted, aligned with the lower shell and falls down, positioning pins at two ends are installed, fastening box body bolts are installed, and the bolts need to be fastened diagonally during fastening so that the shell joint surface is in uniform contact.
2.4.1.1.9.3 box and case lid mould assembling back, the screw hole should be adjusted well, and when box length was less than 1200mm, the mutual dislocation volume should be no more than 2mm, and when box length was more than or equal to 1200mm, the mutual dislocation volume should be no more than 3mm. After the box body and the box cover are combined, when the total center distance is not more than 650mm, a filler gauge of 0.1mm is used; when the total center distance is larger than 650mm, the contact tightness of the split surfaces is checked by a 0.2mm feeler gauge, and the depth of the feeler gauge inserted in the split surfaces is not larger than one third of the width of the split surfaces.
2.4.1.1.9.4 side cover Assembly: the large shaft side cover is assembled firstly, the bearing is tested or pressed firstly to determine the thickness of the asbestos pad, if the large shaft bearing is a double-row self-aligning bearing, a reserved gap of 0.5mm is reserved between the pressed end cover and the outer ring of the bearing, and if the large shaft bearing is a single-row thrust bearing, the reserved interference of-0.5 mm is reserved in the gap. After the large shaft edge cover is assembled, the coiling gear rotates stably, and then the middle shaft end cover and the small shaft end cover are assembled.
2.4.1.1.9.5 the crank assembly is reversed in the disassembly sequence, and the assembly is recommended to use another spare key slot on the shaft, because the service life of the gear can be prolonged.
2.4.1.1.9.6 Assembly of crank key: the proper thickness of the crank key is determined according to the total height of the crank key groove and the crank key groove, so that after the crank key is assembled, each square centimeter of upper and lower contact surfaces of the crank key groove is provided with a contact point, the contact surface is up to more than 70%, the crank scissors difference is checked, the crank scissors difference is in a specified range of a standard SY/T5044-2003 beam pumping unit 5.17, and if the crank scissors difference is out of tolerance, the crank scissors difference is adjusted by processing a step key.
2.4.1.1.10 acceptance of reduction box:
a) Each technical parameter should meet the requirements of standard SY/T5044-2003 'Beam Pumping machine' 9.2.2.4 and 9.2.2.5;
b) The requirements of a standard SY/T5044-2003 'beam pumping unit' 9.3.1 are met;
c) After the box body is subjected to repair welding, tools such as a magnifying glass, a ruler and the like are used for carrying out weld joint inspection, and a leakage test is carried out;
d) After the heavy repair of the reduction gearbox, the running test is carried out, and the running and the test are carried out according to the regulation of a standard SY/T5044-2003 'beam pumping unit' 9.4.1.
e) The reduction gearbox after overhaul can not have oil leakage phenomenon, and if the box body has serious cracks, the box body needs to be replaced.
f) The precision and technical standard of the reduction gearbox need to be recovered after overhaul.
2.4.1.2 major repair of Beam
2.4.1.2.1 Beam Overhaul conditions
a) The bending degree or torsion degree of the walking beam exceeds; b) Fatigue deformation of the horse head or tearing of the steel plate; c) The middle bearing or the tail bearing is seriously damaged by 2.4.1.2.2 beam overhaul contents; a) Correcting or replacing the connecting rod and replacing the connecting rod pin; b) Repairing or replacing mid-tail bearing assembly
c) Replacing and preparing the braided rope; d) Replacing the horse head positioning pin and the suspension disc; e) Correcting a walking beam and a horse head; f) Replacing the jackscrew and the through-ceiling screw; g) Dismounting the donkey head shaft; h) Assembling a shell pin; i) Repairing the platform and the lifting lug; j) Rust removing and paint spraying
2.4.1.2.3 Beam disintegration
2.4.1.2.3.1 dismounting of bearing: when the middle bearing is disassembled, the middle bearing jackscrew is firstly disassembled, and then the middle bearing fastening screw is disassembled.
2.4.1.2.3.2 disassembly of the beam assembly: the disassembly of the beam assembly should be performed in the following order, first loosening the tail bearing jackscrew, disassembling the tail bearing screw, then separating the walking beam body from the beam assembly, and in the separation process, preventing the tail bearing screw from being twisted.
2.4.1.2.3.3 separation of Beam Assembly: firstly, disassembling the two tail bearing lifting lugs to separate the tail bearings from the cross beam, then cushioning the cross beam, loosening the connecting rod clamping screw and the connecting rod jackscrew, taking out the connecting rod pin, and if the connecting rod pin cannot be taken out, extruding by using a press machine.
2.4.1.2.3.4 decomposition of horse head and walking beam: and (3) removing the horsehead positioning pin and the hair braid rope, placing the walking beam on a horizontal press, aligning the shaft end of the horsehead shaft with the main shaft of the press, and pressing down the horsehead shaft.
2.4.1.2.4 degree of deformation of walking beam body: and (3) detecting whether the bending degree and the torsion degree of the walking beam exceed the specifications of SY/T5044-2003 standard table 18 by adopting a wire drawing method, such as exceeding the specifications to be corrected or corrected, until the walking beam reaches the standard.
2.4.1.2.5 overhauling middle and tail bearings; and (3) disassembling the side covers of the middle and tail bearings, checking the damage condition of the bearings, and if the bearings have metal scraps, loosening the main frame, pitting corrosion on the balls, the roller paths and the inner and outer rings, wherein the radial clearance of the middle and tail bearings exceeds 0.25 mm, the axial displacement of the tail bearing is more than 1mm, and the bearings need to be replaced under one condition. When the bearing is disassembled and replaced, the shell and the bearing are separated by slightly knocking the shell by a method of heating the shell by a blast lamp. The press fitting can be carried out during the assembly, and grease is required to be filled after the assembly.
2.4.1.2.6 overhaul the horse head locating pin whether firm, the damage-free, it is nimble to slide, and the spring elasticity is good. Such as sliding inflexibility, oil invasion or spring replacement. If the damage is serious, the replacement is required.
2.4.1.2.7, the wearing condition of the cambered surface of the horse head is checked, and if the wearing condition exceeds one third of the wall thickness, the horse head is required to be replaced.
2.4.1.2.8 Assembly
a) Assembling the parts according to the reverse operation of the sequence of the walking beam disintegration;
b) During assembly of the center tail bearing, care is taken to correct its position to the longitudinal line of the walking beam and then tighten the screws and jackscrews.
C) When the positioning pin is installed, the parallelism between the side plane of the horse head and the side plane of the walking beam is not more than 2 degrees.
d) When the connecting rod is assembled, the connecting rod is aligned with all relevant positions and bolt holes matched with the connecting rod, and any force application measures cannot be adopted for alignment.
2.4.1.2.9 Beam acceptance
a) The bending degree and the torsion degree of the walking beam are checked by adopting a stay wire method, and the bending degree and the torsion degree accord with the regulation of a table 18 of a standard SY/T5044-2003 oil pumping unit of walking beams,
c) The bending degree and the torsion degree of the beam are checked by a stay wire method, and the beam meets the specification of a table 19 of a standard SY/T5044-2003 beam pumping unit,
d) The bending degree of the connecting rod is checked by the same method, and the connecting rod is in accordance with the standard SY/T5044-2003' Beam Pumping Unit
e) The appearance and the welding position of the connecting rod are inspected, and the continuously used connecting rod is subjected to magnetic powder inspection, so that the defects of cracks, internal injury and the like which influence the use are avoided;
f) Inspecting the braided rope without the defects of broken wire, twisting, strand scattering and the like;
g) The parallelism of the side surface of the horse head and the side surface of the walking beam is checked by a stay wire method, and the parallelism is less than 2 degrees.
2.4.1.3 major repair of base
2.4.1.3.1 base overhaul conditions
a) The bending degree of the base section steel exceeds the specification; b) With obvious breakage or fracture phenomena
2.4.1.3.2 base overhaul Contents
a) Replacing or repairing the brake assembly; b) Repairing a slide rail, a pressing bar and a bolt; c) Repairing sections of the I-shaped steel and punching reinforcing ribs; d) Correcting the deformation of the chassis; e) Rust removing and paint spraying
2.4.1.3.3 overhauling the chassis I-steel: checking whether chassis I-steel has fracture, crack or welded trace, if yes, hanging the chassis on a large platform, aligning two halves of I-steel with the fracture on the platform for the completely broken I-steel, measuring relevant sizes on the chassis at the same time, ensuring correct size, correcting the I-steel by adopting an auxiliary backup plate, and ensuring that the longitudinal curvature of the I-steel meets the regulation of SY/T5044-2003 in 22 (for the welded I-steel or the incompletely broken I-steel, after cleaning a repair welding steel plate, fixing the I-steel on the large platform, and correcting the longitudinal curvature of the I-steel); and then, beveling along two sides of the fracture, welding, and attaching two reinforcing steel plates with the thickness of 12 mm from two sides of the fracture of the rib plate of the I-shaped steel, wherein the width of the plate is as wide as that of the rib plate, and the length of the plate is generally 600 mm. And finally, welding a reinforcing plate with the thickness of 10 mm on the corresponding edge of the I-shaped steel fracture, wherein the length of the reinforcing plate is about 700 mm.
2.4.1.3.4 slide rail, pressure thick stick and brake assembly's maintenance: whether the slide rail is smooth or not is checked, welding spots and sundries are cleaned, whether the brake pull handle and the rocker arm are flexible and reliable or not is checked, whether the pull rod has an adjustment room or not is checked, and the damaged and lost parts are required to be replaced and matched.
Acceptance of base 2.4.1.3.5
a) Checking the bending degree of the base by a wire drawing method, wherein the longitudinal bending degree of the base is in accordance with the specification of a table 22 of a standard SY/T5044-2003 beam pumping unit, b) checking the repair and breakage position of I-shaped steel, wherein the connection is firm, and the welding line is free from the defects in a table 13 continued from a technical condition of a welding piece for petroleum drilling and production machinery products of a standard SY 5305-87;
c) The sliding rail and the brake assembly are inspected, the surface of the sliding rail is free of impurities and deformation, the brake and the rocker arm of the brake assembly are flexible and reliable, and the pull rod has an adjustment room;
2.4.1.4 Overhaul of Stent
2.4.1.4.1 Stent Overhaul Condition
The support is seriously deformed, so that the deviation of the projection of the horizontal plane center on the base and the longitudinal center line of the base exceeds the specification: 2.4.1.4.2 The overhaul contents of the support
a) replacing or repairing a support plate b) correcting support deformation c) repairing platforms, guardrails, ladders and support connecting plates d) repairing support cross braces e) derusting and painting
2.4.1.4.2 Stent Overhaul procedure and technical requirements
2.4.1.4.2.1, hanging the support on a chassis which is horizontally found and has the same model, checking whether four support legs of the support are on the same plane, and whether connecting holes of the support legs and the chassis are aligned to determine whether the support legs are deformed, if the support legs are deformed, adopting gas welding for heating and correcting, and fastening the support legs on the chassis by screws to prevent secondary deformation. Then, the weight is hung from the center of the top of the support to verify whether the projection of the support is in the specified mark center and the error is within the range required by table 22 in the standard SY/T5044-2003. If the torsion and bending of the stent are exceeded, the torsion and bending of the stent are measured and corrected until the standard requirements are met.
2.4.1.4.2.2 overhauling a bracket disc; the bracket disc is a key part for connecting the bracket and the walking beam, and whether the bracket disc is deformed or has cracks is carefully checked, if the bracket disc is slightly deformed, gas welding and hammering can be used for correcting, and the cracks can be repaired by electric welding. The support plate should be replaced when the deformation is serious. In addition, whether the slips are intact or not and whether metal is accumulated at the inner diameter position or not are checked, and when the slip screw is broken, the slip screw can be reassembled after tapping after drilling by a drilling machine.
2.4.1.4.3 Stent acceptance
a) Fixing the bracket on the chassis, and checking the deviation of the top center on the longitudinal center line of the base by using a line drop method, wherein the deviation is not greater than the specification of a standard SY/T5044-2003 'Beam Pumping machine' table 23;
after the support is corrected, the projection of the top center on the base does not deviate from the longitudinal center line of the base by more than the specification.
b) The defects of deformation, cracks, metal accumulation and the like are avoided when the bracket disc and the slips are inspected,
c) Checking that the cross brace has no defect and the welding is firm;
d) Safety facilities such as ladders and platforms need not be out of shape, and firm in connection.
2.4.1.5 crank device overhaul
2.4.1.5.1 crank device overhaul conditions
a) The crank hole is worn, and the roundness or cylindricity tolerance of the crank hole and the crank pin hole exceeds half of the diameter tolerance of the crank hole and the crank pin hole; b) Key slot damage c) crank hole wear is severe or crank body damage is severe, the crank must be replaced with a new one.
2.4.1.5.2 crank device overhaul content
a) When the crank hole is worn, the bushing is bored or the shaft diameter of the reduction gearbox is increased, and if the key slot is damaged, the key slot is re-opened at the interval of 90 degrees or 120 degrees in the original key slot; the matching of the repaired hole shaft is consistent with the original matching; b) The crank pin hole is worn, as above; c) When the crank hole is seriously worn or the crank body is seriously damaged, the crank needs to be replaced by a new crank.
2.4.1.6 overhaul of the complete machine
2.4.1.6.1 overhaul conditions of the complete machine
a) The service life of the first overhaul of the new machine is more than 6 years, and the safety and the technical performance are seriously reduced;
b) The safety and technical performance of the old machine are seriously reduced at an interval of 4-5 years after overhaul;
c) Except the reduction box, two or more parts reach the overhaul condition;
d) The base or the bracket is seriously deformed, and the normal and safe operation cannot be ensured;
e) Major mechanical accidents happen, and the pumping unit is seriously damaged.
2.4.1.5.2 overhaul content of the whole machine,
a) The method comprises the overhaul contents of the four parts; b) Inspecting, assembling and testing the machine; c) Painting the whole machine; d) Marking leaves factory
2.4.1.6.3 major repair procedure and technical requirements of complete machine
The overhaul steps of the four major components are respectively carried out
2.4.1.6.4 Assembly
a) The parts of the oil pumping unit can be assembled after being inspected to be qualified, b) the assembly is carried out according to the reverse order of disassembly when in assembly,
2.4.1.6.5 test
2.4.1.6.6 run-in
The whole machine running test is carried out according to a specified step-by-step loading method under the maximum stroke and the maximum stroke frequency. Loosening the brake, starting the motor, stopping when the crank rotates by 180 degrees, tensioning the brake, and checking the reliability of a brake system; and (4) determining that the pumping unit is free of obstacles, and then starting the motor again to start the test when determining that the swinging direction of the crank is consistent with the running direction. In the process of testing the oil pumping unit, whether the oil pumping unit operates stably or not is observed, and abnormal noise or shaking exists. The consistency of the longitudinal line of the walking beam and the longitudinal line of the chassis is checked, and the adjustment can be realized by adjusting the middle bearing jackscrew. In the process of testing the machine, if the abnormal phenomenon is found, the machine is stopped immediately, and fault factors are checked and eliminated.
In the process of testing the machine, noise testing is carried out, measuring points are distributed at two ends of an output shaft of the reduction gearbox, the distance between the measuring points and the end face of the shaft is 1 meter, the distance between the measuring points and the bottom face of the pumping unit is 1.5 meters, the sound level A (slow gear) of the sound level meter is used for measuring and obtaining an arithmetic average value, if the torque of the reduction gearbox is smaller than 37KN.m, noise cannot exceed 85dB, and if the torque of the reduction gearbox is larger than 37KN.m, the noise cannot exceed 87dB.
Checking and warehousing or leaving the factory; the repaired complete machine can meet the regulations of standard SY/T5044-20039.3.2 and 9.4, and after the complete machine is checked to be qualified, the complete machine is marked and put in storage or leaves the factory.
2.4.2 Belt conveyer type oil pumping unit
2.4.2.1 overhaul of the reduction gearbox
Same as 2.4.1.1 beam-pumping unit reduction box overhaul
Overhaul content of 2.4.2.2 roller overhaul 2.4.2.2.2 roller
2.4.2.2.2.1 removing four fixing screws of the roller, taking down the roller, disassembling, cleaning and checking.
2.4.2.2.2.2 inspecting whether cracks exist at the welding part of the roller, wherein the cracks can be repaired by welding, and during welding, the heating and the heat preservation are carried out to prevent the welding cracks.
2.4.2.2.2.3 the roller shaft and the roller have serious welding cracks or are separated from the shaft and the cylinder, and are rejected.
2.4.2.2.2.4 the roller shaft is inspected to have no damage, the damage of the bearing part can be repaired by welding and turning, and the repaired shaft diameter meets the technical requirements.
2.4.2.2.2.5, the bearing seat is inspected to have no damage, and the bearing hole is seriously damaged and needs to be replaced.
And 2.4.2.2.2.6, updating bearings and oil seals at two ends and filling lubricating grease.
2.4.2.2.2.7 according to the technical requirements, cleaning a bearing seat, spraying antirust paint, and carrying out antirust treatment on a roller.
2.4.2.3 go-and-return rack assembly overhaul (including weight box)
2.4.2.3.1 Overhaul Condition for shuttle
a) Damage of the carriage frame; b) The shuttle rails are severely worn or deformed; c) Damage to the bearing in the carriage; the weight box is corroded or deformed.
2.4.2.3.2 overhaul Contents of shuttle
The reciprocating frame and the balancing box are connected into a whole, and deformation and distortion of the reciprocating frame are checked and corrected. And correcting the parallelism and the size of the upper guide rail and the lower guide rail. And correcting the parallelism and the size of the left frame and the right frame. The guide rail is repaired according to the abrasion and the damage degree of the guide rail, and the guide rail needs to be replaced when the guide rail is seriously damaged and abraded. Replacing the pulley bearing; repairing balance box, foot balancing iron
2.4.2.4 Overhaul of sprocket assembly
2.4.2.4.1 Overhaul condition of Upper sprocket Assembly
a) Cracks are seriously obtained when the tooth part of the upper chain wheel is worn; b) Upper sprocket shaft and bearing damage
2.4.2.4.2 overhaul of the chain wheel Assembly
2,4.2.5 overhaul of lower chain wheel
2.4.2.9.2 overhaul content of the whole machine,
a) Comprises the overhaul content of 2.4.2.1-2.4.2.8 assembly parts; b) Inspecting, assembling and testing the machine; c) Painting the whole machine; d) Marking leaves factory
2.4.2.9.4 Assembly
a. The parts of the oil pumping unit can be assembled after being inspected to be qualified,
b. during assembly, the assembly is carried out according to the reverse order of disassembly,
2.4.2.9.5 test
a) The welding line is uniform, flat and beautiful, has no defects of cracks, burn-through, shrinkage, discontinuity and the like, and has no foreign matters such as welding slag, metal splashes and the like at the welding line;
b) Carrying out radiographic inspection on the quality of welding seams at key parts such as connecting rods and the like;
c) Each connecting and fixing part is firm and reliable;
d) The motion of the running part is flexible, and the bearing lubrication is good;
e) The installation of the electric appliance is safe and reliable, and the safety protection device is complete.
2.4.2.9.6 derusting and spray painting: and after the operation test is qualified, spraying paint on the surface of the oil pumping unit, spraying anti-rust paint on the primer for 2 times, and spraying finish paint for 2 times.
2.4.2.9.7 run in
2.4.2.9.7.1 preparation: and preparing a pressing bar and a pressing bar screw, balancing a balance weight iron, a motor, a belt, a motor jackscrew and the like, and leveling the foundation of the test machine.
2.4.2.9.7.2 install the whole perpendicular of beam-pumping unit on the examination machine basis to install the bearing diagonal, in proper order with installation regulation positions such as reducing gear box, motor, fasten base set screw and each parts connecting screw, connect and adjust the brake and reach reliable brake state.
2.4.2.9.7.3 installing a load belt and connecting the load belt with the weight box;
2.4.2.9.7.4 installing a motor, installing the motor on a slide rail, installing a belt, tensioning the belt by using a motor jackscrew, braking the vehicle, and installing a test run counterweight (a static load which is 80 percent of a rated load);
2.4.2.9.7.5 according to the specification, adding lubricating oil to the reduction gearbox and the chain box to a proper amount.
2.4.2.9.7.6 test run: the running test of the whole machine is carried out according to a specified step-by-step loading method under the maximum stroke and the maximum stroke frequency. The brake is released, the motor is started, and meanwhile the reliability of the brake system is checked; and determining that the pumping unit is free of obstacles, and then starting the motor again to test the engine. In the process of testing the oil pumping unit, whether the oil pumping unit operates stably or not is observed, and abnormal noise or shaking exists. Checking and adjusting the clearance of the guide wheel, stopping the machine immediately if an abnormal phenomenon is found in the process of testing the machine, and checking and removing fault factors.
2.4.2.9.7.7, testing the noise, wherein the testing points are distributed at two ends of an output shaft of the reduction gearbox, are 1 meter away from the end surface of the shaft and 1.5 meters away from the bottom surface of the pumping unit, an arithmetic average value is measured by using the sound level A (slow gear) of the sound level meter, if the noise of the pumping unit below 700 type cannot exceed 85dB, the noise of the pumping unit above 700 type cannot exceed 87dB.
2.4.2.9.7.8 reduction gearbox in operation should meet the following requirements
a. The bearing temperature rise is not more than 40 ℃, the oil pool temperature rise is not more than 15 ℃, and the highest temperature is not more than 70 ℃; b. the phenomena of oil leakage and oil seepage cannot occur at each sealing part and combination part; c. the operation is smooth and no impact, vibration and abnormal sound are produced.
2.4.2.9.7.9 demolition: and after the test machine is finished, reversely and sequentially dismantling the large components according to the installation sequence.
2.4.2.9.7.10 inspection warehouse entry or delivery: and (4) the repaired complete machine is required to reach the regulation, and after the complete machine is qualified through inspection, the complete machine is marked to be put in storage or leave the factory.
3 complete machine test and acceptance
And after the repair is finished and the test is qualified, the repair factory presents the product overhaul qualification certificate to the use unit. (described in overhaul)
Taking the conventional beam pumping unit and belt pumping unit of an oil-gas field as examples, the method for measuring and calculating the maintenance cost is described in detail as follows:
1 inspection and maintenance expense measuring and calculating method
1.1 method for measuring and calculating maintenance cost of single oil pumping unit 1.1.1 measuring and calculating thought
The method for measuring and calculating the inspection and maintenance cost of a single pumping unit is the core and key of measuring and calculating the inspection and maintenance cost of pumping unit facilities and is the basis of the whole cost measuring and calculating method. The method for measuring and calculating the maintenance cost of a single pumping unit comprises the following steps:
1) Determining the working contents of maintenance, minor repair, intermediate repair and major repair according to the inspection and maintenance contents specified in the regulations;
2) Calculating the average cost of each maintenance project in single maintenance, minor repair, middle repair and major repair according to the statistical data;
3) According to the inspection and maintenance cycle specified in the regulation, the times of time period maintenance, minor repair, intermediate repair and major repair can be measured and calculated;
4) According to the single expense of major, medium and minor repair and maintenance of the pumping units of different types and the measured annual occurrence frequency, the annual inspection and maintenance expense can be calculated.
1.1.2 determining the content and cost of single large, medium and small repair and maintenance of a single pumping unit
1.1.2.1 determining the inspection and maintenance contents of major, medium and minor repairs and maintenance
The specific inspection and maintenance contents of major, minor and minor repairs and maintenance determined according to the maintenance rules of oil pumping unit facilities are shown in table 1.
Beam-pumping unit type large, medium and small repair and maintenance content meter
| Maintenance Species of | Maintenance contents of beam-pumping unit | Maintenance contents of belt type pumping unit |
| Maintenance | Mainly adopts the cleaning in the cross operation method, Fastening and adjusting are the main contents. | Mainly adopts the 'cleaning' in the 'cross' operation method, Fastening and adjusting are the main contents. |
| Minor repair | 1) Maintaining all content; 2) According to the regular maintenance and repair regulations of the pumping unit Found in content or daily spot and periodic inspections Problems, disassembly of the relevant parts for inspection, Adjusting, repairing, or replacing failed parts to recover And repeating the normal functions of the pumping unit. | 1) Maintaining all content; 2) According to the regular maintenance and repair regulations of the pumping unit Found in the content or in daily spot-checks and periodic checks Problems, disassembly of the relevant parts for inspection, Adjusting, repairing, or replacing failed parts to recover And repeating the normal functions of the pumping unit. |
Table 1 Beam-pumping unit type large, medium and small repair and maintenance table
| Maintenance Species of | Maintenance contents for beam-pumping unit | Maintenance contents of belt type pumping unit |
| Middle repair | 1) Minor repair of all contents; 2) The oil pumping unit or the assembly is partially disassembled, and to identify, repair or replace the assembly, repairing or replacing the main parts and the standard parts; 3) Maintaining, plugging, exchanging oil and the like the reduction gearbox; 4) Matching safety protection facilities; 5) And carrying out corrosion prevention operation on severe corrosion. | 1) Minor repair of all contents; 2) The oil pumping unit or the assembly is partially disassembled, and to identify, repair or replace the assembly, repairing or replacing the main parts and the standard parts; 3) Maintaining, plugging, exchanging oil and the like the reduction gearbox; 4) Matching safety protection facilities; 5) And performing corrosion prevention operation on severe corrosion. |
| Major repair | 1) Repairing all contents in the middle; 2) Overhauling a reduction gearbox; 3) Overhauling the walking beam; 4) Overhauling the base; 5) And (5) repairing the bracket. | 1) Overhauling the reduction gearbox; 2) Overhauling the roller; 3) Overhauling a reciprocating frame assembly; 4) Overhauling the upper chain wheel assembly; 5) Overhauling a lower chain wheel assembly; 6) Chain overhauls (including skate frames); 7) Overhauling a load belt; 8) The tower overhaul (comprising a tower footing, a tower beam and a base). |
1.1.2.2 determining unit price of each maintenance project in single large, medium and small repair and maintenance
The maintenance of the pumping unit is mainly the replacement of parts, and the cost of the pumping unit is composed of three parts, namely labor cost, mechanical cost and material cost. Wherein: maintenance, minor repair and intermediate repair projects are repaired by oil extraction plants, and labor and mechanical cost is contained in the cost of branch companies, so the unit price of the inspection and maintenance projects only contains material cost; the major repair project is carried out by a professional repair manufacturer, and the unit price of the inspection and maintenance project comprises material cost, labor cost and mechanical cost.
And the unit price of each maintenance item in single large, medium and small maintenance and maintenance is measured and calculated according to the recent average market price of parts and components of the pumping unit, maintenance and repair labor service and processing cost statistical data.
1.1.2.3 determining the average workload of each inspection and repair item in major, medium and minor repair and maintenance
When maintenance, minor repair, intermediate repair and major repair are carried out each time, firstly, which parts of the oil pumping unit need to be repaired or replaced is determined according to evaluation before repair, so that not all maintenance workload needs to be generated during each maintenance inspection. The project group carries out a large amount of investigation on the occurrence of the detection and maintenance cost of the oil pumping machines in the victory oil field in recent years, and 9858 oil pumping machines in five oil production plants including winning, dongxing, existing river, island and lone east are selected as data samples to be analyzed. And measuring and calculating the average replacement frequency of each part of the pumping unit of different types according to the statistical data, thereby measuring and calculating the average single-occurrence workload of each maintenance item.
1.1.2.4 determining average Single major, minor, major and minor repair and maintenance costs
According to the unit price of each maintenance item and the average maintenance workload of each maintenance in large, medium and small repairs and maintenance, the average single cost of each maintenance item in large, medium and small repairs and maintenance can be calculated, as shown in formula 1.
Average single charge of a maintenance project = maintenance unit price × average work load per time (equation 1)
The average cost of single maintenance, minor repair, intermediate repair and major repair can be obtained by accumulating according to the average cost of single maintenance of corresponding maintenance items.
1.1.3 determining the repair and maintenance period of the large, medium and small size according to the regulations
According to the regulations, the repair and maintenance periods of the walking beam pumping unit and the belt pumping unit are shown in table 2.
Maintenance cycle for beam-pumping unit and belt-type pumping unit
| Type (B) | Maintenance (moon) | Minor repair (moon) | Middle repair (moon) | Overhauling (moon) |
| Beam machine | 1 | 3 | 12 | 60 |
| Belt conveyor | 1 | 3 | 12 | 72 |
1.1.4 determining the number of times of major, minor and minor repairs and maintenance of the predicted year
The maintenance, minor repair, intermediate repair and major repair times of each year in the service life cycle of a single oil pumping unit can be determined according to the maintenance cycle. Taking a beam-pumping unit as an example, the maintenance is carried out 12 times per year, the minor repair is carried out 4 times per year, the middle repair is carried out 1 time per year, and the major repair is carried out 1 time per 5 years.
1.1.5 determining maintenance cost of single pumping unit in prediction period
The maintenance cost of the predicted time period can be calculated according to the single cost of major and minor maintenance of the pumping units of different types and the annual occurrence frequency, as shown in formula 2.
C i ＝Q Big (a) ×F Big (a) +Q In ×F In +Q Small ×F Small +Q Maintenance ×F Maintenance (formula 2)
In the formula:
C i annual maintenance cost for a single pumping unit;
F big (a) 、F In 、F Small 、F Maintenance Respectively the single large, medium and small repair and maintenance costs of various types of single pumping units;
Q big (a) 、Q In (1) 、Q Small 、Q Maintenance Respectively the times of major repair, minor repair and maintenance in the year.
i is the age (i =1, 2.., 18).
1.2 measurement and calculation of total maintenance cost of pumping unit
After the service life distribution data of various pumping units in different management ranges are mastered, the maintenance cost of all the pumping units in different management ranges in the measured year can be calculated according to the rule of the cost of a single pumping unit. The management range can be a reservoir operation management area, an oil production plant, a branch company, a medium petrochemical industry and the like.
The formula for measuring and calculating the maintenance cost of a certain type of pumping unit in a certain management area is as follows:
In the formula:
b is the maintenance cost of the oil pumping unit which is calculated and taken year by year;
C i measuring and calculating annual inspection and maintenance cost for a certain oil pumping unit;
i =1, 2.., n, for the pumping unit number
The formula for measuring and calculating the maintenance cost of all oil pumping machines in a certain oil reservoir management area is as follows:
(formula 4)
In the formula:
a is the maintenance cost of all types of pumping units in different management ranges for predicting annual occurrence;
B i the maintenance cost of the pumping units in different management ranges is predicted to occur in the year;
i =1, 2.., n, which is a pumping unit category.
2 application of measuring and calculating method
2.1 measurement example
According to the measuring and calculating method, the project group actually measures and calculates the maintenance cost of the oil pumping unit in the victory oil field in 2006. According to the distribution of different service lives of various pumping units with the service life of the victory oil field being 20 years, the checking and maintenance cost of all the pumping units in the victory oil field in 2006 can be calculated by combining the result of calculating the checking and maintenance cost of each year in the life cycle of the main machine type.
And (3) measurement and instruction:
the measuring and calculating range is determined to be all types of pumping units with the service life not exceeding 20 years. In the charge measurement, five pumping units such as an 8-type walking beam type pumping unit, a 10-type walking beam type pumping unit, a 12-type walking beam type pumping unit, a 700-type belt type pumping unit, a 900-type belt type pumping unit and the like which have wide use in a victory oil field or have good application prospects in the future are selected as typical machine types to be intensively researched, the single-time detection and maintenance cost of the 5 pumping units is actually measured, and the measurement results are shown in a table 3.
Main specification single oil pumping unit single station single time checking and maintaining expense measuring and calculating meter
| Type (B) | Specification of | Maintenance (Yuan) | Minor repair (Yuan) | Middle repair (Yuan) | Major repair (yuan) |
| Walking beam Machine for working | 8 type | 164.48 | 258.14 | 3706.89 | 24988.10 |
| 10 type | 219.31 | 344.19 | 4942.53 | 33317.42 | |
| 12 type | 358.17 | 1009.25 | 5979.80 | 55490.00 | |
| Leather belt Machine for producing thin films | 700 Model (III) | 412.00 | 846.49 | 5103.14 | 50694.44 |
| 900 Model (III) | 470.70 | 905.19 | 5413.84 | 64454.94 |
The maintenance unit price of 8 types and the following types of beam-pumping units is measured according to the maintenance unit price of 8 types of machines, the maintenance unit price of 12 types and the above types of machines is measured according to the maintenance unit price of 12 types of machines, the maintenance unit price of 700 types of belt-type pumping units and the following types of machines is measured according to the maintenance unit price of 700 types of machines, the maintenance unit price of 700 types and the above types of machines is measured according to the maintenance unit price of 900 types of machines, and the proportion of the maintenance cost of 2006 year-old beam-pumping units and belt-type pumping units in the other types of pumping units is calculated according to the proportion of the total value of 2006 year-old maintenance cost of the beam-pumping units and the belt-type pumping units.
Through measurement and calculation, the inspection and maintenance cost which needs to be invested in 2006 is 2.54 billion yuan.
According to the statistics, the original value of equipment for winning all oil pumping units in the oil field is 24.94 billion yuan, and the proportion of the inspection and maintenance cost which needs to be input in 2006 accounts for 10.19 percent of the original value. Considering that the pumping unit has long service life and changes in the market price of equipment and accessories, the total value of the equipment is calculated according to the market price of the current pumping units of various types, the total value of the pumping unit in the victory oil field is 31.71 million yuan, and the annual inspection maintenance cost of the pumping unit accounts for 8.01 percent of the total value.
Claims (5)
1. A method for detecting, maintaining and calculating expenses of pumping units is characterized by mainly comprising the following steps:
(1) Detecting and maintaining the oil pumping unit in a fixed period;
(2) The quality of the detection result is evaluated according to the quality standard of the related pumping unit, and corresponding maintenance is carried out according to the quality evaluation result of the pumping unit;
(3) Estimating the overhaul cost according to the detection and maintenance contents, wherein the overhaul cost estimation can provide reference and standard for investment of the overhaul cost of the pumping unit and solve the problem of insufficient investment or excessive investment;
(4) And (4) testing and accepting the maintenance result, and checking whether the maintenance quality meets the quality requirement of the oil pumping unit and whether the oil pumping unit can be put into normal use.
2. The method for inspecting, repairing and calculating the expenses of the pumping unit as claimed in claim 1, wherein: the detection and maintenance contents of the oil pumping unit comprise minor maintenance, middle maintenance and major maintenance, the maintenance contents are that according to the contents specified by the regular maintenance and maintenance of the oil pumping unit or the problems found in daily spot inspection and regular inspection, relevant parts are disassembled to carry out inspection, adjustment, repair or replacement on invalid parts, the oil pumping unit or an assembly part is partially disassembled, and the assembly part is identified, maintained or replaced, and main parts and standard parts are repaired or replaced to restore the normal function of the oil pumping unit.
3. The method for inspecting, repairing and calculating the expenses of the pumping unit as claimed in claim 1, wherein: the maintenance cost is composed of the maintenance cost of the pumping unit, the minor repair cost, the middle repair cost and the major repair cost;
(1) Maintenance cost of single pumping unit in prediction period
The maintenance cost of the predicted time period can be calculated according to the single cost of major, medium and small maintenance of the pumping units of different types and the annual occurrence frequency, as shown in formula 2,
C i ＝Q big (a) ×F Big (a) +Q In ×F In +Q Small ×F Small +Q Maintenance ×F Maintenance (formula 1)
In the formula:
C i annual inspection and maintenance costs for a single pumping unit;
F big (a) 、F In 、F Small 、F Maintenance Respectively the single large, medium and small repair and maintenance costs of each type of single pumping unit;
Q big (a) 、Q In 、Q Small 、Q Vitamin C The number of times of major, minor and repair and maintenance in the year is respectively.
i is age (i =1, 2.., 18);
(2) Measuring and calculating the total maintenance cost of the pumping unit
After the service life distribution data of various pumping units in different management ranges are mastered, the maintenance cost of all the pumping units in different management ranges in the measured year can be calculated according to the rule of the cost of a single pumping unit,
the formula for measuring and calculating the maintenance cost of a certain type of pumping unit in a certain management area is as follows:
In the formula:
b is the maintenance cost of the oil pumping unit which is calculated and taken year by year;
C j measuring and calculating annual inspection and maintenance cost for a certain oil pumping unit;
i =1, 2.., n, for the pumping unit number
A formula for measuring and calculating the maintenance cost of all pumping units in a certain oil reservoir management area:
In the formula:
a is the maintenance cost of all types of pumping units in different management ranges for predicting annual occurrence;
B i the maintenance cost of the pumping units in different management ranges is predicted to occur in the year;
i =1, 2.., n, which is a pumping unit category.
4. The method for inspecting, repairing and calculating the expenses of the pumping unit as claimed in claim 1, wherein: the oil pumping unit is a common beam pumping unit or belt pumping unit for oil-gas field development.
5. The method for inspecting, repairing and calculating the expenses of the pumping unit as claimed in claim 1, wherein: the maintenance period is 1 month, the minor repair period is 3 months, the medium repair period is 1 year, and the major repair period is 5 years.
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| CNA2007101128303A CN101122993A (en) | 2007-09-10 | 2007-09-10 | Pumping unit inspection maintenance and fee determination method |
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| CN106227715A (en) * | 2016-07-13 | 2016-12-14 | 广东电网有限责任公司 | A kind of electricity electricity charge acquisition methods |
| CN106471475A (en) * | 2014-04-11 | 2017-03-01 | 哈佛蒸汽锅炉检验和保险公司 | Model to improve the reliability prediction in future based on system operatio and performance data |
| CN109682629A (en) * | 2019-01-07 | 2019-04-26 | 中国石油大学(华东) | A kind of pumping unit simulation loading is test bed |
| CN112633520A (en) * | 2019-09-23 | 2021-04-09 | 珠海格力电器股份有限公司 | Repair reporting method and repair reporting system |
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- 2007-09-10 CN CNA2007101128303A patent/CN101122993A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN106471475A (en) * | 2014-04-11 | 2017-03-01 | 哈佛蒸汽锅炉检验和保险公司 | Model to improve the reliability prediction in future based on system operatio and performance data |
| CN106227715A (en) * | 2016-07-13 | 2016-12-14 | 广东电网有限责任公司 | A kind of electricity electricity charge acquisition methods |
| CN109682629A (en) * | 2019-01-07 | 2019-04-26 | 中国石油大学(华东) | A kind of pumping unit simulation loading is test bed |
| CN109682629B (en) * | 2019-01-07 | 2020-06-02 | 中国石油大学(华东) | Oil pumping unit simulation loading test bench |
| CN112633520A (en) * | 2019-09-23 | 2021-04-09 | 珠海格力电器股份有限公司 | Repair reporting method and repair reporting system |
| CN112785142A (en) * | 2021-01-19 | 2021-05-11 | 翰克偲诺水务集团有限公司 | Intelligent work order early warning method and system for sewage treatment equipment based on Internet of things |
| CN112785142B (en) * | 2021-01-19 | 2023-11-24 | 翰克偲诺水务集团有限公司 | Intelligent work party early warning method and system for sewage treatment equipment of Internet of things |
| CN116575890A (en) * | 2023-06-29 | 2023-08-11 | 大庆石油管理局有限公司 | Tower type oil pumping unit guiding device safety protection structure |
| CN116575890B (en) * | 2023-06-29 | 2023-11-21 | 大庆石油管理局有限公司 | Tower type oil pumping unit guiding device safety protection structure |
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